Westerbeke 5.5 EGCD, 5.0 EGCD Operator's Manual

OPERATORS·

MANUA.L

· 5

5.0

.

MARINE

•.

5

EGCD

DIESEL

·siNG

GENERATORS

&OH.Z

50HZ

SE

..

·

.

'PUBLICATION

.

...........

l..,

····.

'WESTERBEKE

~

WESTERBEKE

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CORPORATION

STANDISH

WWW.WESTERBEKE.COM

Mt!lltbu

NO.

REV/SIONO

JULY

2016

INDUSTRIAL

N«illln«l

M«rlM Ma••ftldltrers

056308

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•150JOHN PARK • TAUNTON

HANCOCK

Anociatio~

MA

ROAD

02780

.

PROPOSITION

Diesel engine exhaust and some of

its

constituents are known

the

State cancer, birth defects, and other reproductive harm.

Exhaust colorless unconsciousness exposure

•

•Nausea

•Headache

•

gasseS

gas. can

Dizziness

Weakness

contain

Carbon

Include:

and

Sleepiness

CALIFORNIA

of

California

A

wARNING:

Carbon

Monoxide

and

death.

Symptoms

65

WARNING

to

cause

Monoxide~

Is

poisonous

•

Throbbing

•

Muscular

•

Vomiting

•

Inability

an

odorless

and

of

Carbon

In

Temples

1Witchlng

to

Think

can Monoxide

Coherently

and

cause

IF

YOU

GET

seek

until

OR

ANYONE

OUT

INTO medical It

has

THE

attention.

been

Inspected

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

This WESTERBEKE bulkhead

WESTERBEKE

CARBON

living/sleeping

They obtainable

ANY

OF

THESE IMMEDIATELY. down

the

repaired.

WARNING

near

MONOXIDE

are

Inexpensive

at

If

symptoms

unit

and

DECAL

and

should

your

engine

also

recommends

DETECTORS

quarters

your

local

SYMPTOMS~

persist~

do

not

restart.

Is

provided

be

of

your

and

easily

marine

by

flxed

to

or

generator.

installing

in

vessel. store.

a

the

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure to

precautions.

toke

the

personne4

The

following

American Boat and

PREVENT

A

while

power.

•

Do enclosures and covers in place.

• Shut off electrical power before accessing electrical equipment

• Use insulated mats whenever working equipment

•

Make (particularly shoes) when handling electrical equipment.

•

Remove electrical equipment.

PREVENT

A

exhaust

hot!

• Monitor engine antifreeze coolant level at the plastic coolant recovery location on the water jacketed exhaust manifold, but only when

I A

•

In before touching the engine or checking the coolant.

Know

necessary

and

your

safety

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not operate this machinery without electrical

sure your clothing and skin are

wristwatch and all jewelry when working on

BURNS -HOT

WARNING:

system

the engine

WARIIJNG:--

case

of

an

engine overheat. allow the engine

carefuUy.

foUow

fundamental

when

dangerous

precautions

machinery.

instructions

Yacht

Council

to

protect

are

Most

conditions

in

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

or

is

present

when

connected

at

these

ENGINE

Do

not

touch

hilt

engine

t:11mp11nents. A running

tank

and periodically at the filler cap

is

COLD.

.....

/#jrltyllfdealll!

acciilents rules

yourself,

compliance

are

and

exist

your

standards.

connections

to

shore

connections!

on

electrical

dry,

not damp

parts

or

engine

gets

to

with

and

very

cool

the

PREVENT

A

• Prevent flash fires. Do not smoke or permit flames or sparks pump, or other potential sources of spilled fuel or vapors. Use a suitable container to catch removing the fuel line, carburetor, or

• Do not operate with the air cleaner/silencer removed. Backfire can cause severe injury or death.

• Do not smoke or permit the fuel system. engine/generator clean and chances

• Be

PREVENT

A

Injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin

after

running the blower. Run the engine compartment blower prior to starting, following the recommendatiin of the vessel builder.

• All

when ventilated

and out

• Do not

• Shut off the fuel service

the fuel system. Take care in catching any fuel that might spill. sources servicing. the fuel system.

•

Do

• Be sure all fuel supplies have a positive shutoff

• Be certain fuel line fittings are adequately tightened and

free

•

Make

properly maintained. Extinguishers rated ABC by the

for all applications encountered in this environment.

BURNS -FIRE

WARNING:

to

aware-

Fire

can

cause

Injury

or

death!

occur near the carburetor, fuel line, filter,

all

fuel

filters.

flames

or sparks to occur near

Keep

the compartment and the

free

of

debris

to

minimize the

of

fire.

Wipe

up

all spilled fuel and engine

diesel fuel will burn.

BURNS -EXPLOSION

WARNING:

or

death!

fueling. Check below for fumes/vapor before

fuel

handling and storing fuels. Store fuel in a well-

fill

DO

not alter or modify the fuel system.

of

leaks.

sure a

Explosions

vapors

are

highly

area

away from

of

the reach

the fuel tank(s) while the engine is running.

NOT allow any smoking, open flames, or other

of

fire

near the

Ensure proper ventilation exists when servicing

fire

extinguisher is installed nearby and

from

fuel

vapors

explosive.

spark~producing

of

children. ·

valve

fuel

system

Be

familiar with its proper

Use

extreme

at the engine when servicing

or

engine

NFPA

are

equipment

when

appropriate

can

valve.

fuel

when

oil.

cause

care

··

is

use.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing the engine/ generator. it

last.

•

Make starting.

•

Make re-installed before starting the

BATTERY

A

WARNING:

or

death!

•

Do

not being serviced highly arcing equipment

during

•

Never positive

Do

not

together. Ventilate accumulation disturb is

being

•

Avoid bums wristwatch, the

battery.

•

Always

the battery connections. Remove the negattve lead first

and

reconnect it last

BATTERY

A

WARNING:

severe

• When servicing level, protection. destructive. H it it off into caps.

STARTING

Remove

certain all

certain

all

Accidental

personnel

covers,

the

starting

negative

are

guards.

can

lead

clear

and

engine.

cause

injury

first

and

reconnect

of

the engine before

hatches

are

EXPLOSION

Battery

smoke or

Lead acid batteries emit hydrogen.

explosive or by lit tobacco products. Shut

in the

servicing.

connect the negative(-) battery cable to the

( +) connection terminal of the starter solenoid.

test the battery condition by shorting the terminals

Sparks

any compartment containing batteries

of

the battery charger connections

charged.

contacting

or sparks that could cause

rings,

tum

the battery charger off before

explosion

allow

an

gas,

which

vicinity

could

ignite battery

explosive

the

terminals with

and

any

when

can

cause

Injury

open

flame

near the battery

can

be ignited by

to

prevent

gases.

electrical

gases

To

avoid sparks, do

tools.

an

explosion. Remove

other jewelry before handling

servicing the battery.

el~cal

o~

all

el~tncal

arcmg

or

fuel

to

while

the battery

etc.,

to

_disconnecting

vapors. prevent

prevent

ACID

Sulfuric

injllry

or

death!

the

wear rubber

Batteries contain sulfuric acid which

at

once with

the

eyes inadvertently when removing electrolyte

acid

in

batteries

battery or checking the electrolyte

gloves,

a rubber apron, and eye

comes

in contact

water.

Acid

may

can

with

your skin, wash

splash

on

cause

the skin or

is

~

not

TOXIC

• Ensure that the exhaust system is adequate to expel

• Be sure the unit and its surroundings

•

• For additional information, refer to

•

• Although diesel engine exhaust

AVOID

EXHAUST

A

WARNING:

discharged from the engine. Check regularly for leaks and water-injected

Run

blowers

Do

not run the generator equipped detector boat builder or dealer for installation of approved detectors.

(educational information

A

odorless nausea

Do

Diesel systems. copper tubing resulting in exhaust/water leakage.

Do

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

exhaust

gas symptoms poisoning

Vomiting Dizziness Headache Nausea

that complies with

WARNING:

gas.

or

death!

not

use

fumes

not install exhaust outlet where exhaust

the

of exhaust.

fumes

is present in diesel exhaust

MOVING

A

WARNING:

or

death!

•

Do

not service the engine while it is

situation arises in which it

make

operating adjustments,

touching moving parts and hot exhaust system .

components.

GASES

Carbon

elbow

when running the generator set or engine.

with

a functioning marine

Carbon

Inhalation

copper tubing in diesel exhaust systems.

can

Exhaust sulfur causes rapid deterioration

exhaust

from gasoline

or signs of carbon monoxtde inhalation or

are:

monoxide

make

is

securely

monoxide produces

rapidly

discharge

Avoid

overloading the

(CO)

is

a

deadly

the

exhaust system

sure

the exhaust manifold/

attached.

are

well ventilated.

set

or engine unless the boat

carbon

monoxide

ABYC

A-24.

Consult your

ABYC

TH-22

on

Carbon Monoxide).

(CO)

is

an

invisible

flu·like

symptoms,

destroy

copper

tubing

in exhaust

can

H the engine

is

near the waterline, water could outlet and close or restrict

craft.

gases

are

not

as

engines,

Inability to think coherently Throbbing in temples Muscular Weakness

carbon

fume~.

S?me

twitching

and

sleepiness

monoxide

of.

the

PARTS

Rotating

parts

can

cause

running.

is

absolutely necessary use

extreme care

injury

H a

to

be drawn

toxic

gas!

ga5es

is

of

the

as

to

avoid

Engines & Generators

ii

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewehy when servicing equipment; rings, moving

•

Make

Keep places

• Do not check

the

engine is

•

Stay

when be caught in these rotating parts.

