Westerbeke 7.0 BCG, 7.0 BCGA, 5.0 BGG Operator's Manual

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OPERATORS

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•GEi-TORS

MANUAL

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PUBLICATiON

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WESTERBEKECORPORATTON•

150

JOHN

FAX

1·508-884-9688

HANCOCK

ROAD.•

~WEBSITE:

MYLES

TAUNTON

STANDISH

MA

WWW.WESTE'RBEKE.COM_

INDUSTRIAL

027S0-7319

•TEL. 1·508-823-7677

PARK

AWARNING:

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF

GET

seBk

until

·

.

W

. . . .

Genaratora

Regular

gasses

gas.

carbon

can

include:

Weakness

YOU

OUT

A.

Produl:e:

IWIWE!!!@!!!1\E

--ras.,,,,.&~

and

OR

ANYONE

INTO

medical

it

h~

been

RN

CARBON

Maintenance

THE

attention.

·1

Required ·

contain

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

Inspected

NG

MONOXIDE.

·Monoxide, is-poisonaas

Sy,;,ptomB:ot

•

Throbbing

•Muscular

•Vomiting

•Inability

IMMEDIATELY. N sympto111$ down

and

repaired.

A

WARNING

WESTERBEKE

bulkhead WESTERBEKE

CARBON

living/sleeping

They

are

obtainable

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

ANY

OF

THESE

the

unit

and

DECAL

is

and

should

near

your

engine

also

recommendslnstalllng

MONOXIDE

Inexpensive

at

DETECTORS

quarters

your

local

can Monoxide

Coherently

SYMPTOMS,

do

not

provided

be

of

and

easily

marine

aµd

cause

persist,

restart

by

fixed

or

generator.

In

your

vessel. store.

to

the

a

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

gasoline

birth

WARNING

engine

its

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

/lead

this

safety

caused

by

failure

precautions.

take

the

necessary

personnel,

As

the

ownttr

safety

rules·

This

safety

Bt>ataiul

·

riaks

page

and

Yacht

are

not

I.:

The

ac~

maintenance

exclusively

manual

Know

·and

your

or

operator,

and

advisories

infonntJt!on

Cou'tleil

lifnited.

respofisibiliiy./or

risks

for

activities,

fiJ)he·

carefully.

to

follow

fundamental

when

dangerous

precautions

to

machinery.

always

provided/or 1our

iS

in

alignment

(Al'fYCJstandtitds;

to

the

i'4forlitdtion•

the

identifictitiOn•of

compliance

ll1id

owllertopetator.

with all

tither

Most

accidents

conditions

protect observe

with theAmerkan

in

stifety · tzdvisories,

codons

PREVENTELECTRIC'SHOCK

"ii

WARNING:·

while

engine

·power.

•

• Shut

•

• Remove wristwatch and all jewelry

Lethal

Do

not operate this machinery without electrical

enclosures

off electrical power before accessing electrical

equipment. Use

insulated mats whenever working on electrical

equipment. ·

Make

sure your clothing

(particula:rly

electtfoal equipment.

PREVENT·BOflNS

.

i\wAflltNG:

·

mam

veryhotl

• Monitor engine antifreeze

sysftml

coolant recovery location when

the engine

Do

alittouch

is

running,

voltage

and

covers in place.

shoes) when·handling electrical

-

DiJ

hot

clllllpanllnts~

· · ·

tank and periodically

on

the

water jacketed exhaust manifold; but only

is

COLD.

AC

sllt:trlaal

or

when

con1111ctt1d

.Is

present

HOT:·ENGINI!

tOut:~.hOt

at

tllese

and

skin

are

When

~

'iltJ~nS.Patts

1l

ian11lng

.·

coolan,t

level at the plastic

are

rules

and

exist

yourself,

the

your

following

.convenience.

however

the

following

potenti.al

belOng

aonneations

to

sllore

aonnections!

dry, not damp

equiptnent.

working

...

·

or

engine

gets

at

the filler cap

and

safety.

on

PREVENT

A

• Prevent

funtp,

·

II ·

•

.·Do

• Be

PREVENT

A

Injury

• Follow re-fueling safety instructions. hatches closed when fueling.

• All

•

Do

• Shut off the

• Do not alter or modify the fuel

•

Be

•

• Make sure a

BURNS -FIRE

WARNING:

sparks

to

or

vapors.

Use a suitable container

remo\Ting I>o

not opetate with the air cleaner/silencer

Bae~ can cause severe injury or

not smoke or permit

the

fuelsysteni. Keep the compartment engine/generator clean and free of debris to minimize chances of

aware

BURNS-

WARNING:

or

tleath!

after fueling. Check below for fumes/vapor before

running

before starting your engine.

fuel

vapors

when

handling well-ventilated area away from spark-producing equipment

not

fill

servicing thannight spill. flames,

or other

engine

when

when servicing

sure all fuel supplies have a positive shutoff

Be certain fuel line fittings are adequately tightened free

of

leaks.

properly maintained. Be familiar Extinguishers rated ABC for all applications encountered in

Fire

can

cause

injury

flash

fires.

Do not smoke or permit occur near the carburetor, other potential sources of spilled

the

fuel

line, carburetor, or

flames

fire.

Wipe

up all spilled

- diesel fuel

will

to

or sparks

burn.

fuel

catch

fuel

death.

fuel

EXPLOSION

the

and

the

blower.

fuel

servicing.

fire

ExplOSions

are

highly

and out

of

tank(s) while

service

system. DO sources

the

extinguisher

from

fuel

vapors

Keep

Open

and

Run the blower

explosive.

storing

fuels.

the reach

valve

Take

NOT

allow

of

fire

Ensure proper ventilation

fuel system.

by

for

Use

Store

of

children.

the

engine

at

the

engine

care

in catching

any smoking,

near

the

system.

is

iii.stalled

with

the

NFPA

this

or

death!

line,

fuel

all

filters.

to

and and

·the

ventilate

four minutes

extreme

fuel

is

when

fuel

system

nearby

its

proper

are appropriate

environment.

flames

or

filter,

fuel

or

fuel

when'

~moved.

occur

near

the .

the

engine

oil.

can

cause

vessel's

cabin

care

in a ·

flllllli?g.

any

fuel

open

or

exists

valve.

·

and

is

use.

ln

case

of

an

• before touching

engine overheat, allow the engine

the

engine or checking

the

to

coolant.

cool

·

Englhf1/1"Jt

Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

a Disconnect

generator.

last.

it

a

Make starting.

a

Make installed before starting the engine.

BAmRY

A

WARNING:

or

death!

a

Do

not

being highly explosive arcing equipment ing

servicing. . _

•

Never tive not

test the battery condition

together. Ventilate accumulation of explosive gases. disturb is

being charged.

•

Avoid burns wristwatch, the

battery.

•

Always the

battery connections. Remove the negative lead

and

STARTING

Remove

certain

Accidental

the

battery cables before servicing

all

personnel are clear

all

covers, guards, and hatches

starting

the negative lead first

EXPLOSION

Battsry

smoke or allow

serviced. Lead acid batteries emit hydrogen, a

or

by

lit tobacco products. Shut off

in

the

connect the negative(-) battery cable

( +) connection terminal

Sparks could ignite battery gases

any

compartment containing batteries

the

battery charger connections while

contacting the terminals with tools, etc.,

or

sparks

rings,

turn the battery charger off before disconnecting

reconnect it last when disconnecting the

sxplaslon

an

gas,

which can be ignited

vicinity

that could cause an explosion. Remove

to

and any

can

open

flame

prevent electrical

of

the starter solenoid.

by

shorting the terminals

To

other jewelry before handling

BAmRYACID

A

WARNING:

sevsrs

Injury

•

When

servicing the battery or checking the electrolyte

level,

wear rubber gloves, a rubber apron,

tion.

Batteries contain sulfuric acid which

If

it comes

with

water.

inadvertently

Sulfuric

or

death/

in

contact with your skin, wash it off at once

Acid may splash

when

acid

In

batteries

·

on

the skin

removing electrolyte caps.

can

cause

Injury

the

and

reconnect

of

the engine before

are

causs

Injury

near the battery

by

elect?cal

all

electrical arcing

to

the

or

fuel

to

avoid sparks,

the

to

battery.

can

cause

and

eye protec-

is

destructive.

or

into the eyes

engine/

re-

dur-

posi-

Do

vapors. prevent

do

battery

prevent

first

not

TOXIC

a Ensure

a a

• For additional information refer

•

a

EXHAUST

A

WARNING:

that

discharged from

regularly

are

securely attention exhaust pipe

Be

sure

the

In

addition install a builder

or

tional

infonnation

A

WARNING:

odorlsss

nausea

Do

not

use

fumes

can

tems.

Exhaust sulfur causes rapid deterioration of

tubing resulting in exhaust/water leakage. Do

not

install exhaust outlet where exhaust through exhaust discharge outlet enter

the

flow

of

exhaust.

Although exhaust

gas

is

present in diesel exhaust

toms

or

are: Vomiting Dizziness Throbbing Muscular twitching Intense headache Weakness

AVOID

a

MOVING

A

WARNING:

or

death!

Do

not

service the engine while it

tion

arises operating adjustments, ing

moving parts

GASES

Carbon

monoxide

the

exhaust system is adequate

the

engine. Check

for

leaks

and

make sure

attached

to

the manifold, water injection

nipple.

unit

to

carbon

dealer

gas.

or

dsatbl

copper tubing in

rapidly

portholes, vents,

exhaust

diesel engine exhaust

fumes signs of carbon monoxide inhalation or

in

and sleepiness

and

no

warping

and

its surroundings are

routine inspection of

monoxide

for

Inhalation

destroy

discharge

Avoid

from gasoline engines, carbon

temples

detector.

installation

on

Carbon Monoxide).

carbon

of to

monoxld1

pradllCIJS

diesel

copper

or

air conditioners.

is

near

the

outlet

overloading the

gases

fumes.

PARTS

in

which it

Rotating

parts

can

is

absolutely

use

extreme care

and

hot exhaust system

(CO}

Is

the

exhaust

exists.

the Consult

approved

ABYC

(CO}

flu-like

exhaust

tubing

waterline,

and

close

are

Some

causs

is

running.

necessary

a

deadly

to

expel

exhaust

manifolds

Pay

elbow,

well

ventilated.

exhaust

your

detectors.

T-22

Is

an symptoms,

systems.

in

exhaust

can

If

water

or

restrict

craft.

not

as

monoxide

of

Injury

If

to

avoid

components.

gas!

gases

system

close

and

system,

boat

(educa-

Invisible

Diesel

sys-

copper

be

drawn

the

engine

could

the

toxic

as

the

symp-

poisoning

a

situa-

make

touch-

lwlWESTERBEKE

f

Engines & Generators

ii

m

Do

not

wear

loose

clothing

equipment;

jackets,

could

II

Make

Keep

places

Ill

Do

not check

the

engine

!Ill

Do

not

the

exhaust generator death

HAIARIOUS,NOISE

'>':":<•···.-."'"'·-.f:.o•.-

'~~WiRNlNG:

tie

shirts,

be

caught

sure

all

protective

at

all

times.

fluid

is

operating.

allow-any

discharge

is

operating.

can

occur.

·

.>··

back

sleeves,

in

moving

attaching

shields

levels

swimming

.

··

•

Hi{l/l:noise-levels

long

rings,

hardware and

opening

Carbon

or

jewelry when servicing

hair

and

avoid wearing foose

necklaces or bracelets that

parts.

is

properly tightened.

guards

in their respective

or

the

drive belt's

or

activity around

for

the generator while

Monoxide poisoning or

can

caus.e

fiip!

II

Never

II

Do

not

flame

II

Do

not

open

(when

A

WARNING:

mentally

operate

arrester

an

run

the

engine

removed.

run

engines

installed).

/lo

or

phY,ically

engine

without

with

for long periods with their enclosures

not

work

incapacitated

its muffler installed.

the

air intake

on

machinery

by

SAFETY

tension

while

or

near

the

hearing

cSilencer)

when

fatigue!

or

.

you

are

INSTRUCTIONS

ABYC, INSTALLING

Read for qonswben installing your engine.

ABYC

"Standards and Technical Information Reports Craft"

Order

NFPA

AND

USCG

ENGINES

the following ABYC, NFPA

safety codes and standards.

{American Boat and Yacht Council)

from:

ABYC

613

Third Street, Suite 10

A.Juiapolis, www.abyci:nc.org

NFPA - No.302 (National Fire Protection

"Pleasure and Commercial

from:

National Fire Protection Association Batfofy Mart:h Park

Qumcy,

U~'¢GJDtiite,d

"reglifatedfons are under titles CFR33

Code

from:

U.S. Washington,

MD

21403 ·

MAOi269

States Coast

of

Regulations"

Government Printing Office

D.C.

20404

PUBLICATIONS

AND

GENERATORS

and

USCG

Follo:w

Motc>rCraft"

their

Gil!!-fd)

recornmenda-

Association)

and

CFR.46

FOR

publications

for

Small

of

the

OPERATORS

Many

of the

in

your

notes

to

carefully, procedures.

GASOLINE

Preparations begin

with a

Yacht

Council's

a combination of sources Sections

H-2

Ventilatio[).

·

H-24

Gasoline Fuer

P-1

Installation of for

P-4

Marine

Blb\C

All

installations

Regulations www.abycinc.org

MANUAL

preceding

Operators

highlight

maintain

ENGINE

to

install

thorough

(ABYC)

of

the

ABYC

for

Propulsion

Inboard

and

DC

(FCR).

Manual critical

your

AND

a gasoline engine

Boats

Systems

Exhaust

and

Engines

Electrical must

comply

safety

tips

and

warnings are repeated

along

with other cautions and

infonnation.

equipment,

GENERATOR

examination

standards. These standards are from

lnc~uding

standards

using

Systems

Auxiliary Engines

and

Systems

with

Reiid,

yo1fr

arid

follow

ail

· ·

INSTALLATIONS

or

generator should

of

the American Boat and

the USCG and

of

particular interest are:

Gasoline

Transmissions

on

Boats

the Federal Code

manual

safety

the

of

NFPA.

·Engines & Generators

iii

When

installing

attention

WESTERBEKE

be

paid

to

the

following

INSTALLATION

engines information:

and

generators it

is

important that strict

CODES

Strict federal regulations, when

AND

REGULATIONS

ABYC

installing engines and

guidelines,

generators

and

safety

in a marine

codes

must

environment.

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust or

will

be

below

the vessel's

break

in

the

raw

water supply

minimum

the exhaust manifold injection port

raw

If

you

to

siphon-break.

NOTE:

operation. engine

EXHAUST

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

of 20"

above

water damage

have

the vessel's waterline under

A

siphon-break

Failure

damage.

to

any

doubt about the position of the

to

Consult

SYSTEM

is

recommended.

turns

without

turns .In

MUST

any

the

this

regard, a single

be designed

sea conditions

waterline,

the

vessel's

the engine

requires

properly

the

siphon-break

MUST

need

of

to

and

at

provisions

hose

to

the

exhaust

waterline.

is at or below the load waterline will result in

and

possible flooding

the

vessel's various operating conditions, install a

periodic

inspection

maintain a siphon-break

manufacturer

be

certified

The

use

of this type of hose

additiinal

prevent

fitting

length

of corrugated exhaust hose

the

entry of

any

angle

Failure

water-injected

for and

of

vessels

must

be

made

to

elbow.

This

hose

to

use a siphon-break wheli -

of

the

boat.

exhaust

and

cleaning

can

to

result

for proper

marine

use.

Corrugated

allows

clamps

to

accomplish

water

into

the

exhaust system

heal.

be

complied

elbow

is

install a

must

ensure

in

siphon-

be

looped a

elbow

proper

catastrophic

maintenance.

Marine

for

extreme

these

can

be

used.

with

close

to

relative

bends

The

AVAIL.&,QLE

YOUR

DEALER

SIPHON-BREAK

LOOP

FROM.

WESTERBEKE

WITH

STAINLESS

A

detailed engines to

download

Marine

and

generators,

from

Installation

is

supplied

our

website

Engines & Generators

Manual at

covering

with

each

gasoline

unH. A pdf

www.westerbeke.com.

iv

and

diesel,

Is

available

TABLE

Parts

Identification

Introduction

Warranly Procedures ............................................... .3

Serial Number Location ........................................... 3

Fuel,

Engine

Preparations

Control

Operating

Break-In

Safety

Maintenance

Cooling

Raw

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

Drive Thern1ostat

lleat Exchanger ......................................................

Fuel

Syslem

Fuel

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

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

Carburetor ..............................................................

Engine

Oil Change .............................................................

Remote Oil Filter ...................................................

Starter

Testing ....................................................................

Battery

Testing ....................................................................

Engine

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

Governor Maintenance ........................................... 28

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

Choke Solenoid ......................................................

Valve

Ignition tirning .......................................................

Torquing Cylinder

Wiring Wiring

Wiring

Generator

\Viring Diagram .....................................................

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

Wiring Diagram (60Hz) ......................................... 36

No-Load Adjustmem .............................................. 37

Generator Resistance Values .................................. 38

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

Lay-Up

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

Oil

and

for

Initial

Panels

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

Instructions Instructions

Procedure

Shutdown

Schedule

System

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

Water

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

Water

Intake Strainer .....................................