HAZARDOUS

A

WARNING:

avoid

wearing

necklaces or bracelets that could be caught in

parts.

sure all

protective

clear

the engine

at

all

times.

operating.

of

the

attaching

shields

fluid

drive is

loose jackets, shirts,

hardware

and

guards

levels

or

the

shaft

and

running;

hair and clothing can

sleeves,

is

properly tightened.

in their respective

drive

belt's tension

the

transmission coupling

NOISE

High

noise

levels

can

cause

hearing

easily

loss!

• ·

Never

operate

•

Do

not

removed.

· A

WARNING:

meDially

OPERATORS

Many of the in

your

Operators notes to highlight critical information. Read your manual carefully, procedures.

maintain

an

run

an

engine

Do

or

physically

MANUAL

preceding

Manual

your

engine without its muffler installed.

with

the air intake (silencer)

not

WDtk

on

11111J:hinery

incapacitated

safety tips and warnings are

along with other cautions

equipment,

and

by

fatigue!

follow

when

you

'

repeated

and

all safety

while

are

ABYC,

INSTALLING

Read for safety codes and standards. Follow their recommendations

ABYC "Safety Standards for Small Craft"

Order AJJYC

613

Annapolis, (410) www.abycinc.org

NFPA

''Ftre Protection Standard for Motor Craft"

Order

NFPA

1 Batterymarch Park

P.O.

·

Quincy,

USCG (United States Coast Guard)

"CPR

Code Order From: U.S.

Washington,

NFPA

AND

USCG

MARINE

the following ABYC,

when

installing your UNIVERSAL engine

(American Boat and

From:

Third Dtreet, Suite

MD 21403

990-4460

(National Fire Protection Association)

From:

Box

9101

MA 02269-9101

33

AND CFR46"

of Federal

RegUlations

PUBLICAnONS

ENGINES

NFPA

Yacht

10

AND

and

Council)

Government Printing Office

D.C. 20404

FOR

GENERATORS

USCG

publications

ENGINE

Preparations ough examination (ABYC) sources including the

Sections of the

All Regulations

AND

GENERATOR

to

install an engine should begin with a

of

standards.

ABYC

H-32

Ventilation

H-33

Diesel Fuel Systems

P-1

Installatiion of Exhaust Systems for Propulsion

and

Auxilliary Engines

P-4

Marine Inboard Engines

E-ll

AC & DC

TA

Batteries

installations

and

must

(FCR).

INSTALLAnONS

the

American Boat and

These

standards

USCG

standards of particular interest

for boats using diesel fuel

Electrical Systems on Boats

Battery Chargers

comply

and

the

and

with the

are

Yacht

a combination of

NFPA.

Transmissions

Federal

thor-

Council's

are:

Code of

Engines & Generators

iii

When

installing

attention

WES1ERBEK.E

be

paid

to

the

following

INSTALLATION

engines infonnation: ·

and

generators

it

is

important

that

strict

CODES

Strict

when

AND

federal

reguiations,

installing

~GULATIONS

ABYC

engines

and

SIPHON-BREAK

For

installations

or

will

be

break

in

the

minimum

the

exhaust manifold

raw

water

If

you

have

to

the

vessel's

siphon-break.

NOTE:

A

siphon-break

operation.

engine

diiiritige.'

EXHAUSTSYSTEM

The

exhaust' Exhaust and and system under

Hose

turns

turns.

MUST

any

where

below

die

raw

water

of20"

above

damage

any

doubt

waterline

Fa.ilr.cre

consult

system's

is

recommended

without

In

this

regard; a single

be

sea

conditions

the

vessel's

supply

the vessel's

injection

to

the engine

about

under

reqUires

~o

properly

the

..

bOse

the

need of

designed

and

exhaust

MUST

to

.

guidelines,

generators

manifold/water

waterlirie,

hose

to

waterline.

port

is

ant!

the

position

the

ves~l's

·

periodic

maititain a siphon-break

siphon-break

be

..

The

use

additional

lengtb

prevent

at

any

angle

and

safety

in a marine

proViSionS

the

exhaust

Failure

at

or

below

possible flooding

of

the

water-injected

various

in,spection

manufacturer

certified

the

for

of

this

type

fitting

and

of

corrugated exhaust

.entry

of water'into

of

vessels

code~

environment.

injected

inUst

elbow.

the

operating

and

marine

clamps

exhaust

be

maae

This

to

use a siphon-break

load

waterline

of

the

cleaning

can

result

for

proper

use.

of

hose

allows

to

heel.

mu.st

be

complied

elbow

tO

irisfull

hose

must

wiU

boat.

exhaust

conditions~

elbow

to

ensure

in

catastrophic

install a

is

close

a

Siphon-

be

looped

result

relative

proper

with

to

a

when

in

riuiintenance.

Corrugated

accomplish

hose

the

exhaust

for

can

Marine

extreme

these

be

used.

system

bends

The

AVAILABLE

YOUR DEALER

SIPHON-BREAK'

LOOP'

ffiOM

WESTERBEKE

.

WITH

STAiNLESS

A

detailed

engines

to

and

download

Marine

Installation

generators,

from

our

website

Manual

is

supplied

at

Engines & Generators

covering

with

each

\WiW.westerbeke.com.

iv

gBSQiine

uniL

A

pdf

and

diesel,

is

available

TABLE

Parts

Identification

Introduction

Fuel,

Engine Preparations Generator

Remote Panels ............................................... ?

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

Oil

for

Control

Starting/Stopping

Remote Panels ............................................... 8

Generator Daily Safety Maintenance Fuel Cooling

Fresh Water Cooling Circuit.. ......................

Changing the Coolant ..................................

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

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

Raw Water Cooling System ........................

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

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

Engine

Engine Oil Change ......................................

Remote Oil Filter (optional) ........................

Starter

Troubleshooting ...........................................

Break-In

Routine

Shutdown

System

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

System

Lubricating

Motor

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

Schedule

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

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

and

Engine

Initial

Panels

Procedure

Switches

Coolant

Start-Up

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

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

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

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

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

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

(Chart)

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

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

Oil

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

OF

CONTENTS

2

Engine

Adjustments

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

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

5 6

?

s

9

1 o

11 13 14

l5 15 16 16 17 17 l7

18

19

20 20

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

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

Timing .................................................

Spill

Testing Glow Plugs .....................................

Testing Oil Pressure .....................................

Engine

Alternator Battery Wiring Wiring Remote Engine/Generator Generator Generator

Single

Dual Shore Integral

Optional Optional

Sugge~ted

Troubleshooting

Electronic Governor ....................................

Troubleshooting Gauges ..............................

Testing

Circuit Diagram Schematic

Panel

............ · .......................................

#056225

Wiring

Specifications lnformation Single

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

Internal Wiring Schetnatic ...........................

Exciter

Power

Controller

Battery Charging Circuit ............................

Water

Installation ...................................................

Power

Spares

Phase

Model

Connections

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

Heater

Take-Off

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

(Chart)

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

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

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

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

Diagram

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

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

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

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

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

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

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

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

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

22 22

22 23 24 25 25

26 26

27

29

31

.32

33

34 35 36 37

.37

37 38

39

39 .40 .40 .41

41

.43 .44

Engines & Generators

1

DRIVE

BELTS

COVER

EGTD'

PARTS

IDENTIFICATION

INTAKE

SILENCER

REAR

CONTROL

PRE~HEAT

START STOP

7.5AMPFUSE 5AMPFU$£

.

ENGINE

EMERGENCY

BOX

LIGHT

STOP

LEFT

SIDE

,.EMERGENICY

STOP

SWITCH

FRONT

SIDE

01~

fliLL

RIGHT

SIDE

/w-IWESTERBEKE

l Engines & Generators

2

This

WESTERBEKE WESTERBEKE's technology. dependable

Thank

In order

is

important that you manual manual throughout.. your

This provided WESTERBEKE equipment WESTERBEKE' S installation

WARRANTY

Your documentation a

Warranty mailed website:www.westerbeke.com. Customer

within

having number

Customer

We performance

you

for

to

get

is

designed

carefully

Should

nearest

WESTERBEKE

is

your

operators

and

a technical

contact

PROCEDURES

WESTERBEKE

Registeration

in

or

you

Identification Card after registering your

60

days.

available

and

date

Identification

Diesel

long

years

take

great

selecting

th~

package

If

WESTERBEKE.

full

use

operate

to

help

and

observe

your

manual. A parts

dealer.

If

your

WESTERBEKE

Warranty

supplied

can

register

you

do

the unit's

you

purchased

Generator

of

experience

pride

in

of our

engines

and

benefit

and

you

do

all

generator

dealer for

manual

you

are manual.

is included in

Card that

your

You

not,

please contact

model

the

Card

is

a product

and

the

superior durability

and

generators.

from

your

maintain

this.

the

require

is available

planning

with

warranty

designation, engine serial

it

correctly.

Please,

safety precautions

servicing,

assistance.

catalog is

from

to

dealer for

ths product.lt.includes

can

be

filled

on

should

receive

the

unit.

: 1-.vtWESTERBEKE

j Engines & Generators

Customer MR.

.

MAIN HOMETOWN, Model: Expires:

Identification

GENERATOR

STREET

USA

OWNER

Serial#

INTRODUCTION

of

advanced

generator it

read this

contact

also

your·

install

this

the

out and

our

a

warranty

factory

and

This

.

PRODUCT

Product brochures

.

WESTERBEKE

WESTERBEKE CONTENT RANTIES

lliEREl'O, COMPLETENESS BE LIABLE INCURRED OF

THE

WESTERBEKE

time

software WESTERBEKE provided WESTERBEKE

be relied

the

respective

but

is

WESTERBEKE

to

determine

product

NOTES,

As

this maintenance engine, CAUTIONS,

NOTE:

A

observed,

your

A

followed,

SOFTWARE

software,

and

OF SUCH

OR

INCLUDING

FOR

IN CONNECTION

FURNISHING

span

between printings ofWESTERBEKE product

and

the with upon

imperative

the

software being consulted.by the

CAUTIONS

manual

schedules, and troubleshooting of your

critical information

An

operating

CAUTION:

can

engine

.

WARNING:

can

(tech·

data, parts

catalogs), provided

are not within WESTERBEKE's

CANNOT BE RESPONSmLE FOR

SOF7WARE,

REPRESENTATIONS

ACCURACY,

THEREOF AND

ANY TYPE OF

OR

customers should

unavoidable existence of earlier .

manuals.

WESTERBEKE

or

exclusively

product.

that appropriate or the supplier in question be consulted

accuracy

In

other suppliers,

as

It

not only

and

AND

takes

you

through the operating procedures,

and

WARNINGS.

p'roeedure

Procedures,

result

in

the

Procedures,

result

in

personal

lists,

manuals,

from

sources other

MAKES

wrni

RESPECT

TIMELINESS

WlU

IN NO EVEN!'

DAMAGE

WIT'H

USE

OF SUCH

also

summation,

products,

must

the

definitive

makes

representatives

cunentness of

OR

ARISING OUT

SOFIWARE..

keep

in mind

product whether not and cannot

authority

good

the

customer.

WARNINGS

will

be highlighted by

An

explanation

essential

which N ..

damage

which

to

not

or

destruction

if

not

injury

or

note.

strictly

properly

loss

NO

sense

follows:

than

control.

THE

WAR-

OR

INJURY

the

software

from

on

of

marine

NOTES,

of

life.

.

ENGINE

This in

(50

Federal

engine

the

United

Hertz)

OPERA

is

States.

in

the

Law.

1....,.,./WESJERBEKE

) Engines &

Generators

3

DON

certified

Operating

United

· ·

to

operate

States

atl800

this

may

rpm

engine at

be

a

violation

(60

1500

Hertz)

rpm

of

INTRODUCTION

SERIAL

The are located on a decal time plate shown when parts.

NUMBER

engine and generator

to enter

below,

seeking

LOCATION

tllis

information

as

technical

on

tllis will provide a quick reference

information and/or ordering repair

serial

numbers

the generator housing.

on

the illustration of the

t=~~~...,.-:~

The

engine serial number can also be

engine block just above the injection

serial number is stamped irito the

fiat

surface

on the left side

gener~r

of

the

gener.a:tor.

and

model

found

stamped into the -

pump.

The generator

housing on the

Take

..

numbers

the

name-

NOTE:

A

carbon

m01wxide

by

WESTERBEKE.

engine

room.

UNDERSTANDIN~

The

diesel

engine

closely

since

1he

mechanism

are

arranged

1he

same diesel connecting

Therefore,

same

most maintenance Replacement tin?e

periods

contamination

tem

is

the

same

designed The diesel engine

however,

carburetor component-the function

ORDERING

Whenever generator

serial

plate located on the

this

information so

set.

In

number Parts because

the

same

above a closed

general

engine

has

rods

type

the

and

to a great

preventive

important

also

of

maintepance

factors

of

1he

of

fuel

specified

(fuat

essential.

brand

of high

specifically

does

in

its

method

and

ignition

fuel

bo1h.

PARTS

replacement

model

number,

number

addition, include a complete part

List).

as

they

for

each part needed (see the

Insist

upon

will fit

or

generic

specifications

warning

Affrx

this

decal

THE

DIESEL

resembles

is

essentially

crankcase;the crankshaft

as

1hat

of a

same

type

of

lubricating

extent,

are

fuel,

and

is

water,

Another

detergent

for

differ of systems

injection

parts

ajlpear

generator

we

may

system.

a diesel

as a gasoline

proper

lubricating

lubricating filter a

must,

and

sediment, etc.) in the

important

diesel

engines.

from

handling

are

pump-

are

needed,

engine

serial

on

the

end.

properly

WESTERBEKE

parts

are

as

original equipment

the

gasoline

valves,

ventilation

diesel

1he

You

frequently

decal

ho.s

been

in

a

visible

ENGINE

1he

gasoline

same.

The

engine,

camshaft,

engine

requires

engine.

and

cooling

elements

frequent

and

replaced

silver

identify

separately

checking

factor

is the

lubrication

gasoline

firing

of fuel The

by

which

pexfonns

always

number,

and

black

must

provide

your

description

packaged

not

provided

position in

engine,

cylinders

is

of

and

the

pistons,

1he

The

proper

systems.

at

the

for

fuel

sys-

use

of

oil

engine,

a single

the

provide the

and

generator

name-

us

with

generator

and

part

furnished

parts

made

to

the

AD.

identification ·plate on the engine

fbe engine model and serial

number.

manifold

also displays

SPARES

Certain spares will be

WBSTERBEKE will assist

See

accessories,

the

AND

you

SPARE

see

ACCESSORIES

needed

to support

engine.

Your

local

in

preparing

PARTS

WBSTERBEKE'

page

an

inventory of

in

this

S

WBSTERBEKE

manual.

ACCESSORIES

/'"tt~V"IWESTERBEKE

(Engines_ & Generators

4

and

spare

For

maintain

parts.

engine

brochure.

your

dealer

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

FUEL

A

CAUTION:

has a Cetane according

Care

Of

The

Use

only

clean fuel!

your

fuel

injection particles which might pass through the filter can damage these

finely and keep it clean. The best unsatisfactory by careless handling or facilities. engine's daily use is clean advisable:

Purchase a well-known brand of

Install

metal bowl and

ENGINE

Use a well known brand oflubricating oil, with an API classification and pages

Change the oil and

· operation. Then specified in the MAINTENANCE SCHEDULE in manual.

Westerbeke Corporation does not approve or disapprove of the use of synthetic break-in must intervals must SCHEDULE section of this manual and the change intervals are not to

NOTE:

statements

To

and

regularly service a

the

engine.

OIL

of

this manual

be

The

information

regarding

Use

only

No.2·D

(SAE

J313}

diesel

that

rating

of

145

or

higher.

Grade

of

diesel

to

ASTM

8975.

Fuel

Supply

The

clearance of the components in

pump

is

very

critical; invisible dirt

finished

type filter/water separator between the fuel tank

parts.

It is important to buy clean

fuel

can be rendered

improper storage

assure that the

SAE

filter

follow

be

performed using convential oil. Oil change

be

as

extended

fuel

going into the tank for your

and

pure, the following practice

fuel.

good,

Coast Guard approved

as

listed in

after the initial 50 hours

the oil and filter change intervals

oil.

If

synthetic oil is used, engine

listed in the MAINTENANCE

if

synthetic oil is used

above

synthetic

the

SPECIFICATION

supersedes

oil.

all previous

of

fuel,

break-in

this

as

is

ENGINE

WESTERBEKE recommends a mixture of 50% antifreeze

and

chemicals that can corrode internal engine surfaces.

The to the cooling circuit from rust antifreeze (SCAs) to

Select a brand of antifreeze specified for diesel engines. Antifreeze specified for diesel engines contains a special additive cylinder walls.

Prestone offer

Select always

Change MAINTENANCE

COOLANT

A coolant recovery tank kit is supplied with each The

coolant without the

the

COOLANT

50% distilled

antifreeze performs double

run

at proper temperatures by transferring heat away

engine

that keep the antifreeze chemically balanced, crucial

long term protection.

to

and Zerex are

antifreeze specifically for use in diesel engines.

the pre-mixed variety so

be added

the antifreeze mixture according

purpose of

expansion and contraction during engine operation

cooling system.

water.

Distilled water

duty.

to

the coolant. It also lubricates

and

corrosion.

that contains supplemental cooling additives

protect against cavitation erosion of the engine's

two

nationally

that

to

the cooling system when needed.

SCHEDULE in

RECOVERY

this

lass of coolant and without introducing air into

TANK

recovery tank is to:

is

free from

It

allows

the

and

protects the

Use

a good quality

known

brands that

the correct mixture will ·

to

the

this

manual.

Bnow

for engine

the

engine

from

generator.

Engines & Generators

5

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting prolonged layoff, check the following items:

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

• Check the engine oil level. Add oil

the

• Check the fuel supply and examine the fuel filter/separator

bowls for contaminants.

• Check the

and battery cable connections.

• Check load leads for correct connection as specified in the

wiring diagrams.

• Examine air inlet and outlet for air flow obstructions

(SoundGuards).

•

Be load lines.

•

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

• Visually examine the unit. Look for loose or missing

parts, disconnected wires, unattached hoses, and check threaded connections. Search for any gasoline leaks.

INSPECTION

your

generator set for the first time or after a

to

maintain the level at

full mark

sure

sure that in power systems with a neutral line that

on

the dipstick.

DC

electrical system. Inspect wire connections

no

other generator

or

open neutral can supply the wrong line-to-

on

unbalanced loads.

or

utility power is connected to

A

CAUTION:

recommended motors, up

This unanticipated prevent a cold

• Check the coolant level in both the plastic recovery tank

NOTE:

the

recovery

cooling system

engine has drawn air.

Before subsequent

manifold should

may need

be

to

speed

precaution

and at the manifold.