Belt

Adjustment ...........................................

............................................................. l 7

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

Lift

Pun1p

Lubrication

Motor

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

Charging

Troubleshooting

Adjustments

Adjustment ................................................... 30

Diagram

(Engine)

Schematic

Diagrams

Information

and

Recommissioning

OF

CONTENTS

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

Engine

(Daily

SWitcbes

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

Oil

Circuit...

Coolant

Start-Up

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

(Remote

Operation)

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

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

Paneis)

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

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

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

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

.,

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

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

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

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

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

Head

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

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

(Engine)

(Panels)

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

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

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

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

1 o

11

12

14

15

16

17

18

t8

18

19

20 21

22

24

25

26

28

28 29

29

30

31

32

33

34

35 35

..40

Specifications ............................................................... 42

Torque

Suggested

Specifications ...................................................

Spares

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

44

.45

2

3

5

6

7

8

9

20AmpDC Circuit Breaker

Lube Oil Dipstick

PARTS

Fresh Water Coolant

Model Data Tag

FUI

IDENTIFICATION

Lube

OH

Fill

Exhaust Temperature Switch

Distributor

45° Exhaust Elbow

Oil Pressure

Switch

...

Heat Exchanger .

Control Panel

8A

&15AFUSES~

--~

/

Air

lntak~

DC Battery Ground Connection

REAR

Starter with Solenoid

Flame Arrester

FRONT

AC

Connections---

Outlet

Gasdenser

Lube Oil Drain Hose

lwiWESTERBEKE

Engines & Generators

2

i--~-Water

Switch

Sea Water Pump

Zinc Anode

Temperature

INTRODUCTION

This

WESTERBEKE WESTERBEKE'S technology. and dependable perfonnance of our engines Thank

In order

it

is manual manual carefully throughout. your nearest

· ·

This provided WESTERBEKE equipment for WESTERBEKE'

We

you

for

to

get

important that

is

designed

Should

WESTERBEKE

is

your

Operators

and

a Technical Manual

yourself,

WARRANTY

Your

WESTERBEKE

folder.

If

you

have

card registering

warranty registration writing

with

model

and

number

commission

Generator

long

years

take

great

selecting WESTERBEKE.

the

full

use

you

operate

to

help

and

observe all.the safety precautions

your

Manual.

dealer.

If

contact your WESTERBEKE dealer

S Installation Manual.

is

a product of

of experience

pride

in

the superior durability

and

benefit from your

and

maintain it

you

do

this.

generator require servicing, contact

dealer for assistance.

A Parts Catalog

is

you

are

planning

PROCEDURES

Warranty

not

received a customer identification

your

warranty

form, , please contact the factory in

information, including

date

60

is

days

included

and

advanced

and

generators.

generator,

correctly.

Please read

is

also

available

from

to

install

in

a separate

after submitting the

the

unit's serial

this

your

this

This

WESTERBEKE

span

between printings of WESTERBEKE product

and

the

unavoidable existence of earlier WESTERBEKE manuals. WESTERBEKE other

suppliers, must

sively

as

not

only

makes

representatives

be

consulted

product

software

SERIAL

The

engine's

sticRers

affixed

engine's serial engine

block

lube

oil

filter.

illustration quick

reference

ordering

SPECIFICATION

MODEL

RPM __________

KW

___

customers

In

summation,

products, whether from WESTERBEKE or

the

definitive authority

good

ofWESTERBEKE or the supplier in

to

determine

being

NUMBER

model

to

either side of the generator housing.

number

on a flat

Take

of

the

I.D.

when

service/repair parts.

should

also

keep

product software provided

not

and cannot be relied upon

on

the respective

sense but is imperative that

the accuracy

consulted

and

by

the customer.

LOCATION

and

serial number can

can

also

be found stamped

surface just above and inboard of

the

time

to

enter this information

sticker

below,

as

this

seeking

te~hnical

50 HZ.

___

~----

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G

_______

_

in

mind

appropriate

currentness of

be

found

will provide a

information

$:JJ

60,

HZ.

the

time

software

with

exclu-

product.

question

on

I.D.

The

into

the

on

the

and/or

It

the

Engines & .Generators

Customer

WESTERBEKE

MAIN HOMETOWN,

Model BCG -

.

Expires·_----·

PRODUCT

Product software (tech

catalogs)

are

not

WESTERBEKE CANNOT CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS

.

INCLUDING ACCURACY, NESS THEREOF

POR'ANYTYPE OF DA0MAGE OR CONNECTION WITH OR FURNISHING

Identification

OWNER

STREET

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Ser.

#

----

SOFTWARE

data,

parts lists, manuals, brochures and

provided

within

from

sources other than WESTERBEKE

WESTERBEKE'S CONTROL.

BE

RESPONSIBLE FOR THE

WITH

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OR

USE OF SUCH SOFTWARE.

-

---

RESPECT THERETO,

OR COMPLETE-

NO

EVENT

INJURY

OUT OF THE

BE

LIABLE

INCURRED

IN

·

KVA

-~---------

VOLTS

AMPS

________

___

ENG.

HP----~-

ENG.

SER.

GEN.

SER.

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RATING

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TEMP.

CLASS

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----------

Fill

in

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informa.tionfor

Engine

l.D.

G

____

NO. NO.

------

Plate

_

.•

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your

I

reference.

Engines & Generators

3

.

ORDERING

Whenever generator include a

needed

part Also

will fit

specifications

NOTES,

As

this maintenance generator,, CAUTIONS,

NOTE:

A

observed,

PARTS

replacement

and

engine

complete

(see

insist

upon

or

generic

as

CAUTIONS

manual

schedules,

critical

and

An

operating

CAUTION:

can

engine.

A

WARNING:

fa/lawed,

NOTE:

by

WESTERBEKE.

the

SPARES

Certain WESTERBEKE

SUGGESTED

as

proper way. spares on-board

NOTE:

manual). the about

can

A

carbon

engine

room.

AND

spares

fuel

WESTERBEKE

and

accessories

inventory

Also

available

These

drive

engine.

these

kits.

parts

are

needed,

model

and

serial

part

description

the

separately

WESTERBEKE

parts

are

frequently

original

equipment.

AND

takes

you

through

and

information

WARNINGS.

procedure

Procedures,

result

in

the

Ptocedures,

result

in

personal

monoxide

Affix

warning

this

decal

and

furnished

packaged

WARNINGS

the operating

troubleshooting of your

will

be

An explanation

essential

which

damage

which

injury

decal

in a visable

ACCESSORIES

will

be

needed

to

support and

generator or engine

SPARE

and oil

of

are

provide

Visit

our

PARTS).

filters

will

brochure

the

basic

can

provide

proper

Spare

Parts

service

website:

Often

be

difficult you

to

assist

WESTERBEKE

Kits

spares

www.westerbeke.com

INTRODUCTION

always

provide

numbers.

part number for each

not

highlighted

to

if

not

or

If

has

when

even

with a suggested

(last

In

addition,

Parts

Catalog).

parts

because

made

to

the

same

procedures,

by

NOTES,

follows:

note.

strictly

destruction

not

prapedy

ar

lass

been location

maintain cruising simple

to

you

page

needed

of

life.

provided

in

(see

items

obtain

along

in preparing

parts.

in

this

in

maintaining

to

the

your

such

learn

an

the

PROTECTING

Care

at

the

have

resulted

many

thousands manufacturer installed

operated

buyer/owner

NOTE:

Six

•

Proper

• An

efficient

anti-siphon

engine.

•

Changing hours.

•

Proper components this

•

Use

•

Winterize

RECOMMISSIONING

UNDERSTANmNG

The

gasoline

ways

similar

are

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

lubrication which

is generator's maintenance The

most proper ventilation, maintenance of the system,

YOUR

factory

during

in a

WESTERBEKE

of hours of

cannot control

in

the

vessel

and

serviced in operator.

important

engine

maintenance

manual.

clean,

steps

and

well-designed

break

to

the

engine

according

filtered

your

engine

THE

engine

driving

to

a gasoline

in-line,

system,

thermostatically

important

cooling

engine

that

system

and

which

The engine

and a fresh

requires

is

required of a

factors

INVESTMENT

assembly

generator

dependable

how

or

the

manner

the

field.

this

to

ensure

long

generator

prevent

oil

of

unleaded

according

exhaust

and

all

engine

to

the

section

fuel

installation.

water

oil

filters

maintenance

in

GASOLINE

an

AC

generator

automobile

the

engine's

is

chain-driven.

which

is

horizontally

incorporates a pressure

water-cooled

controlled.

the

same

gasoline

to

the

generator's

and

the

generator

and

thorough

capable

service.

where

the

in

which

is

up

to

generator

system

thaJ

from

entering

every

and

generator

schedule

to

the

JAY-UP

this

manual.

ENGINE

engine.

cylinder

head

The

mounted

engine

To a large

preventative

automobile

fuel

system,

back-end.

testing

However

generator

the

unit

the

life:

includes

the

I

00

operating

AND

is

in

many

The

cylinders

has

engine

type

block

degree,

longevity

ignition

of

the

is

an

in

an

utilizes

and

the

engine.

are

CARBON

WESTERBEKE recommends mounting a carbon detector in

even

The presence from elbow/e:xhaust

If

carbon monoxide is present, ventilate the area

air

MONOXIDE

the

vessels living quarters. Carbon monoxide,

in

small amounts,

of

carbon monoxide indicates

the engine or generator or

hose.

and

correct

the

DETECTOR

is

problem immediately!

deadly.

from

the

an

exhaust

monoxide

with

.

leak

clean

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

·A

CAUTION:

higher.

Etbana/

BefSDll°'e

a~/e;far.·use.!R·tbesemo*/s

warranty.

Gaisoline With an

highar

than

108/e

and

mllY

Care

Of

The

Use

only

clean properly filtered components particles

these

and

keep unsatisfactory by careless handling or improper facilities. engine's daily use is clean advisable:

Purchase

Install

metal

and

the

in

which might

finely

finished

it

clean.

To

a well-known

and

regularly service a

bowl

type

engine.

Ilse

unleaded

gasa/lne'must

·wif~

hillher.1111rce11tages

89

Octaae

not

exceed of·Ethaaol

and

ETHANOL

lE10) is

void

Fuel

the

unit's

The best

assure that the

filter/water separator between the

content

nOt

warr~nty.

·

•llowed'

. :

Supply

fuel!

The

fuel

system are very critical; dirt

pass

through the filter

parts.

It is important to buy clean

fuel

can be rendered

fuel

going into the tank

and

pure, the following practice

brand

of

fuel.

good,

Coast Guard

gasal/ae

E10

caa

cl~~

can

(100/o).

are,

not

void

the

of

damage

storage

for

approved

fuel

or

some

fuel,

your

tank

.

,

is

ENGINE

WESTERBEKE and chemicals

The run at proper temperatures

the engine to the coolant

cooling quality Additives balanced,

The distilled water

being polired into the cooling circuit.

NOTE:

antifre~

A engine

COOLANT

A coolant recovery tank kit is supplied

The coolant without the loss of coolant

the

COOLANT

recommends a mixture of

50%

distilled

antifreeze performs double

circuit from rust and

antifreeze that contains

crucial to long term

Look for

proper

SO/SO

coolant

pmpose of this recovery tank

expansion

cooling

water.

Distilled

that can corrode internal engine

by

It

(SCAs)

that

that keep

and

·antifreeze should

tlie

new

environmentally-friendly

is

now

available.

mixture

temperature

RECOVERY

system.

as

and

contraction

recommended

TANK

and

water

du~.

transferring

also

lubricates

corrosion.

Supplemental

the

antifreeze

protection.

to

tempCratures

is

to

during

without

\

50%

antifreeze

is

free

from

surfaces.

It

allows

the

heat

away

and

protects

Look

for Cooling

chemically

be

premixed

will

protect

of

-40°R

with

each

allow

for

engine.operation,

introducing

\{i

the

engine

from

the

a

good

before

'wng

lasting

the

generator.

engine

aii:

into

to

ENGINE

Use

Specifi~

eilgine:

break-in

change intervals

SCHEDULE in this

Wesrerbeke

disapprove

oils

using

be as

sectiOD.

oils

NOTE: The infor,mation above supersedes all

a

heavy

duty

enghie

oil as called fbr

Section oftbis manual.

oil

and

filter after the initial

opetatian.

Corporation does

the use

are

used, engine break-in

conventional

listed

in

of

this

are

used.

statements regarding synthetic

TJ:ten

follow the

ti

specified in MAINTENANCE

manual.

of

synthetic oils.

oil.

Oil

change

the

MAINTENANCE SCHEDULE

manuai

and

not-extended

SQ

-0ilan.d

not

approve or

If

~ust

be

iJ:ltervals_

in

the

Change

hoUrs

filter

synthetic

pertbr:in~

must

if

sYnthetic

oil.

of

the

NOTE:

Thi.s

located at or

tank,

with its short

above

the

level

of

run

the

of

plastic

engine's

hose,

exhaust

is

best

manifold.

PREPARATIONS

COOLANT·

FILL

FOR

INITIAL

START·UP

OIL

DIPSTICK

4-MAX.FULL

PRESTARTINSPECTION

Bef91'e

starting layoff,

longed

• Check the

full

a Check

bowls

a Check

and

battery

a Check

and at

NOTE:

the

engine's rec<JVery the

cooling after

tank

replace Before

manifold

tank

•

Visually parts, threaded

your

check

the

engine

mark

on

the

fuel

supply

for

contaminants.

the

DC

electrical system.

cable

the

coolant

the

manifold.

After

the

cooling

tank.

Open

system

the

engine

will

be

drawn

the

purged

subsequent

should

may

need to

exainine

disconnected

connections.

generator for the

the following oil

level:

add

the dipstick.

and

examine

connections.

level

in both

initial

running

system

will

the

air bleed

is purged

has

cooled, into air.

operation

be topped

be

filled

the

wires, unattached

<Jf

the

engine's

of

off,

to

the

unit.

Look

Search for

first

items:

Qil

to

maintain

the

Inspect

the

plastic

of

tlJ.e

generator,

bepurged

petcock

air.

After

coolant

cooling

the

generator,

and

the

MAX

for

loose

any

time

or after a pro-

fuel

filter/separ:ator

wire

recovery

to to

shutdi:Jwn

from

system

coolant

leveL

or

missing

hoses,

and

gasoline

the

level

connections

tank

the

air

in

the

coolant

ensure

that

and

the

rec<JVery

to

the

engine's

recovery

check

leaks.

at

a

.Che(:kl()ad

the

Wiring

•

Examine

• Be

sore

the

load

a

Be

sure

neutral

isproperly.grounded,.(or.ungrolJJlded)

requires,

to

the

load

or

open

~ge

onunbalanced

A

CAUTION:

teOO/llllltllltltld

·motors,

'"

speff/

precaution

patsd

operation

cold

qine

leads

for

correct

diagrams.

the

air

inlet

~d

no

other generator or

lines. ·

that

in power

and.

that

generat()r

neutral.

neutral

can

In supply

loads.

If/lien

tbatall M

be

swltdled

anti,

will

tram

In

cold

prtJvent

al the

stalling.

tiff

<;onnections

outlet for air

utility

systems

single

with

neutl'at

phase

the

V'lrong

start!PI!

loar$,_

until•

t:lialates,

damage

AC

machinery

.as

specified

flow

obstructions.

power

is

connected

a neutral line

is

properly

systems

line-to-neutral volt-

ti!•

fP11Jllflllor,

that

as

the

connected

.~

incomplete

n

Is

11$/lf1Dlallylarg11

1111!Ji.n11

b.f!s

t:Oflle

·starts

to

watm

up.

callSfld

by

and

unantlBJ.

will

prevent

in

to

the

system

up

This

a

Engines & Generators

6

CONTROL

PANELS

DESCRIPTION

The generator mounted control ON

switch (black), a START switch(white) and a

switch (red). The

ON

switch provides power switch by-passes the protective oil pressure shutdown switch until the oil pressure reaches 5 -

The

START switch energizes the start solenoid/starter which

cranks the engine. This switch will switch is depressed and held at the same time.

The

STOP switch will twn

switch must The

panel also has two fuses to protect the

•·A

Stow-blo

•An 8 Amp

any

REMOTE

An

optional remote start/stop panel is available for

controlling the generator from a remote location. This panel has the same ON, START, and STOP functions

previously described. Also included is a green LED light which glows once the engine/generator has reached

rpm's. The purpose release the engine/generator

be

depressed until the stop sequence

15Amp

Fuse

to

protect

optional

remote.

~a'!_efs.

START/STOP

of

the LED is to alert the operator to

START switch. It is also an .'ndication that the

is

running.

panelis

to

the start circuit.

10

psi.

not

off

the engine/generator.

to

protect

the

start

the

engine

operating

PANEL

(OPTIONAL)

equipped with

operate unless the

DC

circuit:

circuit.

circuff

15

RECORDING FOR

8

an

STOP

nus

is

complete.

ancf

AMP

FUSE

HOURMETER

MAINTENANCE

AMP

FUSE

600

on

HOURS

REMOTE

An optional remote instrument panel is available which

includes a water temperature gauge, oil pressure gauge,

DC charging voltmeter, operating hourmeter switches.