After

engine's

tank.

into

that

switched

and,

will

operation

engine

the

initial

cooling

Open

is

purged cooled, the

engine's

be

to

be

filled

When

starting

all

AC

OFF

in

cold

prevent

from

running system the

air bleed petcock

the

coolant from the recovery tank will

cooling

operation

topped

to

the

generator,

loads,

especially

until

the

engine

climates,

of

the

will

of

air.

off,

MAX

starts

damage

stalling

of

and

caused

AC

machinery

.

the

generator,

be

purged

to

After shutdown and after

system

to

replace

the

generator; the coolant recovery tank

level.

large

has

to

warm

by

and

to

the coolant

ensure that

the engine's

it

is

come

up.

will

the air

the

in

the

purged

be

MANIFOLD

PRESS

DOWN

TO

LIFTOFF

WAIT

FOR

BEFORE

REMOVING

CAP

PRESSURE

AND

TURN

THE

ENGINE

TO

COOL

THE

RADIATOR. . RECOVERY

.

CAP..--...-""'="~~

OIL

FROM

DIPSTICK

COOLANT

TANK

ELECTRONIC

THE

ECU

TO

CONTROL

OF

THE

CONTROLLER

IS

FACTORY

ALL

DRIVE

ENGINE

PROGRAMMED

ASPECTS

TO

NIPPLE

MANIFOLD

\5)

I

(5))

AT

PRESSURE

CAP

Engines & Generators

6

GENERATOR

INSTRUMENT

CONTROL

PANEL

ENGINE

DESCRIPTION

The Generators Instrument Control

gauge package, control rocker switches, circuit fuses, check engine light, emergency stop toggle switch and a recording hounneter. These components are

The

8 pin connector that is on the back

is used to connect an optional remote start/stop panel

second instrument panel. When

an

optional panel is connected, the 8 pin connector

with

jumper

troubleshooting. Secure

COOLANT

temperature should normally indicate:

(80"

to 90"C)

ENGINE

depending on the generator load but should range between 35 to 55 psi.

DC

VOLTS:

charged and should show 13V to

HOURMETER:

for when to perform scheduled maintenance.

PREHEAT:

activates the preheat circuit and activated the K2 Run Relay. This supplies power Instrument panel, switch.

START:

· Kl-Start Relay which activates the starter motor.

STOP:

opens the DC circuit supplying power to the K2 Run Relay.

De-activating it and shutting down the engine drive.

should be

TEMPERATURE:

OIL

PRESSURE:

Indicates the amount the battery is being

Registers elapsed time and is used

The PREHEAT rocker switch serves two purposes:

The START rocker switch when pressed

The STOP rocker switch when pressed and held,

kept

for future needs when

it

to

Engine coolant (water)

Oil Pressure )psi) may fluctuate

to

the DC alternator

K3

Fault Relay pin #87 and Start toggle

Box

contains a compact

de~cribed

of

the lifting eye.

175• to 195°F

14V.

R,

below.

the Control Box

or

as

a guide

fuel pump, ECU,

activat~:.;

the

MOUNTED

a

FUSES:

amp fuse protects the ECU and a 7.5 amp to protect the control circuit and instrument panel.

CHECK

illuminate Shutdown in this manual).

EMERGENCY

(Normally Closed) is located at the side When depressed, it will open the DC circuit to the control box. This switch can be used when servicing the unit prevent an unwanted start.

REMOTE

box will allow for the remote mounting

instrument panel or the remote stop/start panel.

NOTE:

It is important to closely monitor the panel gauges. Become aware

· the normal engine readings and

take immediate action

· if these readings start to vmy.

The control box has two automotive type fuses. A 5

ENGINE

LIGHT:

The CHECK ENGINE LED will

if

the engine shuts down. (Refer to the Safety

STOP:

The EMERGENCY stop toggle switch

of

the control box.

PANEL

PLUG

IN:

A plug on the side on the control

of

the remote

to

of

l...v-IWESIERBEKE

l

Engines

&

Generators

7

STARTING/STOPPING

PROCEDURE

,

ENGINE

PREHEAT:

approximately 5-10 rocker

START:

voltmeter register a mounted Continue until

PREHEAT Once

on discharged

00.

apply

FAILURE

START both above run

MOUNTED

Depress the

still

depressed.

With

a remote panel, observe

gauges.

reading,

on

the

generator,

to

hold the

the

oil

pressure

rocker

the

generator

the

instrument

with

the

t,l\e

generator

your higher

TO

rocker

start

the

starter continuously for

and

START:

has

switches

procedure.

INSTRUMENT

PREHEAT

seconds.

When

release

PREHEAT reaches

switch.

has

panel.

exhaust.

allow

amperage

Should

been depressed for 5-10

and

Then with

depress the

the

oil

the

START

release

10

started, observe

Ensure that

Apply

it

to

loads

the

engine not start after

wait 30 seconds

Preheat a

more

CONTROL

rocker switch

START

the

and

voltmeter start

rocker.

the

START

rocker

switch

psi.

Then release

the

raw

a light amperage load

warm

up

as

needed.

few

seconds

than

PANEL

for

the

PREHEAT

rocker.

oil

and

DC

to

With

a panel

rocker.

depressed

the

meter

readings

water is being

to

140"F,

then

seconds,

and

repeat

longer.

20-25

seconds.

the

release

the Never

STOPPING:

switch the

oil pressure. rocker release the to a complete

REMOTE

The switches the

same.

This

When

when

START

generator starts, the release switch oil

pressure

For the REMOTE

and

wiring harness, refer

To

stop

and

hold it

When

switch.

With

STOP

stop.

START/STOP

Remote

LED

Start/Stop

as

the Instrument Control

This panel

will illuminate

this

panel

is

the

generator

rocker

switch,

the

START

is

held depressed

to

reach

the

generator,

depressed.

it drops to zero, release

the

panel

rocker switch

depress the

With a remote

mounted

when

PANEL

Panel

has

the

has

a

RELEASE

when

the

remote

rocker

STOP/START

has

this

LED

10

mounted,

started.

LED

will

switch.

for

about

psi,

then

to

the

When

will dim.

brighten.

The

release

PANEL

Table

STOP

rocker

panel,

observe

the

STOP

on

the

generator,

the

generator comes

same

three

rocker

Panel.

Their

function

STARTER

PREHEAT

this

depressing

This

PREHEAT

4-5

seconds

of

Contents.~<,,

is

depressed.

LED

will

the

When

the

indicates

to

allow

it.

wiring diagrain

1

is

LED.

indicate

to

rocker

the

_

/----/~

/~

1

·

.

EXTENSION

PN.

056236

PN.

056235

·HARNESSES

EG EG

DIESEL

(8 (8

PINJ PIN)

~~

5

feet'

~30

feet

.I..,..IWESISIBEICE

l

Engines a GenetlltOI'rl

8

.

DESCRIPTION

Although hour assembly operated life of operated

Breaking-in a piston and scored, break-in period ..

Your conditioning

to

Perform following:

Start the engine section. water

your

of

test

operations

procedures

properly,

your

engine

and

serviced

new

rings

to

smoky

operation

which

is

new

engme

operation

maximize the

this

conditioning

Run

the

pump,

oil

engine

the

caused

requires

performance

according

engine

pressure,

GENERATOR

has

experienced a minimum of

at

the

factory

were

followed

a break-in time

is

dependent

during

engine basically

cylinder

indicate that

by

to

while

upon

its initial

walls. overloading the engine

approximately

break in

and

carefully,

to

the

STARTING

checking that all

battery

to

make

and

that the engine

is

required.

how

hours

involves

Excessive

the

cylinder

50

each

moving

service life

~ing

charging)

BREAK·IN

one

sure accurate

The service

the

engine

is

of

~e.

seating

oil

hours of initial

in

are functioning.

the

consumption

walls

are

during

part in order

of

the

engine.

mind

the

PROCEDURE

systems

(raw

the

PROCEDURE

After

the

first

10

hours

of

the

generators

load

can be

increased

periodically Avoid

smoky Monitor it

within

1800 control current

NOTE:

current

amperage amperage.

overload

exhaust

the

rpm

to

of

the

drawn

Be

aware

drawn

draw

See

vary

current

generators'

produce

generato~

GENERATOR

Once the generator has been placed into operation, there the need for a

50 hour break-in service. (see Generator Information).

to

the

full-load

the

load.

at

all

times.

An

overload

with

reduced

being

from

the

ofnwtor

required

can

be

GENERATOR

drawn

rating.

60

hertz,

engine

generator.

starting

for

starting

3

to 5 times

output

from

Since

or

break

INFORMATION

ACJUSTMENTS

AC

no-load voltage adjustment before or at the

operation,

rated

output, then

is

signaled by a

voltage

at

.1500

loads

nwtors. nonnal

and

the

generator

the

generator operates

to

produce

-in ~ governed by

OJ7d

the high

This

running

the

frequency.

and

50

starting

in

this

manuaL

hertz,

keep

the

may

at

be

·

AFTER

Once the generator has tion and between

START·UP

then

encourage

20%

and

CHECKLIST

Follow this checklist

•

Check

that all generator circuit

the

off

position before starting.

•

Record

to

•

Visually

•

Check

•

Check

•

Check

• Check

• Check the

CHECK Wll'H

• Check for blow-back

• Confinn

When When When

the

hourmeter

the

maintenance

inspect the engine for

the

oil

level

the

coolant

your

fuel

the

starting drive

THE

abnom13l

sounds.

exhaust

the

engine

the

engine

the

engine

been

a fast

60%

of full load for

each

reading

schedule).

(dipstick).

level

supply.

batteries

belt

for

ENGINE

noise

smoke:

is

cold-

is

warm-

is

overloaded

started, check for proper opera-

wann-:up.

the

Run

fifst

the generator

10

hours.