REMOTE

The remote instrument panel has two sending installed on the engine block, a water temperature sender and an

oil pressure gauge sender. Plugged ports for each are

located on the engine. installed in the thennostat housing and the oil pressure sender is adjacent to the oil pressure switch. on the threads each sender are tied wiring harness).

The blue wire is for the oil pressure sender and the is for the water temperature sender. between terminal board connections removed. Refer to the REMOTE INSTRUMENT WIRING

DIAGRAM

NOTE:

installers responsibility to comply with the standards

INSTRUMENT

of

both senders. Electrical connections for

in this manual.

When

installing the optional remote panels, it is

33

CFR

part 183.

PANEL

The

water temperature sender is

off

next to the senders location ( in

(OPTIONAL}

INSTALLATION

Use sealing compound

If

there is a jumper

T-1

•.

·

and

U.S.

aQd

start/stop

units

to

tan wire

T-2,

it should

Coast Guard

be

the

be

the

Engines & Generators

7

OPERATING

INSTRUCTIONS

STARTING

A

for a minimum WJntilatlng fumes

1.

Depress this

2.

Depress

· starts, the

NOTE:

the

oil pressure maintain

3.

Release

·A

when caused and

Once ator

and

ature lf

an

gauges

NOTE:

This and

when

111EGENERATOR

WARNING:

from

primes

release

ON

switch a

Keeping

pressure

to

the

CAUTION:

starting.

by

will

prevent a cold

The

engine

allow

(130°-150°

optional

for

nonnal readings. · · · ·

Soin~·unstable

condition

the

..

Ventilate

of

five

blowers

the

generator

the

ON

switch

carburetor.

the

START (white),

the START switch. Continue

few

the

ON

shutdown circuit allowing the oil

rise

enough

ignition circuit

the

ON

switch.

AllAC

This

precaution

unanticipated

is

running

the engine

Fl

55°-56°C)

instrument panel

should smooth our

generator

the

generator

mlnut•

remove

seconds

switch depressed by-passes

to

loads

running

prior

any

explosive

comjlarlment

and

hold

Continu.e

when

longer.

close

the

mast

will

operation

engine

ttom.sttllllag.

apply

to

wartn

before applying

is

installed, tnonitorthe.·

may

(l$,th.e

loads

a~

appJit4

A

compatfment

to

starting.

gasoline

and

it

down

(5-15

to

depress

the

geneyator

. ·

switch

an.ti

be

swllched pre"6nt of

AC

machinery

-"-

a ligbtJoad

up

ti:>

qperating temper-

the

The

bilges~

•.

sec~nds),

ON.

to

.engage

exhaust pump c11olin!J entettll.e manifold

frorll

throug/Fhull cogecting Engine warrantable in

mind.

STOPPING

1.

Remove generatorto its

off

damage

.·1

operating temperature).

.

2.

Depress

~.

When

NOTE:

the stop

to

the gener-

heavy

·.

loads.

panel.

CAUTION:

engine

with,

is

pumping

system

happening

damagetesultlngfrom

the

In

an

switch,

Prolonged

starting

raw

water.

raw

during

engine's

once

the

emergency,

cylinders

the

exhaust

byt:Joslng

Shutoff,

the

cause

issue:

the

THE

GENERATOR

AC

loads

run

for

an

STOP (red)

generator stops, release the STOP

remove

t;ra11klng

can

result

In

fllllngthe

This

may

water

through

cranking.

draining

of

the

This

by

way

system

the

raw

the

excessive

raw

(Jwner/operator

·

from

the

added 3

the 8

to

S minutes

switch.

if

the

generator will not stop

amp

ju.se

Intervals

happen

tile

miff

of

the

fills.

Prevent

water

exhaust

engine

water

should

generator

in

engine

because

raw

water.

waler

exhaust

supply

muffler,

entry

and

(this

the

control

occ1'tNiJacd!(:l,~ng:i11.e.

e~gtne

'warms'

up

without

the

can

this

and

cranking.

is

not

a

keep

this

allow

the

stabilizes

switch.

using

·

.·Engines

& Generators

8

OPERATING

ABNORMAL

An

abnormal stop

and

comes to a stop

may

cause damage

unsafe operating condition. The fault stop conditions

1.

Overspeed condition!.

2.

High

3. Low oil pressure.

4. High exhaust temperature.

Should a fault condition occur, the engine will shut and

the green LED light indicating that a fault should

OVERSPEED

In the case of

must be reset before re-starting the

Stop switch mtarily

sequence.

If

the overspeed switch itself depressing T-1

coil connection end of only

as a test.

successful, replace

Do

not

switch.

STOP

is

one

in

which

the

generator

as

a result of

to

the

engine temperature.

on

has

be

located (see ENGINE TROUBLESHOOTING).

an

operating fault which

engine, the generator, or create

the remote panel will

occurred. Once detected,

ceases

SHUTDOWN

an

overspeed shutdown, the overspeed circuit

the

generator. Simply

then

the

T-1

run

the generator

STOP

from

wire

with

Re-start

the

proceed with

is

switch

will

the

overspeed switch

electrical

the

generator,

faulty

overspeed switch.

with

faulty

not reset

tape.

out replacing

the

and

re-setting it

the

By-pass

if

this by-pass

the

normal

circuit,

and

this

overspeed

go

tape

is

to

are:

down,

off

the

fault

depress

start

by

lift

the

circuit

INSTRUCTIONS

NOTE:

Overspeed switches draw a small amount

run

an

the

amperage (25 milliamps) at all times once the generator connected to its starting battery. This amounts mately 18 amp-hours concerned with this slight amperage draw during normal

. seasonal operation.

unused for many months, it

amp ignition fuse from tum

off

the

generator's starting battery

A

CAUTION:

shutdown tampering would injury

and

REMOTE

The remote startpanel operate the same except that they have remote location (where be

audible). The green generator is running switch should be released. For the remote start/stop sequence refer to

always

with

cause

should

cause

the

PANELS

STARTING

in

a month. It is not necessary

However,

It

is

be

installed

the

overspeed

it

to

malfunction,

the

generator's

generator

as

the generator mounted control panel

green

LED

at

about

THE

if the generator set

is

best to either

the

controlpanel

very

important

and

functioning.

shutdown

could

belt-driven

to

run

away.

and

the remote instrumentpanel

LED lights for starting

the

sound

of

the

lights indicate

600

rpms.

GENERATOR

remove

on

the

switch..

that

the

module,

be a cause

governor

generator.may not

when

That is

on

the

of

to

approxi-

to

be

is

to

be

the

8

generator or

overspeed

Any

which

of

fail

at

a

the

when

the

start

previous page.

is

A

the

Refer manual.

to

WARNING:

overspeed

the CONTROL

switch

Do

not

operate

by-passed.

PANEL

the

generator

WIRING DIAGRAM

with

in

this

Engines & Generators

g

BREAK•IN

BREAK·INPROCEDURE

After

the.generator

and

then

encourage a fast

20%

to

60%

A

CAUTION:

tor

by

running

After

the

first

can

be

increased

vary

the

foad.

Avoid

.

<lverlo~d

smoky

eXhaust Monitor it at hertz, by

To

the

breaker

NOTE:

current drawn amperage drawn age. See

the

within

the

1800

rpm

control

the

current

protect

against

generator;s

that

Be aware

GENERATOR

has

been

started,

warm-up.

of

full

load

for

the

first

·Do

not

attempt

without

10

~all

with

currentbeing:d.rawn

genei;a.tors~

to

produce

of

drawn

output

is·

rated·

required

a

/aad~

hours

of

the

generators'

to

the

full-:load

time:;.

¥

l'edoCed:

the

generator's engine

from

unintentional

at·

of

motor starting

can

be 3

output

tating.

60

hertz; the

leads

should

the

rated output

for

starting

to

5 timesnormalrunning

INFORMATION

rated

·· 9yertoa.d

Since

generator.

overloading

check

Run

the

10

hours.

to

break-in

operation,

output;

i~

voltage.

from

i:he

generator

the

generator

or

at

1500

break~in

be

routed

of

the

toads

anti

motors.

in.thisfrtanua.L

PROCEDURE/DAILY

NOTE:

This

for

proper

generator

operation

between

is

reached

condition

A

your

genera-

periods

OPERATION

Some

unstable

should abate

and

loads

CAUTION:

of

time

Do

not

without a load

generator.

the

load

then

periodically

·

.signa}~

and

by

a

frequency~

and

keep

operates

to.produce

cjfi:he

through a circuit generator.

th~

This starting

is

governed

generator,

high

r:zmper-

50

·

STOPPING

Remove Allow

the

operating

CONTROL

NOTE:

After

.

the

nuzintelltlnce

.

GENERAToR

Once be

governor

during

this

period under ment

speed

the

ENGINE

may

adjustment

.

tHE

GENERATOR

the

major

AC

generator

temperature

PANELS).

the

first

schedule for

ADJUSTMENTS

generator

engine's

(see ENGINE SPEED (HERTZ) ADJUSTMENT

also

has

adjustments

break-in period (first 50

ADJUSTMENTS. A

be

required

(see

running may occur

as

normal operating

are

applied.

operate

the being

loads

fu:im

the

tb.run

for a

few

and press

SO

hours

beeh

GENERATIOR

of

the

placed

required

in

conjunction

the

STOP

generator operation

50 hour service

in

for

no-load

~n

a cold

temperature

generator

placed

generator

minutes

operation,

engine

INFORMATION).

to

switch

speed

hours)

voltage

with

for

long

on

the

one

stabilize

down,

check.

there

(hertz) or

the

engine's

engine.

at a time.

the (see

check

may

after

adjust-

CHECKLIST

Follow

this

checklist

•

R.ecord

the

hounneter reading

relate

to

the

maintenance

•

Visually

II

Check

•

Check

•

Check

•

Check

a

Check

•

Check

blow-by

•

Confirm When When When

inspect the the your the the for

abnormal

sounds.

exhaust

the

engine

the

engine

the

engine

oil

level

coolant

fuel starting drive

each

day

before starting

in

schedule).•

the

engine for

(dipstick).

levelin the coolant

supply.

batteries

belts

for

.noise

smoke:

is

cold

is

wann - almost

is

overloaded -

fuel,

(weekly).

wear

and

such

-White

your

oil,

proper

as

knocking,

Smoke.

Smokeless.

some

your

log

(engine

or

water

recovery

tension

vibration

Black

Smoke.

generator.

hotirs

leaks:

tank.

(weekly).

and

Engines & Generators

10

SAFETY

SHUTDOWN

SWITCHES

. SAFm

The engine Should a shutdown

finding

Engine TROUBLESHOOTING

The following is a switches:

SHUroOWN

is

protected

occur,

and

correcting

starts,

runs

and

desCription

SWITCHES

by

a variety

do not attempt

the

cause. Refer

then

section

of

shuts dbwn in the

of

this manual. .

of

these automatic shutdown

shutdown switches.

to

restart without

to

the heading

ENGINE

EXHAUST TEMPERATURE

SWITCH

Exhaust

An

elbow. This switch will open and interrupt the DC voltage tn

the ignition coil (which turns

switch's sensor indicate an excessive exhaust temperature

inadequate supply.of raw water coolant causes high exhaust temperatures). (

127° -132"

Temperature

exhaust temperature switch

This switch opens at 260" - 270° F

C)

and resets

Switch

at

approximately

is

located

OFF

on

the

the engine), should the

22."i'F

exh;~ust

(107'' C)

(an

low

Oil

Pressure

A low oil pressure engine's oil gallery. The switch pressure. Should the

t11e

switch

will open interrupting the DC voltage

ignition

coil (which turns

Oil

FILTER.

Switch

shutdown

engine's

1.·~¥.-V~

~Ji

switch

oil pressure

OFF

the engine).

LOW

is

located off the

is

kept closed

OIL

PRESSURE

fall

by

engine oil

to

10 -.15

to

the

SWITCH

psi,

r.;:;;

High

RPM

Shutdown

An overspeed shutdown switch shuts

by

grounding out the ignition system should the engine's

speed reach approximately

momentarily depressing the

cause

of

the engine

Engine

Circuit

Breaker

The.

generator's engine is protected manual reset circuit breaker (20 amps DC). Excessive current draw

or electrical overload anywhere

wiring or engine wiring will cause

the generator will shut down because

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

Switch

2175

STOP

overspeed

OFF

the generator set

rpm. Reset the switch b)

switch. (Make sure the

shutdown

to

is

cnrre.cted).

by

an

engine mounted

in

the instrument panel

the breaker

the K2-run

the

to

opened

relay.

trip.

If

the

In

this

High

Water

A

high

housing. This switch

to

the

ignition coil (which turns

fresh water coolant's operating temperature reach

approximately 205" F (96" C). ·

This switch resets at 195" F

Temperature

water temperature switch

will

Switch

open and

(!OTC).

is

located on the

inte1rupt

OFF

thcm10st.at

the

DC

voltage

the engine). should

l"flV'iWESTERBEKE

~

the

Engines'&' Generators

11

A

WAllNING:

running.

11$8

the

curreot

serrlcin9

NOTE:

Many

more

difficult

MAINTENANCE

Nsver

attetnpt

Wear

tbeprap11raletyeq'1i/1"1ent

t~ols

,,,,

any

of

the

e11gi11e'I

of

the

following

and

may

require

to

perfQrm

,.ch/o/l.111$coanect

DC

BlilctriQal

mamtenance

the

expert

SCHEDULE

any

service

such

the

equipment.

procedures

knowledge

while

as

g11119/e$

battery

are

$imp

of

a

service

terminals

the

engine

and

gloves,

le

but

others

mechanic.

Is

and

when

are

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

V!sual

Sparks Starting

(and

Engine

Generator

Fuel

and Air Exhaust

Engine

Raw

Belt

Separator

Oil

Level

Belts

Inspection

Plugs

Batteries

House

Batteries)

Oil

Lift

Pump

G11sdenser

Screen

(Flame

System

Hoses

Water

Pump

Driven

Governor

of

engine

Arrester)

CHECK

EACH

DAY

0 0

D

·weekly

0

weekly

HOURS

OF

OPERATION

5Q

100

25.0

500

NOTE;.

Keep.

engine

surtace.cle~n·Dirta~r:frJif

wlll

lnhi/Jit

too

engifie'S

ab.lffJYt~iem~in.cgpl.

[j

0 0

0

0 D

·

..

··D··.•

0

. •

I

0

c-

0

D

0

D

0 D

D

O D 0 0 D 0

D 0 D D

.750

·cc-

.

0 D

·o~

D D

..

0

..

D.

0

1000

D

0

D

0

.·

. i

••

MAINTENANCE

1250

Unleacled Check

·

necessary). Oil

clipstick

.

1

crieC:k~recovery

.:Acid#P91ilJJt:if·n.eeded.

· · ·

••·

• ·

··

1

"lli$g~oftorpr~perterlston

. . I

a,ng

•tjbep~:tor

' ·

.•

eleetncat

tor19~sebe~tt!nsiqn.

c'

Eve~

and ei.<c.essive.

0

Initial change

D

Check no

addition~l

Periodically

0

·Clean.

>o

Initial lnspept Check buildup

necessary~

D

Hose

oecome

Visually

and. impeller. wobble.

pump

0

~

Change

governor·

gasoline

for

water

and

level

should

indicate

•.

tan~j.jf

~cllll~lifntieded•

fuer;

oil

aild

cortnectio~s.

50

ope~ting

make

sure

~nnections

porrosion.

engine

oil

and

both

every

that

AC·

connections·

chafing-see

at check

should

inspect

GENERATOR

lnformation.

Inspect

50hrs~;

then

at

50J1ours;

for

leaks.

Ch.eek

the

e,xtiaust

on

inside

passages;

Clleck

that:all

be.

hard

spongy.

Check

inspect

tor

cover

Ensure

impeller

Replace

items

as

needed.

gooernor

oil

operation

DESCRIPTION

with

octane

rating

of89

of

higher

dirt

In

fuel

(drain/repl~e

between

MAX

empfy,

check

(3/8''.

fo

1/2·

9~1ick

belt

edges

v\iaterleaks;•

Keep

·.

h~!Jrs

filter

100

hours.

tor

leaks.

every

then

anti-siphon.

elbow

for

c~n.oections

& tight

~nd

leaks.

surface

shaft

as

every

as

needed.

Inspect

bolts & nutS

·

check

electrolyte

are

very

change

at

50

are

clean

INFORMATION

100

hours.

every

250 valve

carbon

and/or

clean

and

Replace ~ hoses

tighten

all

Remove

the

and

cam

1or

is

secure

needed.·Rebuild/replace

250

!lours.

filter

and

LOWon

at

manifold.

defle~on)

ror

wear.

wiring.

tight.

levels

tight

Glean

hours,

and

secure

for.

hours.

operation.

corrosion

replace

are

tight

hose

clamps.

pump

cover

wear,

Inspect

and

does

Adjust

if

·

and

Check·

·.