THE

day

before starting your

breakers

in

your

log

fuel,

oil,

in the coolant

(weekly).

wear

and

RUNNING.

such

White

almost

proper

as

knocking,

Smoke.

Smokeless.

-some

recovery

(power

or

Black

generator. panel)

(engine hours relate

water

leaks.

tank.

tension

(weekly)

vibration and

.

Smoke.

DAILY

ROUTINE

NOTE:

This

is

reached

are

in

A

periods generator.

·STOitflNii'RIE,GENEMTOR:'

Remove the time. Allow the generator the and hold depressed until the generator

STOP.

NOTE:

in the

(50

Federal

Some

unstable

condition

.arulloads

CAUTION:

of

time

. . .·.

~-

. . . . . .

AC

operating temperatures. Then depress

This

engine is certified to operate at

United

States.

Hz)

in

the

Law.

should

Do

1U1111ing abate

afe

not

may occur in a

as

nonnal

applied.

operate

without a load

.·.

. .

amperage loads

to

run

Operating this engine at

'United

States may be

operating

the

geniJI'Bfor

being

placed·

from

the generator one at a

for

3 - 5 minutes to stabilize

comes

a"

violation

·

cold

engine.

temperature

for

on

the

·

the

STOP switch

to a complete

1800

rpm

1500

of

long

(60

rpm

Hi}

Engines & Generators

- 9

SAFETY

SHUTDOWN

SWITCHES

SAFETY

The Should a shutdown

Check Engine LED

detennined fault back

High

A housing. coolant's operating temperature reach approximately

(99°C),

shutting

Low

A

engine's oil switch's engine's oil pressure interrupting

SHUTDOWN

engine

is

protected

and

by

turning

ON

in

order

Water

high

water

Normally

will

open

off

the

Oil

Pressure

low

oil

pressure shutdown switch is located off the

gallery.

sensor

the DC voltage thereby shutting off the

SWITCHES/SENSORS

by three safety shutdown switches.

occur

due

to

one,.

of

these

switches,

will

illuminate. corrected. off

to

the

start

20

The

amp

the

engine.

Temperature

temperature switch is located

closed,

and interrupt the DC voltage thereby

engine.

this switch, should the fresh

This switch resets at I?5°F

The cause should

ECU

must

be

cleared of

DC breaker and turning it

Switch

at

Switch

Normally open in a static state,

monitors

the engine's oil pressure. Should

fall

to

5-lOpsi, this switch will

the

tl}ermostat

CHECK

ENGINE-

High

An

the

be

this

water

210°F

(107°C.

elbow. the sensor indicate an excessive exhaust temperature inadequate supply of raw water causes high exhaust temperatures). This switch opens at

1Jris

Engine

The generator's engine is protected by

manual

current draw or electrical overload instrument panel breaker to trip. because should After

·

generator.

OVERSPEED

this

the open engine.

The

from

flywheel's ring gear teeth. 2200

the

LED

.

Exhaust

exhaust temperature switch is located on the exhaust

Normally closed, this switch will

DC voltage (shutting off the engine) should the switch's

switch resets

Circuit

reset circuit breaker (20 amps

the open breaker interrupts

occur,

repairing the fault, reset the breaker

unit's ECU is

the

MPU

rpm

Check Engine

Temperature

at

approximately 225°F

Switch

open

260°·270°F

EXHAUST

and

(107°C).

Breaker

an

engine

DC).

Excessive ·

~ywhere

Wiring

or engine wiring

In

tlif~

event, the generator will shutdown

the

check and repair the source of the problem.

SHUTDOWN

monitoring

(Magnetic Pick-Up) positioned over the

(73 hertz), the

LED

the engine speed via a signal

Should

ECU

will

the

engine speed reach

will shut

illuminate.

in the

will

cause

DC circuit.

and

restart

the

engine down and

interrupt

(an

(127°·132°C).

ELBOW

mounted

the

If

this

the

·

OIL

PRESSURE

SENDOR

.

Engines & Generators

10

A

WARNING:

and

gloves,

control

panel;

and

Never

use

or

film

attempt

the

correct

off

the

battery switch. ·

to

perfDnn

tools

MAINTENANCE

any

servit:e

while

the

for

each

job.

When

servicing/replacing

SCHEDULE

engine

is

nmnlng.

DC

components,

Wear

the

proper

turn

safety

off the

equipment

DC

cll't:llit

such

as

breaker

goggles

tin

the

SCHEDULED

Maintenance

I

DAILY

Coolant Engine Fuel/Water

Fuel

Visual

Drive

II~ITIAL

Engine

*Exhaust

*Valve

Inlet Fuel Generator Electronic Re·Torque

MAimNANCE

procedures

CHECK

Level

Oil

Level

Separator

Supply

Inspection

Belts

50

HOURS

Oil

and

System

Adjustment

Fuel

Filter

Governor

Cylinder

are

BEFORE

(owner

of

Engine

OF

FiHer

.Control

Head

all

detailed

START-UP

installed)

OPERATION

Hold

Down

in

Bolts

this

manual.

EXPLANATION

Gheck Oil

level

Check hours

Use

properly

there

is

Check securing

connections. Inspect

Initial

engine

Check Ensure

Check Remove

Remove Check

Factory Re-torque

OF

SCHEDULED

at

recovery

tank,

should

indicate

for

water

and

or

once a year.

filtered

adequate

fuel

for

fuel,

oil

and

v-clamp

is

tight.

Look

for

frayed

edges.

oil

and

security

of

there

adjustment

that

water

are

no

leaks.

of

and

replace

and

replace

AC

comiections

programmed -No

bolts.

Engine

if

empty,

between

dirt

in

fuel.

#2

diesel

for

the

water

and

No

loose

bolts/hardware

Belts

filter

change

injected

valves. inlel

fuel

filter

are

adjustment.

colll,

MAINTENANCE

check

at

manifold.

MAX

and

LOW

Drain

filter

if

necessary.

with

a

Cetane

rating

V8$Sel's

needs.

exhaust

leaks.

exhaust

leaks

around

and

must

be

tight.

at

50

hours.

exhaust

elbow

filter.

and

all

sealing

Q-rings.

secure

with

no

then

check

the

valve

Add

on

dipstick.

of

#45

Gheck

the

correct

to

exhaust

chafing.

clearance

coolant

Do

Replace

or

higher.

that

the

elbow.

as

needed.

manifold.

adjustments.

if

neetled.

not

overfill!

filter

Check

water

injected

Inspect

every

wiring

250

that

exhaust

and

operating

elbow

electrical

I

EVERY

50

OPERATING

Drive

BeH

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

I

EVERY

100

OPERATING

Engine

Oil

and

Filter

Air

lnlake

and

Filter

*WESTERBEKE

recommends

HOURS

(if

applicable)

this

OR

service

MONTHLY

OR

YEARLY

be

performed

Inspect

for

slipping,

Check off

corrosion Inspect Inspect

your

Change

Keep

by

an

knowledgeable

for

proper

cracking

electrolyte

for

leaks,

and

clean

·own

inspection

engine

air

intake

tension

and

levels

if

needed.

ensure

zinc

schedule.

oil

and

clear

of

mechanic.

(318"

to

1/2"

wear.

Adjust

Make

sure

Apply

fuel

anode.

filter

obstructions.

cables

petroleum

and

electrical

Replace

at

1

00

deflection)

tension

and

jelly

connections

if

necessary.

operating

Clean

air

and

adjust H neooed.

or

replace

connections

to

terminals

are

Note

the

hours

or

yearly

filter

(if

applicable)

as

needed.

are

in

for

corrosion

clean

condition,

..

Replace

good

and

tight.

Check

belt

cover.

order.

Clean

protection.

then

determine

I....,.IWESTERBEKE

l Engines & Generators

11

NOTE:

Use

the

engine

MAINTENANCE

hourmeter

gauge

to

log

your

SCHEDULE

engine

hours

or

record

your

engune

hours

running

time.

SCHEDULED

I

EVERY

*Exhaust

Fuel

Inlet

*Generator

Hoses Fuel

DC

I

EVERY

Raw

Coolant

*Valve *Starter

Fuel

He-Torque Pre·Heat

MAINTENANCE

250

OPERATING

Elbow/Exhaust

After

and

O·Rings

Fuel

Alter

Water

Separator

Alternator

500

OPERATING

Water

Pump

System

Clearances

Motor

Infectors

Cylinder

CircuH

System

RHer

Head

HOURS

Hold

Down

OR

YEARLY

OR

FIVE

Bolts

YEARS

EXPLANATION

Check

the

structural

of

the

exhaust

chaffing.

ROTE:

Remove Remove

Check

See

GENERATOR

Engine delaminated.

Inspect Inspect

Check

Remove

and

cover

at

re-assembly.

·

Drain, condition and

connecting

·

.Mjust Check

motor

Check

Re-torque Check

system

No

exhaust

An

exhaust

and

repla~

and

repla~

that

AC

connections

hoses

should

Check

bowl

for

wiring,

connections

mounting

and

disassemble

for

wear

flush

and

of

the

hose.

valves.

(Incorrect

solenoid

and

pinion

driVe

and

adjust

bolts.

operation

OF

SCHEDULED

integrity

of

the

attached

Hoses

wiU

cause

filter

and

fuel

filter.

are

firm

and

tighten

water

in

should

and

alternator

the

pump

corrosion.

the

cooling

gaskets

valve

clearance

for

corrosion.

opening

cold,

then

solenoid.

to

clean

tight

all

fuel.

of

leaks.

leak

fuel

inlet

INFORMATION.

be

and

dirt

or

bracket

and

re-fill seating

motor

injection Engine of

preheat

MAINTENANCE

water

injected

exhaust

the

elbow.