-"-

off

then

with

as

not

.:

·

lw;UfSSTElllJI!~

I

Engine/$

& Generators

12

MAINTENANCE

NOTE:

l

:H

t''ngtne

e11gi11e

huun

,-i

-----,,--·---~-~·-~--~-'

I

SCHEDULED

~~~~TEN~N._ff_

I

Heat

Exchanger

CHECK

EACH

-~y

r1111nmg

1 -

j

--

-~0_

1·

0 O O ! O 1 O O ' 0

hourtli1/'!er

ti11n'.

HOURS

- · --

110~

);;UUtte Jo

Of

--

OPERATION

- -

250

_

50~750

! , I

L : \

I

Coolant

System

I j

I I I

l

Start~-r_M_o_t_o;------·---<c----+----+---f

l

I I l · I

r

Distributor

----+--0--<>---+i

' O

'

---+-1

-0--+1--j,___..__O_--+---C--hr-:c_.k_s_o_le-110_1_d_a_n1-.-m-{-1to_r_fo_r_c--o-n--o-si-on-_-R_e_m_o_vc-n--<

'

1

--1-·

0

SCHEDULE

/p'.!,_

r1>ur

r·n,~ine

i!uuts·

---r-

· -

-

__

11_!)0

_j

~

l

50

___

c:.:an

;,,,p

for

and

pnnon

Ci1(;Ck

and

---r1_000

--

tir

H'\:01'1

EXPLANATION

~-

or

replace

clean

out

f!usl-:.

and

;mtltreeze

luonc:ite

Clean

dnve.

1go1t1on

------"-----

Of

SCHEDULED

MAINTE~~~f~

anofle

Open

c!ebns

Remove

and

refill

cooling

rn:x

and

!utJricate

heat

pressure

system

every

________

exchanger

ever;

1000

testing

wittl

500

holirS

!lie

start

_

end

hours

ot

motor

;----------·-----

·Engine

I

l

I

t···---·----,..-~~-------<~---·--------+----+---

1

I

!---------·-----+----+-----+-·

I

Cylinder

Compression

Valv__e_~t:aran~:

·Engine

·Exhaust

Carburetor

Timing

Elbow

Filter

and

____

Belt

~

Screen

__

_,_

_

_,_

__

·-rr

Ii

0 0

O O

111

1

0

d1S!!1'.lu!Qr

lncorrec1

Inspect

Test

exhaust

castmg

WARNING:

carbor

Clean

cap

valve

every

elbow

is

corroded

A

detective

rnonoxide

after

50

every

and

rotor.

clearance

500

hours.

for

or

t;ours

of

250

operating

will

result

Replace

casting

deteriorated

extiaust

elbow

operation.

hours.

in

a!

3000

can

Clean

hours

Replace

cause

and

1!

13

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine engines are designed fresh water cooling. Heat produced in the engine tion

and

friction

is

transferred

to

fresh water coolant circulates throughout the engine. This circulating fresh water coolant cools the engine block, the engine oil. The heat fresh water coolant exchanger, similar water

flows fresh water coolant ferred

to

the fresh water coolant

tube walls to the raw water which is then pumped

through

to

raw water

in

function

the

flows

its internal moving

is

transferred externally

by

to

an

tubes

of

the heat exchanger

around

the,

is

exhaust system where finally it is discharged overboard. In

other words,

this coolant

the

engine is cooled by fresh water coolant,

is

cooled

by

raw

water, and the raw water carries

the transferred heat overboard through the exhaust

the

fresh water coolant

dent of each

other.

and

raw water circuits are

Using only fresh water coolant within the

engine allows the cooling water passages to stay clean free

from

harmful

deposits.

-

and

equipped

by

parts,

from

means

of

a heat

automotive radiator.

tubes; engine heat

conducted through

into

system. indepen-

r---.....,

WATER INJECTED ELBOW

ENGINE

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

-----

for

combus-

which

and

the

Raw

while

trans-

the

and

------

Coolant

A coolant recovery and

contraction

cant

loss

ing

system.

engine manifold level

COOLANT

COOLING

PRESSURE CAP

Recovery

tank

during

of coolant

This

and

tank should

EXPANSION

KEEP

THESE

A'FULL

THE

COOLANT

CLEANER

DIAGRAM

Tank

allows

for

engine

engine operation,

without

and

FLOW

WORKS

introducing

be

located at

should be easily

!TO

TANK

PASSAGES

OF

COOLANT

RECOVERY

WELL)

(TYPICAL)

.

without

COOLANT

CLEAR

TO

AND

TANK

(A

coolant

expansion

any signifi-

air

into the

or

above

accessible.

RECOVERY

ENSURE

FROM PIPE

cool~

the

·

·FRESH

WATER¢

··

RAWWATER

NOTE:

Periodically

sure

cap.

good

condition

closes

tightly.

.....

Ensure

that

and

Carry a spare

check

the

check

·MANIFOLD

•PRESSURE

CAP

the

condition

upper

and

that

the

vacuum

cap.

of

lower

INCOMING RAW WATER

the

manifold

rubber

seals

V{llve

.operis

pres-

are

and

in

RAW WATER DRAIN

14

RAW

WATER

NOTE:

Always

the strainer will

A

clean

raw

water engine's strainer

in the glass

Perfonn operation:

1.

2:

3. ·

4.

5.

6.

7.

NOTE:

aground.

If

normal may raw

cooling

when

the

Close

the

Remove

Clean

the Replace Reassemble Open

the

Run

the

Also follow

the

engine

reading, the

have been

water

through

should

following

raw

and

the

seacock.

engine

temperature

INTAKE

install

the

always

int.alee

system.

making

glass.

your

be

clear.

maintenance after

water

clean

the

washer

and

install

and

the

above

cause

caught

up

tQ.e

cooling

~

STRAINER

strainer at or below

be

self-priming.

strainer is a

Include a

periodic engine

seacock.

strainer

if

necessary.

the

check

procedure after

gauge ever

may in the

vital

visual

filter.

strainer.

for

leaks.

shows

be that silt, leaves

strainer,

system

COOLING

the

waterUne

component

inspection

check.

every

a higher

slowing

100

·

having

or

the

of

The

hours

run

than

grass

flow

of

the

this

water

hard

SYSTEM

RAW

so

of

The non-ferrous,housjng

has

wiililii

On

always

(an

when

operation.

are up. broken

SCHEDULE.

NOTE:

(seals

chase

Changing

Close

and,

impeller

Move push bling,

gasket.

WATER

raw

flexible

ihe

no account should this

be

impeller kit}.

lubricant

cautioned The

or

Should a failure occur with

and

a

the

with

the

the impeller into

apply

Open

PUMP

water

pump

pladeS

which

@peller

a spare impeller

Such

mw

tom

bearings),

new

raw the

out of the

blades

housing,

Raw

(mw

failures

to

make

water pump

impeller

pump

and

the

Raw

water

aid

oftwo·small

pump.

to confonn

a thin

coating

the

~w

is a self-priming,

and a Neoprene

wipe

water

water)

are

sure

should

blades.

it

may

ntbuild the

Water

int.alee

the

water

against a curved

producing

pump

fJ'e

and

impeµer

pump

impeller

is not present

not

warrantable,

raw

water

be

inspected

See

MAINI'ENANCE

the

be

more

original

Pump

valve.

Remove

screwdrivers,

Install

the

to

the

c:urved

pump's

of

lubricant

int.alee

housing.

valve.

rotary

pump

impeller.

The

cam

the

pumping

run

dry.

There

cover

gasket

failures

during

engine

and operators

flow

is

present periodically

pump~

cost efficient to

internal

pump

as a

1...,eller

the

pump

carefully

new

impeller

cam

plate

When

assem-

to

the impeller

with a

impeller

plate action. should

aboard

occur

at

start-

parts

pur-

spare.

cover

pry

and

gasket.

and

for

the

SEAUllG

WASH~

RAW

The

raw impeller water water through the

heat

ing

fresh

into

the ing the exhaust water discharge

WATER

source strainer.

is

COOLING

water

fiow

pump.

This

(ocean,

The

the

raw

water

exchanger

water

coolant.

water-injected

gasses.

discharged

pressure.

RAW

WATER

OWNER

INSTALLED

CIRCUIT

is

created

pump

draws

lake,

or

raw

water

pump

tubes)

where it

~.raw

eifiaust

This

overboard

INTAKE

STRAINER

(TYPICAL)

by a positive

water

river}

through a hose

passes from

to

the

heat

cools

water is

elbow,

mixture of exhaust gas

by

the engine's exhaust

displacement

directly

the

exchanger

the

engine

then

mixing

from

strainer

discharged

with

the

raw

to the

(through

circulat-

and

cool-

and

raw

gas

RAW

PUMP

IMPELLER

A

CAUTION:

impeller,

the

exchanger.

they

cooling

WATER

If

any

must

circuit.

of lhe

vanes

be located

They

often

have

to

prewmt

can

be

APPLY

OR

·AT

ASSEMBLY

btalceo

blOckage

found

LUBRICANT

LIQUID

SOAP

off

in

the heat

lhe

lwlWEBTERBEKE

l Engines & Generators

15

COOLING

SYSTEM

CHANGING

The

engine.'s

MAINTENANCE

become

A

COOLANT

coolant

SCHEDULE.

contaminated,

CAUTION:

Proper critical; a substantial traced

back

to

cooling

Drain.

the

e11gine

coolant

engine

block

and

opening

the

system

with

fresh

the

refill

proc~ss.

NOTE:

The

drain

petcock

be

used

to

help

drain

A

WARNJNG:,

Wea1

protective

Refilling

After exchanger-!s_cgolant

slowly

Monitor the

pressure Remove

coolant the flow

After

Coolant

engine

needed

spilled

the

replacing

pour

the

manifold

cap. the

mix

cap.

Run

into

the

checking

should

cools

and

coolant.

BewB1e

glares.

Coolant

the

engine block

petcock.

clean,

premixed coolant

coolant

in the

to

the

filler

cap

on

the

to

halfway

the

engine

recovery

for

leaks,

draw back

down.

Add

check

the

must be

it

can

lead

cooling

numbe1

syst_em

by

removing

the

water,

then

on

the

engine

coolant.

of

manj.fold

neck

coolant between

and

observe

tank.

stop

into

coolant

coolant in

changed

If

the

coolant is

to

overheating

system

of

engine

according

maintenance

c011asion.

the

manifold

the

Then

and

the

pressure

reinstall

heat

drain

recovery

LOW

the

to the

the drain

exchanger

hot

engine

plug, close

run

the engine at

into

the

and add as

install the manifold

tank

and MAX

the

coolant

engine

and

cooling

the

recovery

manifold. Cean

to

the

allowed

problems.

failures

~ain

can

plug

cap.

and

should

coolant.

the

manifold.

needed.

and

fill

and

expansion

allow

it

system

as

tank

to

Is

be

on

the

Flush

start

also

heat

idle

Fill

with

replace

to

cool. the if

up

any

and

DRIVE

BELT

ADJUSTMENT

For

your

safety,

Weste:rbeke

with

belt

guards that cover over

engine.

("Out of sight - out installed inspection,

Drive

will

•

ally pull tor

also of ence high

The· no (12mm)

point

A

for that purpose.) Operators are advised that

service,

beltS

must

not

provide

damage

the

alternator out of

to

wear out prematurely.

cause

rapid wear

the

fresh

water pump's

'of oil

on

operating temperatures.

drive belt is properly

less than 3/8 inch

as

the

between

spare

belt

A

WARNING:

ddre

.belt's

and

be

properly

proper alternator charging

the alternator.

the belt can cause belt slipping, resulting

belt is

the

two

or belts should

llerer

tension

generator models come

the

of

mind." The belt

maintenance

tensioneO.

Drive

.belts

alignment

Excessive

of

the.

belt

and

bearing.

adjusted

(lOmm)

depressed

pulleys

altBmpt

while

A slack belt or

if

and

no

with

on the longest span of the

always

to

check',,,

the

engine

equipped

belt(s) on the

is

required.

Loose

that are

and/or cause

drive belt tension

reduce

the belt

more

the

thumb at the

be carried on board.

and

the

can

than

front

guard

is

drive

belts

will

eventu-

too

tight

the

altema~

service life

the

be

deflected

1/2

inch

adjusttbe

ls

/11

opntloll.

of

the

NOT

proper

will

can

pres-

in

mid-

belt.

FRESHWATER

PUMP

POLLEY

Adjusting

1.

Remove

2.

Loosen

mounting

3.

With edges.

4.

Pivot

or right

5.

Tighten bolt.

6.

Operate

and

Belt

the

belt

the alternator on

as

the

recheck

lwlWESTl!RBEKE

I

Engines_

&

ae~r~tqrs

16

Tension

belt guard.

alternator adjusting strap bolt and

bolt.

loose,

inspect

for

the

base mounting bolt

required, to

base mounting bolt

generator

the belt

loosen

for

about 5 minutes

tension.

FRONT

wear,

cracks,

or tighten.

and

the adjusting strap

7.

Replace

CRANKSHAFT

the

base

and

frayed

to

the left

then'·

shut

down

the

guard.

PULLEY

COOLING

SYSTEM

Heat

After

and

pressure test tive exchanger).

Exchanger

approximately

radiator

shop

Service

1000

the

engine's

should

ZINC

ANODES

hours

be

able to

of

heat

exchanger.

operation,

clean

and

remove, (A

local

test

the

clean

automo-

heat

HEAT

EXCHANGER

Cool

raw

water

flows

through exchanger. heat

is

then

engine

the

The

other;

hmnful deposits

NOTE:

that a heat exchanger cleaning be peeformed every

As

the

en~e.

of the internal

pumped

coolant

circuit

repeats

engine coolant

this

keeps

Operating in silty arul/or.tropical waters

1000

into

(now

hours.

engme

the

cooled)

itself.

and

the

engine's water passages clean

found

the

inner tubes of

coolant passes around these

is

conducted to the

exhaust

system

and

discharged.

flows

back though the

raw

water

are

independent of

in

raw

water.

THERMOSTAT

A thermostat controls continuously the

engine coolant thennostat to heating). opens. cleaned,

gasket.

If

you

bring

is

from

As

The

thermostat

or

replaced

suspect a

to

a

bOil.

flows

first

flowing

prevent

the

started

engine

faulty

A

working

the

coolant temperature

through

the closed cooling circuit.

the

closed

(some

coolant

the

.exhaust

warms

up,

is

accessible

easily.

Carry a spare thennostat

thermostat,

thermostat should

thermostat prevents .

is

by-passed

manifold

the

place it

thennostat

and

can

from

in a pan

raw

may

more

as

be

checked,

open

the

heat

tubes

water

The

engine

each

from

require

often then

the

coolant

When

around

over-

gradually

and

of

water

about

!11e

which

and

the

and

112"

..

NEW

ZINC

.

ANODE

A

zinc

anode (or pencil) is located

circuit

within

anode

is

to

in

the

raw

of

electrolysis

dition

of the

anode

cleaned

be

carried

NOTE:

Electrolysis

and vessel location, not that

If

the

zinc

which

the loosening hex

boss

from

removing

poor

condition,

the

exchanger.

clean

the

inside

exchanger

damaged

(refer number),

NOTE:

not

insulate

housing preventing electrolysis action on the

when

to

your engine model's

0-ring

The threads

require

the

THROWOUT

the heat

sacrifice itself to electrolysis

water

zinc

onboard.

anodes

zinc

the:

anode

the zinc, note the condition of it.

end gasket

sealant. Sealant should not be used as it

zinc from

exchanger.

cooling

on other

or

anode

possibly tearing off the exchanger

there

Remove

of

removing

circuit,

components

anode

should

replaced,

is

need

all

and

of

as

the

r.esult

replacement,

is·

threaded

with

another

are

probably

the end of the heat

zinc

debris.

in

case

the end

cover,

the

zinc anodes are pipe

the

metal

THROWOUT

in

the

raw

water

The

purpose

thereby

of

be

checked

required.

of

each particular installation

of

the

engine.

hold

with a wrench

wrench.

alot

Al.ways

the

present one

cover.

heat

exchanger

and

install a new

of

the

heat exchanger

of

action

taking

reducing

the

system.

monthly

Spare

anodes

the

hex

This prevents

If

the

of

zinc

flakes

exchanger

have a spare

becomes

Replace

end zinc

threads

zinc.

CLEAN

REUSE.

cooling

the

zinc

place

the

effects

The

con-

and

should

boss

into

while

shell.

After

zinc

is

within

and

heat

the gasket

gasket part

anode.

and do

may

AND

the

in

THERMOSTAT

ASSEMBLY

IW'IWESTERBEKE

.f Engines & Generators

.

-17

FUEL

SYSTEM

GASOLINE

Use

u.nkatied

follow companionways ventilate

NOTE:

fume

detector/ala.rm

AWARNING:

When Ing

any

Ing,

fuel

system

tion

GASOLINE/WATER

A primary

installed

water

and

be carried Most installers include a type of filter/water

the generator installation package

the problems that contaminants in the

These gasoline filters must

through")

bowls

have

impurities. · ·

89

octane

or

higher

gasoline.

U.S.

Coast

Gtiard

regtilations,

to

prevent

fuines

ii:om

after

fueling.

The

generator

servicing

fae/tbat

011110

flames

exists

when

. . .

fuel

between

other to

the

to

meet

drain

compartment

properly

Shat

o"

the

tael

may

spill.

or

other

wbell

servicing.

servicing

SEPARATOR

filter

of

the

fuel

tank

conUllillnants

fuelsystem

U.S.

Coast0u$l

-valves

to

should

installed

the

fuel

system.

DO

Take

NOT

SOUICllS

Ensure

the

fuel qstem.

water separating type must

and

the.

from the

on

the

en~e,;

as

have

metal

requirements.

use

when checking for

When

fueling,

close off

valve

of lire

AND

they are

all

hatches

entering

and

allow

proper

the

boat,

have a gasoUne

working.

at

the

tank

care

in

catch·

anysmok·

near

the

ventila·

FILTER

engine

to.

remove

~elbefore

fuel

cari

bowls

they

·

sep~tor

:Well.

aware

·cause:

(not

"see•

The

water

and

be

cari

with

of

Jn.eta}

and

GASDENSER

The

gasdenser consists

coiled around the raw water intake line

located between the raw water intake pump.

The

gnsdenser

lock.

12V

CONNECTION

FUEL

CONNECTION

.

FUEL

LIFT

PUMP

Periodically check

and

make

sure

that

and

are tight pump's the

mounting bolt

The

engine

secure.

mounting

mounted

of

a portion

cools

:..l'

[Ii

I

bolts should be clean

to

. _,,..

11

FUEL

TO

MOUNTING

the

fuel

connections

no

leakeage

The

DC

ensure proper pump

fuel

lift

of

the fuel line that is

and

insulated. It

and

the raw water

the fuel to help prevem vapor

CARS

"

FUEL

LIFT

PUMP

BOLT

to

and

out of

the

is

present

ground

pump

and

thatthe fittings

connection

and

is

~ain1enance

at

one

well

~e9ured

operation.

free.

of the

i»

puJN)

by

GASOUNE/WA'FER

SEPERATOR & FILTER

A

WARNING:

connections Make.sure

faelsyst.em

proper

CARBURETOR

This generator has just

carburetor.

·

shown. screen

To

Clean

should

lw/WESTERSEKE

~rutlne.s.,S

Generators

18

Fuel

leakage

Is

a lire

hazard

ventilation

components.

FILTER

remove the be cleaned

filter

SCREEN

one

filter

the

filter

screen

periodically.

and

exists

screen

screen,

or,

if

at

the

should

~

unscrew

needed,

fuel

pump

be

corrected.

whenever

that

is

located in

the plug

replace it. This

or

Its

servicing

the as

;

FUEL

SYSTEM

CARBURETOR

The

carburetor

cleanable

The

electric

opens

the remains generator load

ori

Air

ScreenJFlame

The air

releasing of

operation,

screen

in

is a single

metal

sereen

choke

uses

choke

automatically

running.

the

is

started,

generator.

Some

Arrester

screen/flami;:

the

hold-down every

100

a water

soluble

air

a 12-volt heating element

hunting

is

on <ne. choke

arrester can

clamp.

hours

barrel,

intake

once

choke,

from

cleaner

down-draft filter/spark

the

engine starts

will

occur

and

is

running

is

factory

easily

be

Clean

after

then

such

as

type

arrester.

when

set).

removed

the

on.

Clean

GUNK.

with

which

and

the

without a

by

first

SO

the

air

a

hours

I

©

Carburetor

Clean

then the there

Idle

Adjustment the

jet

turns.

Note:

induce a sooty

this

clean

screen

if

are

no

Mixture

slowly

An

idle

Filter

filter and

is

down.

Screen

element

inspect

necessary.

leaks.

Jet

performed

in

until

mixture

exhaust

after

the

every

250

Tighten

with

the

it

seats,

then

jet adjusted

discharge

first

50

operating

the

plug

generator

back

too

far off

at

engine

hours

and

it

out

start-up

hours.

of

operation, Replace

make

certain

operating.

1-112

to

its

seat

can

and

Screw

2

shut-

·,

;'

IDLE

MIXTURE

SCREW

Engines & Generators

19

ENGINE

OIL

CHANGE

Engine

1. Draining the Oil Sump. Discharge the used

WARM THE SUITABLE

Always observe yellow/gray emulsion indicates the presence the oil. Although this condition is prompt attention petent" water present in the oil can exhaust system attached of

caused by the poor location of or the lack

2.

NOTE:

to make certain it

·(Oil

Oil

Change

oil

drain

hose

the sump while the engine is replace the hose

securel_y.

THE

ENGINE.

OIL

INTO

A

CONTAINER

mechanic should water be present in the oil.

raw water through the raw water cooling circuit into

the exhaust,

siehon

Replacement

oil filter, you hole in the upper and lower portion drain the oil This helps to lessen spillage. A small style automotive ter wrench should be helpful in removing the old oil

Do

Place some paper towels and a plastic bag around the ter when unscrewing

cooling ability.

old oil filter as it sealing gasket came off with the old oil filter. ber sealing gasket remains sealed against the engine block, gently remove it.

When installing the

gasket's sealing surface on the engine block free

apply a thin coat of clean engine oil to the rubber gasket on the new oil filter nipple, and then tighten the filter firmly

:filling

valve.

may

from

not punch this

or

any other

(attached

warm.

in

its bracket,

SHUTDOWN

of

can

filter.

AND

the

used

to

prevent serious damage. Call a

the engine. This problem is often

the Oil Filter. When removing the

find

it

it into a container before removing it.

hole

be

removed!

it

to catch any oil left

fluid

on the engine reduces the engine's

Please keep your engine clean.) Inspect the

is

removed to make sure that the rubber

new

Screw the filter onto the threaded oil

to

the front

Drain

the used

and

DRAIN

.

oil as it is removed. A

rare,

be

the result

to

the engine and/or a siphoning

helpful and cleaner

of

without first loosening the filter

oil filter element, wipe the filter

of

the

oil

completely,

replace the end cap

of

water

it does require

of

a fault

of

an

to

punch a

tbe old filter to

in

the

If

~y

through

en!iine)

com-

Raw

in

the

anti-

u~

filter.

this rub-

of

oil

hand

in

fil-

and

3.

Fi16ng

the

Oil Sump.

cap on the top of the engine or through the side oil fill. After refilling, run the generator for a checking the engine's oil pressure. Make sure there is no leakage around the new tem,

and stop the generator. Then check the quantity

with

the lube oil dipstick.

mark on the dipstick, should the engine require

Add

oil

SEALING

APPLY

CLEAN

.

WHEN

ASSEMBLING

NEWRLTER

new

oil through the oil filler

few moments while

filter

or from the oil drain sys-

Fill

to,

but

not

over the high

GASKET

OIL

additionalo_it.

SPIN-ON

TURN

HAND

NOTE:

Generic filters standards mi.ght

after

sure

around

A

or diameters

be

entirely different

an

oil filter change

the

oil pressure is normal

the

new

WARNING:

contaminants.

and

aails

thoroaghly

distanl

used

Oil

The engine's oil pressure, during operation,

the

mal

psi.

NOTE:

reading

pressure reading as low

depending upon the

placed

clothing

oil

ptopetly.

Pressure

oil

pressure gauge on the instrument panel. During

operation, the oil pressure will range between 35 and

A newly started,

upwards

on

the

are

oil

filter.

Used

Avoid

or

rags

of

60 psi. A

temperature

generator.

not

recommended,

of

important items on generic parts

from

genuine parts. Immediately

and

oil

fill,

run

and

that there

engine

on

t:llllfains

/lfO/Dllgell

using

soap

skin

and

IJfllltaining

cold

engine

can

warmed

as

35

psi.

These

of

the

as

the

material

the engine to make ·

are

no oil leaks

bannful

contact.

watet.

llSlld

have

engine

engine and the load

Clean

l.allndet

ail.

Dist:artl

is

indicated

an

oil pressure

can

have an oil

readings will vary

of

OIL

FILTER

skin

or

by

nor-

oil

ENGINE

BLOCK

TIGHT

55

,,...,.,WESTERBEICE

Engines & Generators

20

INSTALLATION

This

popular

ter

from

engine

NOTE:

instructions

To

install, WBSTERBEKB's install

Cont.act

accessory

the

engine

room

bulkhead.

Refer

to

ENGINE

on

simply

this

kit

with

your

WESTERBBKE

to a more

removing

remove

remote

the

is

OIL

the

oil

used

to

convenient

CHANGE

oll

the

engine

oil

filter kit

filter

dealer

REMOTE

relocate

filter.

facing

oil

as down

for

the

engine's

location

in

this

filter

and thread

shown.

as

more

nu.mual

Always

illustrated.

information.

OIL

PN.

oil

such

as

for

FILTER'(OPTION_AL)

040078

Nm:

on

til-

an

Westerbeke

incorrect

installation

A

CAUTION:

rsattr.

If

pass

valvll

frtllll·~

falln.

-

lmmedialllly

thB

oil flows

In

tile

If

ttlel'S

aad.t:het:k

is

notresponsible

of

the

Remote

It

is

vital

In

t/IB

mter:

ll$Sllllbty

tile

••n•

Is

no

oitpnis$1frs

tllfl

for

Oil

Filter.

to

Install

tbs

,,_,..

will

t:a~t1111

a1Jtnt11111a1111g1n1

,.,.,,,,,,,

bOStJ

OOIHlflDtlOllS.

engine

fail1.1re

on

111111$

dilllDtlon,

pnw1111t

tbs

$hufd0wn.

cor-

tile

all

due

by·

to

APPLY A lHIN INSTALLING TIGHTEN

AN

CONTACTS

THEGUrCONNECTIONHOSE MUST

ATTACH

TO

THE

CONNECTION REMOTE

OIL

AT

THE

FILTER.

IN

COAT

OF

THIS

THE~

CLEAN

KIT.

THRWI

ADDmONAL

3/4

OIL

TO

THE

TURN

lllE

KIT

ON,

AFTER

IHllNG

1llEH

THE

0-RING

WHEN

~

APPLY A THIN GASKET

WHEN

CQ.NTACTS

THE

CO~

OF

CLEAN

INSTALLING.

BASE.

l\FTER

TIGHTEN

OIL

TD

lRE

ALTER

IT

AN

ADDITIONAL·

FILTER

Engines & Generators

21

STARTER

MOTOR

DESCRIPTION

The

starter

can

be

roughly

divided into

• A

motor

section

which

generates a drive

•

An

overrunning

ture

torque,

• A

switch

ating

the overrunning

supplies

The

starter

is a new high-speed internal-reduction arate

from

the

ion

shaft.

A reduction

shaft

and

a pinion

exposed outside the

smoothly motor shaft lever

are identical

ADJUSTMENT

If

should

Pinion

1.

A

secandS

2.

.·

3.

without

mechanism,

. .

any

abnormality

be

disassembled

Gap

Connect and

the

starter

and

stop.

CAUTION:

continuously.

Lightly

push the

stroke (called pinion

Ifth~.pinioii

2.0

mni), adjust

of

shims

number

clutch

section

preventing

section

load current

motor

is

supported

to

conventional

AND

motor

(solenoid)

clutch

to

type,

small,

shaft;

gear

shaft.

The

starter

becoming

at

switch

and

REPAIR

is

found

and

lnsp~ctlon

a pattery (12V) between

body,

and

Never.apply

pinion

gap).

gapis not

it

by

increasing or decreasing the

on

the

Solenoid.

of

shims

increases.

the

following

power.

which transmits

overrun after

which

is

operated

through a lever

the

motor.

light-weight

starter.

The

pinion shaft

the

pinion

slides

only

is

installed

pinion sliding part

so

thatthe pinion may slide

fouled

both

overrunning clutch inner circuit

ones.

by

repaired.

the

battery

back

within

The

between

with dust and

ends

on

ball

the following

the

starter terminal S

pinion drive should

voltage

an.d

measure the

the standard range,

gap

is

decreased

an

starting.

when

and

which

and

is

called

on

the

motor

is

not

grease.

bearings.

tests,

the

rotate

for

over

return

as

sections:

arma-

is

the

(0;5

number the

actu-

a

sep-

pin-

The

starter

out

10

to

No-Load

1.

2.

Connect as

illustrated.

When

the

starter

the

current

semble

Test

the

ammeter,

the

~witch

is

must

run

or

starter

the

starter

.--------------1

A

CAUTION:

tighten

type

starter

that

of.a

starter

in

contact

Use

11very

tllflllinal

Which

direct-drive

rotation

with

at

the

SOLENOID

Perform satisfactory,

1. Inspect the solenoid

the

( +)

and

M and

between between the

body.

following replace

(

~)

and

between

the

body.

There should be terminals S and terminals S and

voltmeter,

closed,

smoothly

speed

and

repa1r

thick

wires

securely.

makes a rotating

type

the

pinion

tests.'

the

solenoid

for

continuity between terminals

terminals

and

battery

the

pinion must protrude and

(at 3000 rpm

is

out of specification,

it.

e

BATTERY

as

much

This

is a solenoid

sound

starter.

gear

If

M. the

When

tip,

be

careful

when

It

any

test result is

assembly.

S and the

no

continuity

Continuity will

body

and terminal M

to

the starter

or

more).

disas-

""

as

possible

louder.than

detecting

not

ta

ptatrudes.

not

body

found

be

found·

If

and

shift·

came

and

D.5··2.omm

PINION

GAP

NOTE:

Disconnect

2.

Connect a

and M for (-).

The pinion

A

CAUTION:

than

10

seconds

Engines & Generators

22

MULTIMETER

the

wire

battery

to

the

Have a switch

drive

should

Oa

not

apply

when

testing

from

terminal

solenoid's terminal S

in

extend

battery

the

M.

the

+ lead and

fully

out

current

solenoid.

far

for

( +)

close

more

it.

.

ATTRACTION

3.

TEST

Holding

minal

S ( +)

pinion Y'hen

released

fully~

test.

@

BAliERY

With

and

to

The

pinion

from

a

battery

the

starter

holding

cionnected

must

with

body,

manually

re1)1aitJ.

your

STARTER

to

the solenoid

pull

out

atthat position

hand.

ter-

the

even

MO'fOR

4.

.

Return

minal pinion when

test:.

M

(-)

and

fully.

The

released

With

a battery

to

pinion must

from

the

starter

holding

connected

body,

manually

return

by

hand.

to"the

solenoid

·pull

out the

to

its original position

ter-

HOLDING

· 5.

TEST

STARTER

1.

DisconI1e~t

2.

Loosen

·

the

3.

Remove fastening

4.

With remove the

Remove washer;

6.

Unscrew same adjustment will

DISASSEMBLY

the

wire"

the

two

screws.

solenoid

armature

assembly.

the

t:Wo

long

the brush

the brushes pulled awayfrom

the

yoke

oul

the

cover,

the boltsand removethe center pracket.At

time,

the

washers

come

from

the solenoid

fastening

through

holder.

Remove

and

brush

pry

the snap ringqut,

for

the pinion shaft end play

off.

INSPECT WEAR & CHIPPING

bolts

holder

FOR

termin&l

the

solenoid.

and

two screws

the rear bracket.

the

armature,

assembly.

Then

·

and

M (-

).

Remove

pull

remove the

the

7.

Pull

front

8.

On

pinion

9.

At a

bearing press-fitted off,

out

the

bracket.

the

pinion

and

pinion

each

end

puller.

replace

SOLENOID

RETURN

reduction

side, pry

shaft. ·

of

the

armature,

It is impossible

in

the front

gear

the

bracket.

bracket

TEST

lever

and

snap

ring

remove

to

If

assembly.

lever

out,

the

replace

_that

spring

and

ba11

the

bearing

from.

pull

out the

bearing

ball

bearing

has

worn

the

with

STAllTER

MOTOR

PINION

SHAF"f

. ,EngiM

23

..

i(&

Generators

;

.•

\ .

. ' .

"------··

NOTE:

lnspect,

if

necessary

solenoid,

following

, .

clean

brnsh,

armature,

pages.

commuter,

etc.

and

replace

See

the

BATTERY

CHARGING

CIRCUIT

The DC Circuit on the stop the generator's engine. The circuit is best understood reviewing the DC Wiring Diagram and Wrring Schematic.

Tue engine's DC wiring is designed with three simple basic

circuits: start, run and stop. The engine has a 12 volt DC electrical control

shown on the

when troubleshooting or when servicing the DC electrical

system or the engine.

Wrring Diagrams. Refer to these diagrams

BCG

functions to start, operate and

by

circuit that is

BATTERIES

A

CAUTION:

ing

circut,

while

the switch, ing

however,

on

the

To

never

shut

engine

is

engine's

avoid

off

running.

to

avoid

electrical

damage

the

engine

Shut

electrical

circuit.

to

the

battery

off

the

shorts

battery

switch

engine

when

charg-

battery

work·

Specificatfons

The minimum recommended capacity .of the battery used in the engine's 12-volt

BATTERY

The generator supplies a continuous 10 amp charge from its battery charger charger put a multimeter between the positive ( +) and

negative (-) leads to the battery. It should indicate 14V with the engine running. indicated, check

are tight. With the unit running, test between the (

terminals

the charger.

CHARGER