All

and

muffler

exposure

all

sealing

and

hose

Drain

be

tight.

and

Replace

system

the

pressure

check

Remove

hose

are

in

good

to

diesel

exhaust!

O·rings.

secure.

Ensure

.

~eplate

if

as

and

replace

Alternator

All

should

inspect

the

impeller

with

appropriate

cap.

will

result

Remove

and

the

valve

glow

hoses

needed.

all

parts:

Clean

in

poor

and

spray

clearance

plugs,

clamps

bolt.

elbow

casting.

connections

serviceable·

wires

have

become

spongy,

filter.

should

be

and

lubricate.

conditions.

clean

tight

drive

gear,

gasket.

antifreeze

out

coolant

engine

performance.)·

Clean

adjustments.

clean

tips

Check

shoulg

be

condition.

no

chafing.

brittle

and

pump

lubricate

mix.

Inspect

recovery

and

arid

check

the

secure.

or

free

of

corrosion.

shaft,

wear

the

impeller·

the

tank

lubricate

operation.

integrity

No

plate

the

starter

I

EVERY

1000

OPERATING

Heat

Exchanger

*WESTERBEKE

recommends

HOURS

this

service

OR

EVERY

be

performed

FiVE

YEARS

Remove

the

heat

exchanger

by

an

knowledgeable

mechanic.

1,...,./WESTERBEKE

l Enalnes & Generators

for

professional

cleaning

and

pressure

testing.

12

FUEL

SYSTEM.

DIESEL

Use

#45

(DO

FUEL

The manufactured and

from water and dirt.

must pass through at least two fuel filters, a separator and the engine's spin-on fuel clean, schedule in this manual.

FUEL

A primary fuel filter of the water separating type must be installed between the water and other contaminants from the fuel before they be carried to the fuel system on the engine.

The owner/operator

fuel reaching the engine's injection equipment is impurities. This process is accomplished by installing and maintaining a proper fuel a 10

FUEL

The fuel injection

of The and it. authorized fuel injection pump service facility. Do not attempt to disassembly and repair it.

FUEL

No.

2-D (SAE

or

higher grade of giesel according

Nar

add any alcohol based additives.

J313)

diesel that has a Cetane rating of

to

AS1M 0975.

FILTERS

fuel

injection pump and the fuel injectors are precisely

they

must receive clean diesel

To

ensure this

and

change these filters according to the maintenance

WATER

tank

micron

INJECTION

the diesel engine, requiring the utmost caution in

fuel

the

owner/operator

If

it requires servicing, remove

SEPARATOR

fuel

tank

is

responsible for making

fuel

filter/water separator between

and the generator/engine. Westerbeke recommends

filter be

used.

PUMP

pump

is the most important component

injection pump has been thoroughly bench-tested

is

cautioned not to attempt

flow

of

filter.

and

the engine to remove

it

and take it to an

fuel,

clean fuel, the

fuel

water

Visually

certain

free

inspect,

the

of

handling.

to

service

can

the

fuel

ENGINE

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

Changing/cleaning

1.

2.

3.

4.

FUEL

FILTER

after

the first

follow

the

MAINTENANCE

the

Shut off the fuel supply. Unscrew the retainer ring that

housing and allow the bowl to housing,

Remove Replace the sealing

to the housing. Thread the retainer ring on carefully

so

"0"

supply aqd run the engine to inspect for leaks. ·

and replace the filter element and clean the

"0"

as

not to cross thread. When retainer contacts the

ring, tighten

114

- 1/2 turns by hand. Open the-fuel

SCHEDULE.

filter

element

holds

the filter bowl

come

away from the

ring and reassemble the bowl

50

hours

LIGHTLY

WITH

to

the

bowl.

CLEAN

WIPE

FUEL

UFT

PUMP

Periodically check and

make

sure that

are

tight

and secure.

pump's mounting bolts should be clean and well

the

mounting

When energized thru purge

air

from

of

fuel

as

the engine

INLET

FUEL

To

ensure clean fuel

in-line

fuel

filter should be

the

fuel

connections to and out of the

no

leakage is present and that the

The

DC ground connection

bolt to ensure proper pump operation.

the

preheat circuit, the

fuel

system and provide a continuous

is

running.

fuel

FILTER

into

the fuel lift pump, there is a

filter connected to the fuel

replaced

every 250 hours

lift

pump

of

operation.

fittings

at

one of

secured

lift

pump will

small

elbow.

pump

the

by

flow

This

Engines.~

13

FUEL FILTER

GeQerators

DESCRIPTION

Westerbeke

for

fresh bustion which circulates water coolant parts, from exchanger, water

and

lmd

the

fresh

flows

marine

diesel

water

cooling.

friction

the

similar

through

is

throughout

c~ols

the

engine

oil.

water coolant to raw water

in

function

the

engines are designed and

Heat produced

transferred

the

engine block, its internal

The heat

to

tubes

of the heat exchanger

in

the

to

fresh water coolant

engine.

This

is

transferred extemally

by

an

automotive

.

"'

------.:...

COOLING

equipped

engine

by

com-

circulating

means

radiator.

moving

of a

while

~

fresh

heat Raw

----·

SYSTEM

fresh

water

coolant

ferred

to

the

fresh

tube

walls

to exhaust other coolant is cooled transferred fresh each allows harmful

system

words,

water

other.

the

deposits.

heat

coolant

Using

cooling

water

the

raw

where

the

engine

by

overboard

only

flows

water

finally

raw

and

water

around

the

tubes;

engine heat

coolant

is

raw

fresh

is

conducted through

which

is

then

pumped into

it

is

discharged overboard. In

cooled

by

fresh

water coolant,

water,

and the

through the exhaust system.

water ciicuits are independent of

water coolant within the

passages

to

stay

raw

clean

water

and

the

carries

engine

free

trans-

this the

The

from

COOLING

CIRCUIT

f-RESH

WATER

RAWWATER

DIAGRAM

¢

..

COOLING

SYSTEM

FRESH

NOTE:

ommended antifreeze

fresh water coolant.

Fresh water coolant circulating pump, absorbing heat from the engine. The i . coolant then passes through the thermostat into the manifold, to engine block via the suction side

When. the engine prevented flow manifold from overheating). thermostat gradually opens, allowing full coolant to flow unrestricted to cooling system.

RECOVERY

FROM

RECOVERY

NOTE:

pressure good condition. the vacuum valve qpens closes cap. coolant passage is clear so coolant within abje to

WATER

Refer to

the

heat exchanger where it is cooled, and returned

by

is

bypassed around the thermostat

..

•··

TO

COOLANT

TANK

COOLANT,

TANK

Periodically check

cap.

tightly.

Check also

tq

expand and contract

and

from

COOLING

the

ENGINE COOLANT section for the

is

started cold, external coolant flow

the closed thermostat (although some coolant

Ensure

the

Check

Carry

a spare

to

ensure

the

system is

the

coolant recovery

CIRCUIT

and

water mixture

pumped through the engine by a

As

the engine warms up, the

the

KEEP

.

COOLANT

CLEAR

.

pOOLANT

the

c;ndition.ofthe.manifold

upper

and

to

ensure

and

the

to

of

the circulating pump.

to

prevent the exhaust

flow

external portion

THE

PASSAGE

Rf!RACnON

lower rubber seals

tank.

be

used as

of

./PRESSURE

,_

the

to

is

the engine's

of

the

CAP

are

rec-

the

in

CHANGING

:The engine's coolant must be changed according to the

,MAINTENANCE

become contaminated, it can lead

A

critical; a substantial

traced

Drain the engine block's coolant by removing the hex head

plug

located just

hex

drain plug remove allow fresh process .

A

Wear

Refilling

After replacing the drain plugs, add through the filler neck on the water jacketed exhaust fold.

until visible in the manifold. Start the engine.

Monitor the coolant in the manifold and add as needed Fill the manifold

pressure

Remove the coolant

the

cap. Run the engine and observe the coolant expansion

flow

into the recovery tank.

After checking for leaks, stop the engine and allow it Coolant should draw back into the cooling system as the engine cools needed and check the coolant in the manifold. Clean spilled coolant

COOLANT

SCHEDULE.

CAUTION:

back

the water jacketed exhaust manifold pressure

the coolant

water, then re-install the drain plugs and start the refill

WARNING:

protectiVe

cap.

mix

Proper

to

c1111ling

to

the left

on

the lower side

to

drain properly. Flush the system with

Beware

glo'IIIS.

the

Coolant

to

the filler neck and install the manifold

cap

on the coolant reeovery tank and fill with

to halfway between LOW and MAX and replace

down.

Add coolant to the recovery tank

If

t:DOiing

number

of

system

of

the oil

of

the

the coolant

to

overheating problems.

system

engine

is

allowed

maintenance

failures

can

t:IJII'tJSi1111.

filter.

Also remove the

the heat exchanger and

bot

engine

new

c1111lant.

pre-mixed· coolant

cap

mani•

to

if

up

to

is

be

to

cool.

any

Coolant

The coolant recovery tank allows for the expansion and contraction out introducing air into the system. This recovery tank is provided with fresh water cooled models and with the fresh water coolant conversion kit and must operating the engine.

NOTE:

located at or

Recovery

of

the engines coolant during engine operation with-

This

tank.

above

with

Tank

its short

the

level

of

run

the

be

of

plastic

engine's

installed before

hose,

manifold.

is best

1-..IWESJERBEICE

l

Engines & Generatt?rs

15

.

THERMOSTAT

A

thermostat, engine, continuously

engine

the coolant hole in overheating). gradually checked,

gasket

and

Replacing

Remove housing gasket, gasket

screws.

cap Run the

are

there

controls

is

from

the

thennostat

opens.

cleaned,

the

as

shown.

apply

before

engine

no

leaks

located

the

flows

first

started,

flowing

As

the The

or replaced easily.

the

Thermostat

cap

screws

a thin coat

pressing

and check for normal temperatures and that

COOLING

near the manifold at the front of

coolant temperature

through the closed cooling circuit When

the closed thermostat prevents

(some coolant

to

prevent the exhaust manifold

engine warms

thermostat is accessible

and disassemble the thermostat

When installing

of

sealant on both sides

it into place.

at the thermostat housing. ·

as

the coolant

is

by-passed (hrough a

up,

the thermostat

and

Carry

a spare thermostat

the

new thermostat and

D6'

not over-tighten the

the

from

can be

of

the

SYSTEM

RAW

WATER

NOTE:

Always install the strainer at or below the waterline

the

strainer will always be

A

clean engine's cooling system. strainer in

the

glass

Perform operation:

1. Close the

2.

Remove

3.

Clean the

4.

Replace

5.

Reassemble and install

6.

Open

7.

Run

NOTE:

Also follow the above

aground.

If

the engine temperature normal reading, the cause may

have been caught

raw

water

INTAKE

raw

water intake strainer is a vital component of the

when

making your

should

be

the

following maintenance after

raw

water

and

clean

glass.

the

washer

the

seacock. ·

the

engine and check

through

the cooling

STRAINER

self-priming.

Include a visual

periodic

clear.

seacock.

the

strainer

if

necessary.

the

strainer.

for

leaks.

procedure

gauge

ever

may

be that silt, leaves or

up

in

the

strainer,

system

inspection

engine check. The

every

100

filter.

after having

shows

a higher

slowing the

.

of

this

water

hours of

run

hard

than

grass

flow

of

so

.. . AIR

BLEED

FOR

.

COOLING

GASKET

USE

PETCOCK

PUSHING

SYSTEM

HI-

TACK

THERMOSTAT ASSEMBLY

AIR

FROM

SEALANT

SENDOR

_

THE

.

S~INER

FILTER

--or,.,....

INCOMING RAW

WATER

SEACOCK.

·

TYPICAL

RAW

WATER

(OWNER.lNSTALLED)

STRAINER

INSPECT

CLEAN

EVERY

toO

HOURS

AND

16

RAW

WATER

The

raw water flow is created

impeller pump. This pump draws water directly

ocean, lake,

to

the water strainer. The raw water passes from

through the

exchanger tubes) where

water coolant. water-injected exhaust elbow,

exhaust gasses. This mixture

driven through the stem tube and overboard.

HEAT

EXCHANGER

Cool

raw exchanger. the

heat

which is then pumped into the exhaust system charged. through the

NOTE:

Operating

that a heat exchanger cleaning

COOLING

or

river from a thru-hull opening through a hose

pump

to the heat exchanger (through the heat

The

raw water is then discharged into the

water

flows through the inner tubes

As

the engine coolant passes around these tubes,

of

the

internal engine

The

engine coolant (now cooled) flows

engine

in

CIRCUIT

by

a positive displacement

it

cools the engine's circulating fresh

mixing with,

of

exhaust gas and

is

conducted to the

and the circuit repeats itself.

silty and/or tropical waters may

be

peifonned more often

and

every 1000 hours.

COOLING

from

the

strainer

cooling the

raw

water is

of

the heat

raw

water

and

dis-

back

require

then

SYSTEM

RAW

WATER

The raw water non-ferrous housing has flexible blades which wipe against a curved

within the impeller housing, producing the

on

no account

always

be (an impeller kit). when lubricant (raw water) is not present during engine

operation. are cautioned

start-up.

periodically for broken

MAINTENANCE

NOTE:

Should a failure occur

(seals

and bearings), it may purchase a

spare.

Changing

Close the raw water intake valve. Remove the and, using an impeller carefully pry the impeller out impeller and gasket. curved

cam ing. When assembling, apply a the impeller

PUMP

pump

is

a self-priming, rotary

and

a Neoprene impeller.

should

this

pump

be

run

a spare impeller and impeller cover

Raw

water pump impeller failures occur

Such

failures are not warrantable,

to

make

sure raw water flow is

The

raw water pump should

or

tom impeller blades.

SCHEDULE.

be

a new pump and

the

Raw

plate and push the impeller into

and

gasket.·Q~n

rebuild

Water

pullef1 screw drivers,

Move

the blades to conform

·.··'

be

inspected

with

the

pumps internal parts

more

cost efficient

the

original pump

Pump

Impeller

of

the pump. Install the

thin

coatjng

the

raw

water

pump

The

cam

pumping

dry.

There

gasket

and

operators

present

See

pump

or

pliers,

to

the

pumps hous-

of

lubricant to

intake

with a

impeller

plate

action.

should

aboard

at

to

as

cover

new

the

valve.

HEAT

EXCHANGER

CLEAN

OUT

BOTH

ENDS

.

NEW

ZINC

ANODE

A zinc anode, circuit within the heat exchanger. anode is to sacrifice itself to electrolysis action taking place in the raw of

electrolysis condition the anode should

NOTE:

Electrolysis

and vessel location; not that

NOTE:

The

not

require

insulate

or

pencil, is located in the raw water cooling

water

cooling circuit, thereby reducing the effects

on

other components

of

the

zinc

anode

should

cleaned

be

carried

threads

or

replaced

on

board.

is

the result

of

the

zinc

sealant. Sealant should not

the

zinc from the metal

as

of

the

anodes

of

housing preventing electrolysis action

REPLACE . CLEAN

The

purpose

of

the system.

be

checked monthly and

required. Spare anodes

of

each particular installation

engine.

are

pipe threads and

be

used as

the

heat exchanger

on

the

zinc.

.

REUSE

the zinc

The

it

may

AND

do

.

A

CAUTION:

impeller, cooling

they

circuit.

exchanger.

INSPECTION:

EACH

REPLACE

ANY

CHECK

BLADE

BY

THE

CRACKS.

"any

must

They

THE

BENDING

IMPELLER

LIGHTLY PUMP AND

IMPELLER

GLYCERIN.

INSPECT AND

IMPELLER.

IF

THEY

OF

WEAR.

of

the

vanes

be

found

to

often

can

BASE

OF

VIGOROUSLY.

IF

THERE

ARE

GREASE

THE

0-RING

SHOW

THE

0-RING,

WITH

REPLACE

SIGNS

CHAMBER,

have

prevent

be

found

broken

off

blockage

in

the

heat

in

the

Engines & Generators

.

17

ENGINE

LUBRICATING

OIL

ENGINE

1. Draining the Oil Sump. Discharge the used oil through

OIL

CHANGE

the

sump drain hose (attached to the front while the engine is warm. replace securely.

the

hose

in

NOTE:

Thread size for the lube oil drain hose capped

Drain

the used oil completely,

its bracket, and replace the

of

the engine)

end

cap

end

is l/4NPT.

Always observe the yellow/gray emulsion indicates the presence the

oil. Although this condition is rare, prompt attention to prevent serious damage. Call a qualified mechanic water present exhaust system attached of

raw water through

· exhaust, filling the engine. This problem is often caused by

the absence

or

lack

of

maintenance.

2.

Replacing the Oil Filter.

filter; you in oil to be

NOTE:

filter

Place filter

(Oil

cooling ability. Keep

oil filter

sealing gasket came rubber sealing gasket remains sealed against the filter bracket, gently remove it.

may

the

upper

from

it

into a container before removing it. This helps

lessen spillage. A

helpful

in

Do not punch this hole without first loosening

to

make certain

some

paper towels and a plastic

when

unscrewing

qr

any other fluid

as

it

used

oil

as

it

is removed. A

it

does require

should

water

be

present

in

the oil

can

be

the result

to

the engine and/or a siphoning

the

raw

water cooling circuit into the

of

an anti-siphon valve, its poor location

When

removing the used oil

find

it

helpful

and lower portion

small

removing

it

your

is removed·

off

and cleaner to punch a hole

of

automotive filter wrench should

the

old

oil filter.

can

be

removed!

it

to catch any

on

the

engine reduces the engine's

engine clean.) Inspect the old

to

inake sure that the rubber

with

the

old

oil

of

bag

oil

filter.

a fault in the

filter

around the .

left

in

of

the

to

in

If

water in

oil. Raw

drain the

the

the filter.

this

of

When installing the new oil filter element,

gasket's sealing surface apply a thin coat on the

new

oil filter. Screw the filter onto the filter nipple filter firmly

A

WARNING:

contaminants. and

nails discard used

NOTE:

on by

Avoid

thoroughly

clothing

oil

properly.

Generic filters

the oil filter bracket, and then hand.

material standards or diameters generic parts might parts.

Immediately after

run

the engine

and

that

3.

Filling the Oil Sump.

cap

on

the After refilling, run the engine for a few checking around stop the engine.

oil

lube dipstick; should the

to

there

are

top

of

the

oil pressure. Make sure there is

the

new oil filter

dipstick.·

on

the bracket free

of

clean engine oil to the

Used

engine prolonged using

or

rags

are

oil

contains

skin

soap

and

containing

not

recommended,

of

be

entirely different from genuine

an

oil filter

make

sure

the

oil pressure

no

oil leaks around

Add

new oil through

the engine

Then

Fill

engine .require additional oil.

or

through the side

or

from the oil drain system, and

check the quantity

to,

but

not over the

wipe

the

of

oil

and

rubber

threaded tighten

harmful

contact.

water.

used

Clean

Launder

oil.