f0r..B.5V to

DC

control circuit is

to

the starting battery.

If

that

the battery charger terminal connections

14V.

If

no charge is igdicated, replace

400

CCA.

To

test the battery

only .the battery voltage is

13.SV

.to

+) and (-)

Battery

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

• Monitor your voltmeter for proper charging during engine

• Check the electrolyte level and specific gravity with a

• Use only distilled water to bring electrolytes to a proper

•

• Keep your batteries clean and free

A

cause protective

"-

Maintenance

operation.

hydrometer.

level. Make certain that battery cable connections are clean and

tight

to

the battery posts (and to your engine).

of

corrosion.

WARNING:

severe

bums

gear.

Sulfuric

on

skin

acid

and

in

lead

damage

batteries

clothing.

can

Wear

NOTE:

FOR

(INTEGRAL

THE

DESCRIPTION

CONTROLLER),

REFER

AND

TO

TESTING

THE

FOLLOWING

OF

THE

BATTERY

PAGE.

CHARGEN

Engines &

24

GeneratoL~

BATIERY

CHARGING

CIRCUIT

INTEGRAL

The

Integral Controller (l.C.) is an encapsulated, solid-state

that supplies a

unit

starting battery while the generator is opening.

Charging Voltage: 13.0 - 14.0 Charging Amperage: 0

A separate group of stator windings supplies AC voltage to a bridge rectifier LC.

unit The

and supplies a

that the I.C. unit is faulty (that is,

low), check the described in the following steps. Check all connections for cleanliness and tightness including the ground before replacing

the

J.C.

NOTE:

produce

the generator

The

Integral Controller is mounted inside the generator housing in the on

the controller that will allow a DC voltage output adjust-

ment of:± 2 volts.

NOTE:

circuit internally. the

~er

CONTROLLER

DC

which converts the AC current to supply the

I.C.

unit senses the needs

DC

charge when one is needed

charging circuit

unit.

When

the generator

a low

charging

is

operated.

12:00

position. There is a voltage output adjustment

New

four

wire

since

the ballast resistor's function is now handled

Whenever

four

wire

mode~

(J.C.)

charging voltage to

volt.$

-10.0

amps DC

if

the

and

it's components

is

first

started,

rate.

This

charging

controllers replacing

eliminate

an

early stylr controller with

remove

the ballast

the

DC

of

the starting battery

battery's charge is

the

rate

the ballast

generator's

..

If

you

_suspect

as

LC.

unit will

will

rise

resistor

as

resistor

and

its

wiring.

BRIDGE RECTIFIER

YELLOW/WHITE POSl!/VE(+)

TERMINAL

INTEGRAL

.

~ON)'RDlLER

OF

RECTIFIER

GROUND GENERATOR

TO

Testing.

1.

the

Battery

Charging

Bridge Rectifier

Normal

eng1ne two illustrated).

AC voltage running

AC

voltage running

is operating at 1800 rpm)

AC connections on the bridge rectifier. (As

to

the bridge rectifier (approximate):

No-load off the generator 16.0 volts AC

Full-load off the generator

Normal DC)

bridge rectifier; that is DC voltage running from the bridge rectifier

(approximate):

DC voltage running out

is measured across the two

+ and

No-load off the generator 17.0 volts DC Full-load off the generator

2. AC winding:

Lift the measure, the resistance between these ohmmeter. It should measure should exist between the main AC stator windings.

0.10.

ohm

two

AC wire leads off the bridge rectifier and

these

3. Testing the Bridge Rectifier (meter

a. Set your ohmmeter's scale on

needle to zero.

CASE

b. Connect the (

point #4. Taking the momentarily touch poirits #1, meter should register points touched.

c.

Remove the positive { +) lead from point connect the negative (-) lead; momentarily touch points #1, deflect when each point is touched.

d. Leaving the negative ohmmeter(-) lead

- touch point #5 with the positive lead. No deflection should

e. Place the positive (+)lead on point

(-)lead on point #3. The ohmmeter again should not register any deflection (no deflection indicated resistance). Reverse these connections and the ohmmeter should again register fails any fier because it is defective.

NOTE:

Different

produce

oppositP

+)

positive lead from the ohmmeter

o~eter's

#2, and #3. The ohmmeter's needle should

take place.

of

the previous tests (A-E), replace the recti-

types

and/or

test

results.

Circuit

to

the rectifier (while the

is

measured across the

17.5

volts AC

of

the rectifier

DC

connections of the

-.

. 18.5 volts DC

two leads

O.lQ

ohm.

two leads and the ground or

used

RXl

(+DC)

negative(-) lead,

#2, #3, and #5.

no

deflection for any

#1

no

deflection.

brands

of

test

(in

with

No continuity

- Simpson

and set the

The

of

#4

and

on

point #4,

and the negative

If

the rectifier

meters

may

volts

an

260)

to

ohm-

the

infinite

.

iNiEGRAL

CONTROLLER

POINTl4

.

BRIDGE·

RECTIFIER

POINTl3

POINTIS MOUNTING

HOLE

The

following

troubleshooting

tables certain engine problem indicators causes of When the reveal other

the

problems;

troublesbooting indicates

GENERATOR

WIRING

posSible

caus~

DIAGRAM.S,

of the problem

listed below.

ENGINE··

are

based upon

and

the

most

an

electrical problem,

as

these

which

TROUBLESHOOTING

NOTE:

The

engine

3'

control

likely

may

are

see

not

protected by a 20-Ampere manual

located terminal. Refer to

of

next to the starter motor and

t/1£

model photographs at

this

manual for a photograph showing

this.

reset circuit

breaker:

sy.vtem

(electrical system) reset

circuit breaker

the

(-)

ground

the

exact position

is

beginning

Engine crank.

Engine fails

'-----

PROBLEM

does

not

cranks

but

to

start.

1.

Voltage

terminal.

2.

Engine tripped,

3.

Battery

4.

Loose

5.

Faulty

6.

Faulty

7.

Faulty

8.

Raw·

1.

Out

2.

Filters fuel.

3.

Voltage switch.

4.

Carburetor

5.

Faulty

6.

Engine a.

b. c.

7.

Fuel

Worn

8.

9.

Higti

10.

Faulty

11.

Fiiulty

12.

Faulty No

13.

PROBABLE

drop

at

20A

circuit

·"

is

low

battery

wire

connection.

start

switch.

starter

solenoid.

water

filled

of

fuel.

are

clogged.

drop

at(+)

filter

ballast

resistor.

is

flooded.

Carburetor

or

damaged.

needle'

Float Repair

Float

securing gasket

engine

float

valve

in

carburetor

or

replace

chamber

screws

and/or

lift

pump

or

faulty

tension

wires

ignition

distributor. wire

connection.

compression.

CAUSE

starter

solenoid

breaker

has

or

dead.

connections.

JMinders.

by

contaminated

at

overspeed

screen

is

clogged.

needle

valve

Clean

or

replace

is

leaking.

float.

gasket

damaged

are

loose.

tighten

screws;

inoperative.

spark.plugs.

grounding.

coil.

open

the

or

Replace

PROBLEM

Engine

starts,

and

then

down.

Engine

starts,

but

does

up

to

speed.

Engine

hunts.

shuts

not

come

runs

1.

Faulty (oil

pressure,

temperature

2.

High

engine

temperature.

3.

Diny

fuel/water

4.

Low

oil

5.

Faulty

6.

Faulty sensor.

7.

Faulty

8.

Cirt::uit

9.

Check line

J!!tp_umit

Fuel

1.

2.

3.

4.

5.

6.

7.

1.

2.

3.

4.

5.

6.

7.

8.

line Mechanical fuel

supply Throttle Faulty Faulty AC

generator Hj[h Governor Generator Cracked Faulty

Faulty High Valves Dirty

Throttle

9.

exha.ust.Q.ressure.

exhaust

fuel

PROBABLE

shutdown

level fuel engine

stop

breaker

the

restriction.

plate fuel wire

distributor high fuel

are

linkage

CAUSE

switch,

water,

exhaust

or

overspeed).

water

or

separator

in

sump.

llft

pump.

temperature

switch.

is

tripping.

valve

in

the

is

not

drawino

check

valve

ls

faulty. binding.

lift

pump.

connection.

overload.

is

out

of

adjustment.

is

overloaded.

cap

tension

wires.

pump.

back-pressure.

out

of

adjustment.

filters.

is

binding.

exhaust

filters.

fuel

supply

at

the

(contlntJed}

fuel.

(

!

l

I

!

.)

·Engines

26

&

Generators

EftGINE

TROUBLESHOOTING

PROBLEM

Engine

Low

oil

misfires.

backfires.

overheats.

pressure.

1.

Poor Incorrect

2.

3.

Dirty

4.

Cracked

5.

Faulty Spark

6.

7.

High

a.

Valve Spark

1.

wrong.

2.

Incorrect

3.

Engine

flooded

to

start

Dirty

4.

5.

Cracked

6.

High

7.

Choke

1.

Coolant cooling

2.

Faulty

3.

Belts Raw

4.

Faulty

5.

6.

Heat Collasped

7.

1.

Low Wrong

2.

3..

Wrong

4.

Relief Faulty

5.

Faulty

6.

Faulty

7.

PROBABLE

quality

fuel.

timing.

flame

arrester.

distributor

ignition

wires.

plugs

are

worn.

exhaust

back~pressure.

clearances

plug

is

under

flame

exhaust

is

loss.

system.

raw

are

water

thermostat.

exchanger

oil

level.

SAE

type

valve

oil

engine

oil

are

wires

timing.

flooded.

Engine

arrester.

distributor

back-pressure.

stuck

closed.

Pressure

water

pump

loose

or

pump

is

hose.

type

oil

filter.

is

stuck.

pump.

bearings.

filter.

CAUSE

cap.

inoom~ct.

are

connected

See

Engine

is

cranks

but

tails

cap.

test

impeller.

broken.

worn.

clogged.

in

the

engine.

PROBLEM

High

oil

pressure.

No

DC

charge

starting

battery.

Blue

exhaust discharge engine.

Black

diseharge engine.

from

exhaust

from

to

the

smoke

the

smoke

the

1.

Dirty

Qi!

engine.

2.

Relief

1.

Faulty

2.

Faulty

3.

Faulty

windings.

4.

Connections loose

5.

Faulty

1.

Lube

oil

2.

High

lube

3.

Crankcase

4.

Valves incorrectly.

5.

Piston or

unseated.

1.

Dirty

flame

2.

Faulty

3.

Idle

mixture

4.

Valves adjusted.

5.

Lube

oil

6.

Piston

7.

Crankcase

PROBABLE

or

valve

connections. bridge

generator

or

faulty.

controller.

is

are rings

carburetor.

are

is

rings

CAUSE

wrong

is

stuck.

rectifier.

charger

to

the

diluted.

oil

level.

breather

worn

or

are

worn

arrester.

jet

too

worn

or

diluted.

are

worn

breather

SAE

controller

adjusted

rich.

incorrectly

type

hose

or

unseated.

hose

oil

in

are

is

clogged.

is

clogged.

the

Engines & Generators

27

ENGINE

NOTE:

WESTERBEKE recommends

be

adjustments

The

information below is provided

perfonned by a competent engine mechanic.

ADJUSTMENTS

that

the

following engine

to

assist the mechanic.

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The

belt-driven, mechanically operated governor maintains the engine's rpm under various load conditions. Engine speed determines the hertz and voltage output

Governor

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

NOTE:

adjust the linkage at no-load before proceeding with the adjustment.

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

1.

Increase/Decrease

sets the no-load speed

between the governor arm and throttle lever should be

adjusted to hold the throttle full open when the engine is not running.) Make sure that the ball joint connectors are properly lubricated. graphite lube for this purpose. Disconnect the ball joint and apply graphite lube

Adjustments

If

the governor

is

severely out

to

obtain a safe output voltage

Speed Adjustment. This adjusting bolt

of

the engine. (The linkage

this linkage moves freely and

to

the inside

2. Hunting/Regulation Aqjustment.

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

If

the governor surges under load, adjust this eye bolt to

the

move adjustment).

3. Bumper

a no-load surge into the governor so far that it increases the no-load speed.

spring away from the lever hub (check speed

Screw

Aqjustment. This screw is used to remove

ONLY.

NEVER tum the bumper screw

of

the generator.

of

adjustment, manually

arm

of

the joint.

If

the variation in

to

the lever

to

Use

be

Governor

·

1.

2. Governor Oil Capacity: 3 ounces SAE IOW/30 oil.

3.

KEEP

LINKAGE

WELL

LUBRICATED

THRO

TILE

LEVER

HUNTING REGULATION

ADJUSTMENT

Maintenance

Periodically lubricate the linkage arm attaching points at the governor lubricant

NOTE:

proper governor/throttle operation.

(Synthetic oil

NOTE:

To

change the oil, remove the oil

container

drain

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

of

plug and the oil

LINKAGE

arm and throttle lever. Use a graphite

or

equivalent.

Free

movement

is

Do not

overfiJl

tinder the governor and remove

plug.

the oil

fill

ARM

.

INCREASE/DECREASE SPEED

ADJUSTMENT

of

this linkage ann is important for

recommended)

the

governor.

fill

alle~

of

the governor. Fill the governor

of

oil

or

more until oil

level opening. Replace the allen head

fill

plug.

plug. Place a small

head oil fill level plug

·starts

the

governor

to flow

4.

Periodically adjust the governor belt tension (see DRIVE

BELT

ADJUSTMENTS). Since belts stretch slightly, this

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

Engines & Generators

28

ENGINE

ADJUSTMENTS

SPARK

The first 50 thereafter and replaced

Spark Spark

NOTE:

the

of

PLUGS

spark plugs should

hour

break-in period, then inspected every 250 hours

AWARNING:

the

engine

is

hot.

removing

spark plugs

the

them.

plug

gap:

0.031 - :!: 0.0002

plug

torque:

10

Loctite Anti-Seize applied to the threaded portion

spark plugs

-15

wilt

easier.

be

cleaned and regapped after the

as

needed.

Do

not

Allow

lb-ft

retard

remove

(1.5 - 2.31

the

engine

in.

(0.8 - 0.05

corrosion,

spark to

kg-m).

making future

GAP

INSPECT

FOR

WEAR & CARBON

INSPECTING

THE

SPARK

PLUGS

plugs

while

cool

before

mm).

removal

INSPECT DAMAGE

,______CHECK

FOR DETERIORATION AND

DAMAGE

FOR

of

CHOKE

The choke solenoid is a 12 volt tions to close the

switch is depressed during engine start-up.

The choke solenoid de-energises once the engine starts and the

present when the engine starts cold

the engine reaches operating temperature. Keep this solenoid dry and periodically lubricate the linkage

between the solenoid and the choke lever.

SOLENOID

choke·plate in the carburetor when the ON

ON switch is released.

DC

operated unit that func-

Some

unstable running may

but

should smooth out

be

CARBURETOR

as

HIGH

TENSION

Check the ignition wires every compartment heat can deteriorate the wires.

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

The

resistance value

CORDS

(IGNITION

500

of

each wire. Do not pull on the wire

is

410

ohm

WIRES}

operating hours

per

inch

of

wire.

as

engine

CHECKING

RESISTANCE

Engines & Generators

29

ENGINE

NOTE:

WESTERBEKE

adjustments

The

information

ADJUSTMENTS

reco~nds

be

peiformed

below is provided to

by

that

the

following

a competent engine

assist_

the

mechani9

engine

mechanic.

-

VALVE

NOTE:

engine's valves (see BOLTS).

1.

Z.

3. Rotate the

CLEARANCE

Retorque the cylinder head bolts before adjusting

Remove the rocker cover and gasket Rotate the crankshaft in the normal direction

placing the No. stroke with the exhaust and intake valves completely closed. Adjust the intake and exhaust valves for No. cylinder, the exhaust valve for No. 2 cylinder, and the

intake valve for No.

crankshaft

rotation.

its exhaust stroke. Adjust the intake valve for

cylinder and the exhaust valve for

chart).

CRANK

Locate

ANGLE

ADJUSTMENT

TORQUING

1 piston at the top

3 cylinder (see chart).

180° in its normal direction

the piston in No. 1 cylinder at the

THE CYUNDER

of

its compression

No.

3 cylinder (see

CYLINDER#

1 2 3

When

No. 1 piston

compression When

No. 1 piston

at

top

of

exhaust

stroke

is

set

at

is

positioned

top

of

IN

EX

IN

EX

•

HEAD

of

rotation,

No.

of

top

2

•

the

l

of

IGNmON

1. Attach a timing light to the front timing pointer to indicate mark on the crankshaft pulley and mark it with white chalk or crayon.

2. Start the engine and warm it up to its nonnal operating

temperature.

a load on it.

3. Using the timing light, crankshaft pulley so timing pointer. Do the distributor specifications.

Timing

TIMING

Make sure

this

body.

Specifications:

(no

#1

spark plug and mark the

100.

Locate the timing

the

generator is operating without

align

the timing mark in the

it

is

just slightly before the

by

loosening and slowly

Use the following timing

10" ± 5°BTDCat1800

load

on

generator)

rpm

front

first

rotati.Iig

_ 4

••

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

ROCKER

COVER

TORQUE:

VALVE

HOT:

2.9 • 5.1

lb·ft

(0.4 • 0.7

CLEARANCE

IN

0.25mm

EX

0.30mm

(0.0098

(0.0118

kg-m)

In)

in)

IGNITION

TORQUING

After the initial break-in period (approximately cylinder head

Tighten the cylinder head bolts according to shQwn. loosen one head bolt one-half between 36.2 - 43.4 lb-ft (5.0 - 6.0 Kg-m). Then proceed the next head bolt in cover stud) securely.

FRONT

OF.......,__,

ENGINE

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

THE

CYLINDER

bolts should be re-torqued.

Make sure the engine is cold when this

the

6 4 2

HEAD

tum

sequence. Tighten the

TIMING

BOLTS

and then tighten it

50

the

sequence

is

RS

hours), the

done,

and

to

(rocker

-7

5

lw/WESTERBEKE

)_Engines & Generators

3.0

ElCHAUST

SW-

,.....

WIRING

DIAGRAM

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~~-

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.Engines

&

Generators

32

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33

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.Generators

STRIPe

____

,~

TO

T61-'5

TBl-1

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The

power

required

than

is

required

require (AC)

motors circumstances, easy-starting applied Because

run,

their

motor

is

repulsion-induction

current varies

with

to

an

air motor

to

In

general,

to

medium

MOTOR

(HI')

*NOTE:

more

for

this

is

that

larger

sizes.

Because required can

bring experienced and,

if

possible,

REQUIRED

Run

the

ator's

capacity,

on

the

generator's checked plant

and

meter

is

portable

NOTE:

tains

AC generator:<! volt

AC

good

motor

to

much

more

reqUire

than

loads,

after

the

motor

they

require 5 to 7 times

use

should

to

be

driven

to

start

as

to

the

load

compressor,

which

no

the

current

starting

SIZE

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

1

In

the

above

some

small

the

hardest

the

heavy

for

only

an

the

motor

in

starting

reduce

OPERATING

generator

and

data

periodically

the

appliances

not

installed

meter

and

When

the

vessel

equipment

AC

terminal

hot

leg

for

starting

MOTORS

to

start

an

keep

it

nmning

current

to

more

current

other

types.

such

as

washing

is

started,

be

avoided,

by

a

small

motors

require

run.

The

connected

for

example,

load

is

connected.

required

loads

will

AMPS

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

table

the

motors

starting

surge

of

current

instant,

up

to

speed

motors,

the

load

first

with

finally

loaded

plate.

to

ensure

it

supplies.

to

monitor

amprobe.

in

which

of

120

volts

block

the

vessel:<!

response

electric

after

startthem

to

They

machines,

such

as

much

whenever

generator.

from 2 to 4 times

current

to

it

An

will

to

start

be

approximately

FOR

maximum

than

for

types

(split-phase)

needed

the

generator

in a few

tum off

on

the

SPEED

no

load

applied,

to

its

The

output

proper

If

voltage

the

only,

be

configured

distribution

.from

the

motor

is

it

is

started.

than

start,

under

are

commonly

as

small

current possible,

Capacitor

required

electric

require

115-Volt

Amps

larger

ones.

for

will

seconds.

all

other

electric

then

full

capacity

voltage

operation

an

AC

and

load,

generator

it

is

recommended

to

panel.

generator.

considerably

Some

others.

Split-phase

similar

used

or

where

power

tools.

to

start

if

the

and

as

much

to

start

any

motor

connected

more

current

motors

connected

as

follows:

AMPS

FOR

STARTING

(AMPERES)

6.4

to

22.4•

9.2

to

32.2*

10.4

to

72.8*

14.4

to

29.2*

20.4

to

40.8*

26to

52

for

Starting

The

reason

are

not

starting

motors

not

be

damaged

If

difficulty

electrical

motor.

at

half

as

indicated

should

of

the

generating

voltmeter

check

is

installed

provide

one

This

will

more

motors

on

loads

as

to

electric

motor

than

is

made

loads

the

gener-

be

or

amp--

it

with

con-

that

120

ensure

for

is

the

are

in

if

a

GENERATOR

Frequency

by

the

following:

•

When output

•

When

output

Therefore, drive

engine's

of

the

AC

GENERATOR

•

a

it

Maintaining Connections corroded, salts, up. heating

•

For petroleum all

•

In

inspected

overheated

•

The

checked for not cracking. generator identified the

•

The maintenance noisy

•

Examine of motion Repair and

Carbon

WESTERBEKE detector

even

The

from

exhaust entering

If

carbon

air

FREQUENCY

is a direct

the

generator

frequency

the

generator

frequency

to

change

speed

output

connections

MAINTENANCE

and

dust,

engine

Clogged

and

reduce

unusually

based

surfaces

addition

the

to to

for

terminals

drive

discs

periodically

any

evidence

be

allowed

The shaft by 6 radial

head.

rearw:mature

or

rough-sounding,

the

shaft

should

is

detectable,

must

cause

major

Monoxide

in

the

in

small

presence

the

engine

hose,

your

monoxide

and

correct

result,

.

is

60

is

50

the

generator's

must

be

reasonable

of

terminal

insulation

exhaust,

ventilation

life

severe

conditions,

coatings

reduce

rusting

periodic

tightness

and

on

single

if

of

incipient

to

become

bolts

which

must

be

marks,

bearing

is

required.

bearing

at

be

inspect

be

made

damage

Detector---------.

recommends

vessel's

living

amounts,

of

carbon or

generator

or

that

fumes

boat.

is

present,

the

problem

ADJUSTMENT

of

engine/generator

run

at

1800

rpm,

Hertz.

run

at

1500

rpm,

Hertz.

frequency,

changed

cleanliness

of

cleaning,

of

possible

hardened

periodic

detected

quickly

is

monoxide

along

at

the

generator.

is

boards

and

rectifiers

surfaces openings

may

carbon,

may

windings.

etc.

thin

should

be

sprayed

and

corrosion.

the

all

connections,

loose

or

damaged

bearing

generator's

for

tightness

cracking

rusty

because

fasten

the steel

one

at

each

is

lubricated

However,

have

to

if

it replaced

inte'l:vals.

when

the

bearing

or

major

the

generator.

mounting a carbon

quarters.

deadly.

indicates

or

from

from a nearby

ventilate

immediately!

with a reconfiguring

important

start

are

cause

rust-inhibiting

generator

failure.

drive

SAE

the

force

components

Carbon

the

speed,

the

AC

the

AC

the

generator's

may

conducting

allowed

excessive

or

evidence

wires.

should

of

rust

may

disc

grade

of the 6

and

sealed;

bearing

No

is

applied.

and

shaft

an

exhaust

vessel

area

as

illdicated

voltage

become

if

to

build

brushed

over

should

be

of

be

screws

and

Discs

should

accelerate

to

the

8,

comers

no

becomes

side

movement

If

for

wear.

will

monoxide

monoxide,

leak

elbow/

are

with

clean

of

side rub

Engines & Generators

34

.

BC··

GENERATOR

NOTE:

WESTER/ltkE

and

ad,iuszment.r

rec()1M1e11(]s

be

performed

SINGl.E

that

~

lollowirig

by

a

quQJified

tecluikJan.

·PHASE

gen~r0ror

..

tests

DESCRIPTION

The

~C.generatoris·a·brushless,

requires

ACoutput.

stator is

induces

Iru-g~

of

win~iD.g~

capapitot(s)

the

steady

drawn

equiPffient

120 AC

secti~n·oftbis

data

the

vatioos

Integi'al

supplies a

battery

see

section

only

the

driving

The

stator

windings

started, residual

~nt

etm:entinthe

a current

in

and

the

four

qu+cJdy

.a,nd

a

stator·

A.tthe

$~e

¥oltage

off

volt AC

f;\VIYwire,

plate

generator.

louver~

the!NTEGRALCONTROUER

in

the

generator's

The

two-wire

at

manual

~ves

An

cover

AC

voltage

Controller

contihuous

when

the generator is

in

this

manual

generator

50hert.z•

the

force

houses

the

exciter

magnetism

in

the

stator

exciter

rot~g

xeacheS

regulated

time.

th~

stator

or

for

voltage,

AC

wiring

at

the

generator

~ections

(IC)

is

DC

self--excite(l

of

th~

engine ~ produee

two

sets

ofwilldings;

windings.

in:

the

which

winding~.

po~es

the

~a®n

energy

this

regtl.l~.

wiridinss

AC

termina1.s

is

a

sjogle--phase,

110

volt

Refer

to

generator

current and

decal

is

moll~ted

charge

to

running.

V/hyn

four

rotating

then

generates

nus

mutual

and.

in

th~

pointof

.field

is

then

field

which

to

operate

AC

two-wire

the

SPECIFICATIONS

ratings.

frequency

is

affixed

end.

A

diagram

provided

inside

the

generators.

Fonnore

DCCHARG~

..

generatotwhich

the

gend'ator

poles

an

bpild

exciter

tJ1e

maintained

produces

can

then

be

AC

reconnectable

or.220volt

The generator's

rating

to

the

inside

of

the

on

the

decal.

generator

starting

infonnation

an

main

e~en

up

in

a

of

An

and

Circuit

A circuit breaker is installed WFSTERBEK£ generators. This circuit automatically disconnect generator el:ectrical off coming

NDTE:

add-on1dtfor

WESTERBEKE

60 50

Breaker

overload:

when

s~rvicing

into theboat.

rhls

circuit

Hz -7.0 Hz

KW

-5.0 KW Circuit Breaker

The

the

breaker

earliet.

dealer.

Circuit

generator

model

on

all single

power

circuit breaker

to

ensure

is

available

generators;

Breaker

Pm1

Part

Number

Number 38797

phase

breaker

can

as

contact

will

in

case

of

be

manually

that

no

power

a

WESTERBEKE

your

38902

an

shut

is

GENERAT-OR.

SCHEMATIC

.

INTERNAL

WITH

CHARGING

CIRCUIT·

WIRING

DC

BATIERY

I

f u

! t

·-

~ii'""

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

f f

DUAL

ir·

EXCITER

&DHz

t !

---

CIRCUIT

I

-.I

Engines & 'Generators

35

BCA

GENERATOR

(60

HERTZ

D

ONLY)

1

0

5

0

4

0

2

0

GENERATOR

WITH

INTERNAL

DC

BATTERY

WIRING

CHARGING

SCHEMATIC

CIRCUIT

ACTERMINAL

A.

ROTATING

WITH

B.

MAIN

C.

EXCITER

D.

DC BRIDGE RECTIFIER

CONTROLLER.

FIELD/AUXILIARY

DIODES. STATOR

WINDINGS.

WINDINGS

BATTERY

CHARGING

BLOCK

WINDINGS

AND

CAPACITOR(S).

CIRCUIT

AND

INTEGRAL

WITH

lwlWESTERBEKE

) Engines & Generators

36

SINGLE

i.

l.

EXCITER

Remove generator, the

capacitot(s).

Start

the

five.minutes generatOr current

from

appliances). correct obtain

the

Referring check

the

voltage

meter.

Make no-load the

voltage

proceed.

~e

louvered

covering

generator

so

is

operating

the

Make

Adjtist

correct

to

the

geiietator's

across

the

sure

voltage

output

NO·LOAD

metal

the

AC

and

allow

the

engine

canwarnt

without

generator

sitte

the

fuel

engine

AC

neutral

you

is

115 -124

is

(that

the

throttle/speed

speed

load

connections

no--load

lead

record

higher

.ac

GENERATOR

NotE:

WisiEi@EKE

and

Odfustments

be

:econtmends

performed

SINGLE

by

a

VOLTAGE.ADJUSTMEIT

plate,

at

the

baclc

of the

tetminat

engine's

or

connections.and

iHo

run

any

equipment

is,

shut

8peed

before

voltage

and

the

this

readitig.

volts

at

lower

· · for

apprpxhnateJ.y

up.

:Make

drawing

off

all

(HertZ)

linkage

as

proceeding.

diagram

by

:measuring

hot

lead

The

60.5

- 6L5

than

specified,

sure

the

~C

electrical

is

needed

below,

the

with

a volt

generator's

Hertz.

If

@

@·

to

·

PHASE

~

thi!follt>wing

qualified

technici<in.

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

A

.WARNING:

age

11tt/:ustmsnt

aapaottoraan.

any

wiring

addition,

·

nilnt

whils

fingers

to

5.

There

are

minal,

tow,

then

nect

the

tor's

no-load

numbered

number. tenninat

6.

· Jf the

generator's because numbered

or

the

vpltage.needs

bered

plug

Oenetator

generator

Do.not

While

produce

tan

JlrodutJB

attempting

t1J'ege11111'8tor

be

caught

three

plugs

#7,

#8,

and

disconnect

plug

with

voltage

plug

and

Note

that the

may

be

any

the

voltage

plug

is

Ct>nnected,

Troubleshot)~

attlJmpt

the

a

4lltJ.50D

11

to

make

In

the

grouped

#9.

If

the

high,

connect

plug

one

no-load

needs

already

to

be

tests

to.make a no-load

generator

severs

Is

operating

generator's

the

lower

higher

presently

of'the

voltage

to

connected

lowered

refer

Is

volt

e/IJCtrlcal

a

no-load

for

the

generator's

numbered

number.

then

disconnect

the

plug

three

cannot

be

increased

and

to

the

Gui~e).

volt·

operating.

charge.

voltage

could

rotor.

right

no-load

with connected

plugs

be

to

the the

WESTERBEKE

Touching

shock.

ad/ast·

cause

capacitor

plug

and

If

the

available.

adjusted

and

the

right

lowest

The

In

your

voltage

congenerahigher

lower this

highest

terminal,

num-

ter-

is

BC

115VJ50Hz

.

<.i:lUilC3)

@

23DV/50Hz

4.

Shut

off

the

generator.

(60

Hertz

#6,

or

·

capacitor(s).

AWAR~INfl;

hailtlllllg

t/ally /stbal

power

NOTE:

insulated

any·excess

as

they

aharge

source~

Simply

cross

(plastic

handle)

electricity.

Make

50

Hertz

#S) is

Capacitors

store

eleatrlaltj

even

when

the

capacitor's

screwdriver.

sure

pltlgged

11111Stlls

and

dlsaonneotet/

two

II

GROUNDED

INSIDE

GENERATOR

the

correct

into

111$/:hlJffled

can

paoka

from

terminals

This

will

discharge

Or

Hertz the

before

poten-

their

with

TO

THE

lead

an

THE

CASE

A

WARNING:

tlie

unused

With

11aah

other

housing.

5

BCD

See

the

ENGINE

ADJUSTING

Make

leads

atB

In

or

Jn

contact

GENERA.

ron

.120V/60Hz

ADJUSTMENT

THE

ENGINE

certain

place

BACK

SPEED.

the

Insulating

and

atB

NOT

with

the

gensrator's

NOTE:

THE

SHOWN

CONNECTED

DEMONSTRATION

THESE

CONNECTIONS

BE

MADE.

END

SHOWN

sectlon

in

covers

In

contact

ll

WIRE

this

JS

AS

OF

HOW

CAN

manual

on

A

for

Engines & Generators

37

BC

GENERATOR

CHECK

SINGLE

7.0

DUAL

7.0

CHECK

SINGLE

7.0

DUAL

7.0

CHECK

60

50

·

ADJUST SPEED

THE

RESISTANCE

EXCITER

BCG

&

BCGA.

EXCITER

BCG

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

THE

CAPACITOR

EXCITER

BCG

&

BCGA.

EXCITER

BCG

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

THE

Hz

ENGINES

.60.5 -61.5

50.5

-

51.5

THE

ENGINES

ADJUSTMENT

RESISTANCE

CIRCUIT:

.......

1.9

CIRCUIT:

........

31.5

CIRCUIT

SPEED

TO

OF

ohm

2.5

ohm

uF ± 5°

18.0

uF

SPEED

BY

OBTAIN

FIGURES

THE

EXCITER

±

5°

USING

THE

CORRECT

WINDINGS··

THE

GOVERNORS

HERT2.

WESTERBEKE'S.

for

BC

Generators

website:

LOAD

NONE

NOTE:

proper If voltage

¥J!MtJf!!..~eke,com..

APPLIED

HALF

FULL

The

operation

an

AC

Voltmeter

and

output

load,

"AC

is

4-POLE

(RPM)

1830

(1530)

1800

(1500)

1755

(1455).

should

of

the

or

Ampmeter

check

Electrical

availabfe

SPEED.

..

be

checked

generator

and

is

it

with a portable

Testing & Troubleshooting

in

pdf

form.

FREQUENCY

(HERTZ)

62

(52)

60

(50)

59.

(49}

I

periodically

the

appliances

not

installed

meter

Download

to

ensure

to

monitor

and

amp-probe.

from

GENERATOR

120V

(110)

122

(112)

120.

(110)

110

I

(100)

l

it

supplies.

the

Guide"

our

VOLTAGE

230V

235

230

225

Bf.5!J.WEB'l!IUIEICE

Engines & Ge!lerstors

38

SHORE

120

POWER

VOLT/60

HER'll

TRANSFER

TWO

WIRE

CONFIGURATION

SWITCH

Switching

If

the

installer

circuit,

this

must

'Il.'ansfer