Discard

as the

important items

change

and oil

is

normal

the

new oil

the

oil

moments

of

high

no

oil

while

leakage

with

mark

filter

gasket

oil

the

skin

or

on

fill,

filter.

filler

fill.

the

on the

LUBRICATION

OIL

PRESSURE-:--~ftllm~

SWtTCH

OIL

FILTER

DIAGRAM

...

~

Engines & Generators

18

REMOVE TO

DRA1N

OIL

UP

THRU

USING

THE

Oil

THE

AN

BMM

•.

OR

HOSE.

(11/W)

PUMP

SOCKET

THE

WARMED

.

FOR

.

..

1/4"NPT

EXTENSION

INSTALLATION

irhls popular ter

from

~ngine

NOTE:

instructions

'tr9

install,

WES1ERBEKE's

4nstall

Contact

accessory

the

engine

to a more

room

bulkhead.

Refer

to

ENGINE

on

removing

'simply

remove

remote

this

kit with

your

the

WES1ERBEKE dealer

oil

is

used

to

relocate

convenient location

OIL

CHANGE

the

oil

filter.

the engine

oil filter kit

filter

facing

REMOTE

OIL

PN#040078

the

engine's

in

this

·

oil

filter and thread

as

shown.

down

as

for

more

information.

oil

such

as

·

manual

for

Always

illustrated.

FILTER

(OPTIONAL)

NOTE:

filan

incorrect

A

rectly.

on

pass

from failure. Immediately

Westerbeke

is not

installation

CAUTION:

If

valve

reaching

If

the

in

there

and

oil

the

It

flows

filter

is

check

responsible

of

the

Remote

is

vital

In

assembly

engine

no

oil

pressure

the

to

install

the

reverse

causing

bose

for

engine

failure

Oil

Filter.

the

oil

lines

direction,

will

prevent

an

Internal

reading,

the

engine

shutdown.

conrnec:tiolirs.

cor-

the

due

by-

oil

to

THE

OUT

CONNECTION

MUST

ATTACH

OIL

TO

ATTHE

FILTER.

CONNECTION REMOTE

THE

HOSE IN

APPLY A THIN

INSTALUNG TIGHTEN CONTACTS

COAT

OF

THIS

AN

THE

....._....._,,,~

CLEAN

KIT.

THREAD

AODITIONAL3/4

BASE.

{;;g;.:\.-E----Dt:l~nn:

OIL

TO

THE

TURN

THE

D-RING

KIT

ON,

THEN

AFTER

THE

O·RING

THE

IN

CONNECTION

MUST

ATTACH

CONNECTION

WHEN

HAND

OIL

ALTER.

TO

AT

THE

HOSE

OUT

APPLY A THIN GASKET

WHEN

CO.NTACTS

THE

COAT

OF

CLEAN

INSTALLING.

BASE,

TIGHTEN

OIL

TO

AFTER

IT

AN

THE

ALTER

THE

ALTER

ADDITIONAL·

Engines & Generators

..

19

STARTER

MOTOR

DESCRIPTION

The starting system includes the battery, starter motor, solenoid, and the start toggle

When the start

' current flows and energizes the starter's solenoid coil. The

energized coil

into the coil, and closes a set to

reacli

the starter

to push To prevent damage

pinion gear incorporates

is splined to the starter armature shaft The rotation

engine may speed motor itself.

Once the start switch is released, the current flow ceases, stopping

the activation contact with the battery-to-start cables by a coil spring, and the flow magnetic fields and plunger is released, from

TERMINALS

that

of

electricity is interrupted

its engagement

switch

becomes

starter

the

of

the solenoid.

switch.

on the instrument

an electromagnet, which pulls the plunger ·

of

contacts, which allow high current .

motor.

At the same time, the plunger also serves

pinion

to

mesh

to

the starter motor when the engine starts, the

an

over-running (one-way) clutch

rotation of

The

tO

the

starter

ceases

its

movement also pulls the starter drive

":'ith

the engine fly-wheel. .

panel

is depressed,

with the teeth

the

pinion but not the starter

plunger is pulled out of

the starter. This weakens the

its rotation. As the solenoid ·

SOLENOID

on

the

of

flywheel.

the running

which

g~

SOLENOID

IGNITION

TERMINAL

To

test

the

ignition

of

the

small

tel111IDal

Use

a

screwdriver,

ignition

terminal

the

solenoid.

If

tlie

starter cranks, the fault

If the

solenoid

motor

is

to

clicks

probably

circuit,

studs

don't

touch

the

positive

but nothing

faulty.

locate and

is

the

ignition(s)

wired

blade,

battery

lies

with the ignition circuit

else

terminal (it

to

the

ignition

to

jump

from

connection

happens, the starter

tenniniu

the

n

is

circuit).

that

on

one

MOTOR

TYPICAL

STARTER

REFER DIAGRAM

TROUBLESHOOTING

..

Prior to testing, make certain the batteries are and that the starting system wiring connections (terminals) are clean and tight Pay particular attention to the ground wire Connections

To check the wiring, try cranking the starter for a few seconds, never more than The wires resistance. Repair or replace any trouble spots.

Using stud on the start solenoid and the engine block (ground).

If

you read 12 volts, the starter

MOTOR

TO

THE

WIRING

IN

THIS

MANUAL

-

..

on the engine block.

10

seconds at a

and

terminals looking

a multimeter, test the voltage between the positive terminal

time,

for

warm spots that indicate

is

faulty.

at

a full charge

then run your

hand

along

SOLENOID

IGNffiON TERMINAL

. H nothing ,

Check

the

connections.

A

WARNING:

fly

when space gasoline.

at

all

battery

It

is

.jumping

is

free

happens the

isolation

also

switch

possible

There

terminals.

of

potentially

solenoid

that

will

be

Be

explosive

isn't getting current

and

inspect

the

solenoid

arching

is

and

certain.fhe

fumes,

~

wiring

defective.

sparks engine

especially

will

Engln_es & Generators

20

Test

again

screwdriver

·

screwdriver would

cause

A

WARNING:

starting

screwdriver.

by

jumping

blade blade

a short

cu"eilt

the firmly to

touch

There

s/iould

two

large

between

the

solenoid

will be

be

flowing

terminal

the

studs.

arching

01;

thru

studs.

Do

starter

as

the

STARTER

Hold

the

not

allow

the

casing,

this

the full

blade

of

the

MOTOR

SERVICE

Westerbeke

serviced

If

replacing certified standards.

TO

1.

Disconnect

2.

If

starter

3.

Label

wires

4.

Remove

5.

Remove

will

uses a standard

or

rebuilt

the

starter

for

marine

If

in

doubt,

REMOVE

necessary,

have

motor.

and

disconnect

to

touch,

the the

to

FOR

the

remove

starter starter

be

at

any

starter

motor,

use.

Automotive

contact

SERVICE

negative

any

the

tape

over

mounting

from

turned

to

marine

starter

motor

make

certain

starters

your

WESTERBEKE

battery

cable.

components

wiring

from

the

terminals).

bolts.

the

engine.

a

different

motor

which

automotive

the

new

do

not

to

gain

full

the

starter.

In

some

cases

angle

to

clear

can

be

service

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

the

starter

obstructions.

the

allow.

If

the starter

If

the starter

If

no

arching occurred. There

NOTE:

the

pre-engaged engages screwdriver motor

provide

magnetic the

solenoid

Starter

the

starter to

without

the

power

field for

are

spins,

fails

motors

model,

bypass

engaging

bad.

the solenoid

to

spin,

are

the

motor

the

to

the

solenoid.

the

arm

is

faulty.

the motor is probably

is

no juice reaching the solenoid.

either

inertia

type

or

pre-engaged.

solenoid

to

solenoid

flywheel.

to

the

flywheel

move

also

moves

of

on

such

Turn

the

Hopefully

even

though

the

a

starter

it

engine.

will

the

faulty.

an

arm

create

contacts

that

Using

will

switch

In

a

run

the

on

enough

inside

to

Engines & Generators

21.

NOTE:

ments

be

below

is

ENGINE

WESTERBEKE

perfonned

provived

by a competent

to

assist

ADJUSTMENTS

recommends

the

that the following engiM

engine

mechanic.

The

information

adjust-

DRIVE

For equipped with belt front

guard is NOT installed for that purpose.) Operators are

advised that proper inspection, service, and maintenance required.

Excessive drive belt tension can cause rapid wear and reduce the service life

· A slack belt or the presence

slipping, resulting The drive belt is properly adjusted

deflected inch (12mm) midpoint between

belt. A spare belt or belts should always be carried

Adjusting

1. Remove

2.

3.

4.

5.

6. Replace

7. Remove the guard

8. Replace

BELT

ADJUSTMENT

your safety, WES1ERBEKE generator models come

guards

that cover over the belt(s)

of

the engine. (''Out of sight- out of mind." The belt

of

the

fresh

water pump's bearing.

of

oil

on

the belt can cause belt

in

high operating temperatures.

if

no

less

than

as

the belt is depressed with the thumb at

the

A

WARNING:

drive

belt's

tension

Belt

Tension

the

belt guard.

Loosen

the

adjusting

With

the belt loose, inspect for

Pivot

the

alternator

Tighten

minutes and then shut

the

adjusting strap bolt

the

guard.

the

guard.

the belt

3/8 inch (lOmm) and

two pulleys on the longest span of

Never

attempt

while

strap

to

properly

Operate the generator for about 5

the

and

to

check

the

engine

bolt

and

the

wear,

tension

and

generator

recheck the belt tension.

no

or