diagrams. simultaneous

Switch

to

A

CAUTION:

utility

shore

at

the

same

coVBl'fJd

bllity

ta

under

make

Shore

Power

connects

be

done

..

Set

the

OFF

position.

connection·

Damage

power

and

time.

This

the

warranty;

sure

all

.

NOTE:

Wire,

12Q•Volt

-

...

to

shore

by

means

transfer of

shore

ta

generator

type

AC

connections

Diafll'UI -

.,..

,..-1

...

Generator

power to

of the

switch

This

switch

power

the

ge11Brator

output

of

generator

It

Is

the

-ctl-

... ffOm -

120-VOlt

-t

Power

the

vessel's

Shore

Power

shown

in

prevents

to

generator

can

resun

are

connected

damage

Installer's

are

col'TBl:t.

fer

a

two-

..,._,

.,...

....

AC

the

output.

ff

Is

not

rssponsl·

. A

CAUTION:

before

switching

rlt:B-versa

with

hBaVy

caUStJ

damage

gllllflrator.

"6-nltor

•

1 N

13

G2

1

t

I

:

Heavy

motor

shore

because

AC

.=.

I

L---~

r--:---\<a> /

I ,

I

I I

I

voltage

loads

an

to

the

exciter

NOTE:

1 wire.120-Volt

-

dotted

.....

-,

ft

__

.,.

leads.should

power

to

surges

the

vessel

cltcull

Dialdlll

llllowll

uatem.

11-

for

bs

generator

Induced

being

operated

compollflnts

con•ct-

Far

•

three•

the

-·

bot

shut

power

by

switching

In

for a

--

wire

syatern

199·

og

or

may

the

Eng~ne_s

&_Generators

-

39

LAY-UP & RECOMMISSIONING

General

Many

owners

rely

on

their boatyards

including season

accomplish

The

own

if

These engine/generator during a lay-up and you

If

your provide assistance.

Propeller

The

be opened

out of the storage in the cradle.

· severe the boat is shaft apply to

not

period

Fresh

A

mended This depending on make

Should

from

Operate

ture of the antifreeze concentration throughout the

system.

Lubrication

With the engine

sump. new

LUBRICATING

change". Run

sure

engines

or

for

procedures

lay-up

others

do

procedures

with

its

you

have

local

transmission

strain

has

actually

small

in

use,

of

time.

Water

SO~SO

solution

for

solution

sure

more

the engine block and add a more concentrated mixture.

the engine

Then

and generators,

long

periods

of

inactivity.

lay-up preparation themselves.

which

follow

and recommissioning, or will seive the procedures.

should provide protection

maintenance

any

qu~stions

servicing

Shaft

up

and

water

or

on

the propeller shaft or coupling or both,

taken

out

boats that

unless

Cooling

use in the fresh water cooling system at

may

the

the.

antifreeze

recheck the antifreeze solution's strength.

needs.

regarding

dealer.

He

Coupling

and propeller half

the bolts removed when

moved

from land to

The

flexibility

or

put

in

been bent they have been

by

are

hauled out of the water

Circuit

of

antifreeze and distilled

require

a higher

area's winter climate. Check the solution to

protection

be

needed,

to

ensure

System

warm,

drain

Remove

oil.

the

there

and replace the oil filter

Use

the

correct

grade

OIL

pages

in

engine and check for proper oil

are

no

leaks.

to

prepare their

for

lay-up

during

Others

prefer to

will

allow

you

to

for

also

help

lay-up

procedures, call

will be more

(Propulsion

couplings

of

the

water.

these strains. This

dry

concentration

is

drain

a complete circulation

all

the

of

oil.

this

manual

than

Engine]

should

the

water,

and

the boat

In

some

for

a considerable

water

adequate.

an

appropriate

engine.oil from

,and

fill the sump

Refer

to

for

pressure

craft,

the

off-

perform your

as

a checklist

your

familiarize

willing

to

always

boat is hauled

during

oftens

puts a

while

cases, the

does

not

when

is

recom-

all

times.

of

antifreeze,

amount

and

mix-

cooling

the

oil

with

the

ENGINE

"engine

and

oil

make

Fuel

System

Top

off

or

higher. A fuel

stabilizer

gasoline/water

Re-install

up

any

Fuel

System

Top off such

as

control

that.the

filter/water seperator

in

ypur

bas

one,

Change the fuel

system,

for

5 -

system. the

fuel needed. allow

movement

equipment

Raw

Water

Close the hose from

gallon check the engine

any

zinc

anode

Start

the

fresh

water

stop

the

solution protection in

Start

the

through

the

engine. water as

providing corrosion

Remove

antifreeze

Examine cover gasket until

recommissioning,

your

fuel

should

separator and

and

make

spilled

fuel.

your

fuel

BIOBOR

algae

and

additives

primary

and

clean

fuel

as

10

minutes Check system

Operating

on

the

Cooling

through-hull

the

fitting.

bucket

of clean

the

zinc

and

debis

is

located. engine

through the

engine

slightly

your

engine

the

raw

This

circuit

from

the

impeller

mixture

the

impeller.

[Gasoline]

tanks

conditioner such

be

(Dleselj

tanks

and

condition the

used

fuel

filter elements

needed.

for

during

of

engine.

anode

clean or replace it

from

Clean

and

and refill

stronger

and

water antifreeze

Do

with

unleaded

added.

Change

clean

certain

there

with

No.2

STABIL

are

compatible with

used

in

the

filter/water

the seperator sediment

Start

the

to

make sure

any

leaks

that

this

servicing,

the engine

the treated

&asoline

as

MARINE:STABIL

the element in your

the

metal

are

no

diesel

should

be

fuel.

Care

system.

seperator,

on

the engine

engine

no

air

is

may

have

correcting

for

5 -

10

fuel

through

Circuit

fitting.

Remove

Place

the

end of

this

fresh

water.

Before starting

found

in

the

primary

as

required

inside

the heat exchanger

the

raw

water

strainer.

allow

the

raw

water

system.

area.

allow

system.

freezing

protection.

from

will

accompany

Get a replacement,

not

replace the impeller

the

than

all of this

mixture

during

your

but

replace

When the

bucket with

needed

for

mixture

Once

the

should protect the

the winter

raw

water

it, so

the cover

~f ~9

~ctane

bowl.

leaks.

Clean

fuel.

Fuel additives

added

at

this

time

should be taken

the

primary

Change the element

if

the

bowl.

and

allow it to

left

in

the

been created

minutes

the

raw

hose

heat exchanger

and

where

pump

bucket

an

antifreeze

winter

to

bucket

lay-up,

pump

cat.ch

if

needed,

(into

and

fuel

system

bleed

the

run

fuel

them

as

will

help

injection

water

intake

into a five

the

engine,

also

clean

the

to draw the

is

empty,

freeze

be

drawn

is

empty,

raw

as

well

(some

it

in a bucket).

and a

the

pump)

gasket

to

in

on

zinc

stop

A

CAUTION:

oil

in

the

combustion

t:h11111it:als Internal

parts.

sump

deposits

wlllch

Do

owr

t:a11

not

leave

the

lay-up

combine

redut:e

the

psriod.

to

the

engine's

Engine

prodace

l«e

al

your

aid

BllfllllB

oil

harmful

engine's

and

Intake

Place a

opening of shove the recommissioning, you note exhaust port

lwlWESIEHBSKE

.

..

l

···.

Engines

···········;41r···········

~

.Ge11erators

Manifold

clean

the

cloth

may

need

to

remove

and

Thru·Hull

cloth, lightly

intake manifold

out of sight.

and

assistance

the cloth prior to start-up.

can

be

an

attempt is

of

blocked

soaked

to

(If

it

the

seivicing

in

the same

block

is

Exhaust

in

lubricating

the

not

visable

made

manner.

oil,

opening.

at

to

start

dealer).

The

thru-hull

(CONTINUED)

in the

Do

the

engine,

Make

not

a

Starter

Lubrication if access battery connections the connections removed

Cylinder

If

WESTERBEKE access cylinders cylinder

Make line sealing washers.

starter.

you

anticipate a

to

sure

Motor

and

cleaning

to

the starter pennits

Take

care

Lubrication

long

recommends

the

cylinders. Squirt light lubricating oil into

to

prevent

walls.

you have replacements

LAY·UP & RECOMMISSIONING

of

the

starter

drive

pinion

its

removal.

are

shut off before attempting

in

properly replacing any electrical

from

the

starter.

(Diese4

lay-up

period (12 months or

removing

the

piston

rings

from

for

Make sure

the

sticking

the

injector

fuel

is

advisable,

the

to

remove

more)

injectors

the

to

the

and

return

for

Spare

Parts

Lay-up

time provides a WESIBRBEKE engine belts

or

coolant

hoses

spares

kit

and

order items

used

during the lay-up,

to

SPARE

PARTS

good

to

need

not

such

section of

opportunity

see

replacement Check your basic

on

as

this

flecommissioning

The

reco~ssioning

seasonal those section regarding preparation for However, counteracted before starting the

lay-up

presented

some of

of

your

generally

in

the

PREPARATIONS

the

lay-up

WESIBRBEKE engine after a

follows

procedures

if

external

hand,

filters

manual.

the

starting

engine.

to

inspect

items

or

replace those

and

zinc

same

procedures

FOR

STARTING

and

normal starts.

will

your

such

as

drive

items

anodes. Refer

as

need

to

be

Intake

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

Cylinder

Spray fogging arrestor removed,

eil

spark

NOTE:

and

Manifold I Gasoline]

the

filter

screen

in

any

opening,

exhaust

Also

port.

Lubrication

oil

into

the

while

will

stall out

plugs

The

regapping

the

engine

for

winter protection.

spark

plugs

at

spring

will need

the

flame

arrester,

place an oil-soaked cloth

Make a note

[Gasoline]

open

air intake, with the

the

generator is running. The fogging

and

coat

to

be

commissioning.

Batteries

If

batteries are

make sure that

way,

to

the

batteries will not remain fully

be

subjected batteries environment

A

WARNING:

highly-explosive

arcing smoke serviced. vicinity

Transmission

Check Wipe

off grime

Protect

corrosion

to

be

they

prevent

them

to

severe environmental conditions, remove

and store

them

or a lighted or

allow

an

Shut

off

to

prevent

(Propulsion

or

change the fluid

and

the coupling

coating. Check

left on board

are

fully

from

in a wanner, more compatible

Lead

acid

gas,

which cigarette, open

all

electrical electrical

charged,

freezing.

batteries

can

cigar,

flame

near

arcing

during

charged,

be

equipment

Engine]

in

the transmission

grease and

and

touch

the output flange with

that

the transmission vent is

and

place a

the

flame arrester

to

remove

cloths

the

valves, cylinders

removed

and

If

there

ignited or the

for

the lay-up period,

will remain

is

any

or that they will

emit

hydrogen,

by

pipe.

battery

in

during

servicing.

as

up

any unpainted

clean

in

the

prior

flame

cleaning

that

doubt that

electrical

Do

not being

the

required.

an

anti-

open.

to

and

the

a

areas.

1.

Remove the oil-soaked cloths

2.

Remove

the old gasket Install the raw removed during Install the

3.

Reinstall the batteries that up, terminals Check

A

and batteries can cigarette,

open electrical electrical

4.

Remove

proper

5.

· it

· solution from the

6.

the

raw

and

reconnect

are

clean

to

make

CAUTION:

eye

protection

emit

be

ignited

cigar,

flame.near

equipment arcing

the spark

tightness

Check

the

condition

circuit and

is

engine

short period of advisable, service,

heat area.

Start in

the

this

clean

not necessary

is

put

as

to

inspect

exchanger

the

engine

PREPARATIONS

manual.

water pump cover

lay-up

water

pump

the

battery

and

sure

that the batteries

Wear

rubber

when

hydrogen, a highly

by

electrical

or

pipe.

the

battery

In

during

plugs,

[gasoline].

of

or

replace

to

flush the antifreeze/fresh

raw

water coolant

into

operation,

time

with

either

an

the

and

clear

in

accordance

from

the

intake manifold

and

gasket.

water

pump

(or a replacement,

cover

with a new

were

removed

cables,

making

that the

connections

are

gloves, a rubber

servicing

batteries.

explosive

arcing

or a lighted

Do

not

smoke

being

serviced.

the

vicinity

ta

prevent

servicing.

wipe

clean,

re-gap,

the

zinc

anode

in

the

anode

as

system.

the

system

no

end of

area

where

any and

FOR

adverse

affects.

season

or recommissioning

the

zinc

811

zinc

with

procedures

INITIAL

START-UP

and

impeller

if required).

cover

during

the

sure

are

tight.

fully

charged.

apron,

LBSd

gas,

or

allow

Shat

and

the

raw

needed.

water

When

will

self-flush in a

It

is

located

debris

described

discard

gasket.

lay-

the

acid

which

an

off

install

water

Note

the

in

from

section

all

to

that

the

that

of

Engines & Generators

41

Engine Type

(8 bhpat1SOO

Governor

Combustion Bore & Stroke

Piston Displacement

Firing

Direclion of Maximum Torque

Compression

Compression Pressure 213.3 psi {15.0

(Limit

Valve

(engine

Engine

Dimensions

OryWejght

Fuel

Inclination

rpm.

Chamber

Order

Rotation

Ratio

ofclillerence

liming

Seat

Angle

Clearance

wann)

Speed

Consumption

maximum}.

(at

1800

between

rpm)

cylinders)

'Gasoline,

tour-cycle, three-cylinder,

Vertical,

In-line

fresh

water-cooled.

Hoof,

flyball

Multi-ephere type.

2.62 x

3.19

51.6

cubic

inches

1·2-3

Clockwise,

13.S lbf.ft

9.5:1

(20psl

[1,5kg/cm

lntipal

Opens

Intake Closes 62"

Exhaust

Opens

Exhaust

Qoses

lntake4S•

Exhaust45°

Intake 0.0098

Exhaust

0.0118

1

BOO

tpm

60

1500

tpm

50

Length: 26.50 Inches

Width: 18.34 Inches (465.8 mm)

Height: 23.44

Approx. 309 lbs (140.1 kgs)

0.8

U.S.

gph

Continuous 14°

Temporary

BCG:

overhead

type,

S'lb

speed

Inches

(66.6 x

(.846

when viewed

kg/~

2

))

ZS'

BTOC

A80C

62"

BBDC

ZS'

ATDC

inches

(Q.25

inches

hertz..

hertz.

inches

(59S.4mm)

(3.02 lph)

2r1'

(not

to

GENERATOR

v81Ve

reg\dation.

81

mm)

lirer)

from

at

400

mm)

(o.30

(673.1

at

full rated

(approximate).

exceed

mechani$m

the front

rpm

mm)

Q!.ltput

20

min.)

INTAKE

IGNmON

FUEL

COOLING

SPECIFICATIONS

SYSTEM

Carburetor

General

Dislrlbulor

Spartc

Spark

General

FUii

FUii Fuel Screens (on engine)

Alrcleaner

Alr

General

Operating

Fresh

Raw

(STD

type)

$YSTEM

Plug

Thread

Size

Plug

Type

SYSTEM

Plll'lp

Flow

(engine combustion) 26.8 elm

SYSTEM

Temperarure

Water

Pump

Was.er

Pump

Manual

with butterfly shaped

with

U.S.C.G.

approved

Baltery

ignition. 12-volts (negative ground),

distributor with points, ignilion

plugs.

Conventional,

14 x

Weslerbeke

(!Jways Identify lhe generator model

when

Conllentional carburetor Regular

89

of

12-volt

Reusable

Metal

Fresh

thannoslalically-controlled

with a

130 • 150"F (SS - 66°C)

centrifugal type,

Positive

contact.point typ$:

1.25

mm

pitch

part

ordering pans.)

or

unleaded

or higher.

DC;

Ill capacity 5

screen type (localed at

screen

type • cleanable.

(O.

758

water-cooled

heat

exchanger.

displacement, rubber

ftame

(O.SS

number

gasoline

cmm)

at

block,

belt-<iriven,

valve,

arrester.

coil

x 0.05 in.)

38568.

type

with

ft

(1.5

m)

1800 rpni

1.13:1 to

Impeller,

~ngle

and

spark

fuel

pump.

an

octane rating

inlet

to carburetor).

crankshaft.

bell-driven

barrel

3.75

4.2

Fully-

·4.0

U.S.

FoRle

Raw

Walll!I

(~before

into exhaust

LUBRICATION

General

Flow,

at

discharging

elbow)

SYSTEM

1800

rpm

crankshaft-driven.

01 Flter

Sump Capacity (not

Opendlng 01

Grade

01

Pressure

lncllXling

(engine

FWI

ftoN,

P.N.036918

titer) 3.0 qts (2.8 liteia)

hot)

50

• 70 psi (3.5 •

API

Servke

SAE

JOW,

U.S.

gpm

(14.19·1S.14lpm)

qts (3.9 liters)

fed

type byTrochoid

paper

element, spin-on type.

4.9

k9'cm2>

Westerbeke 7.0 BCG, 7.0 BCGA, 5.0 BGG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual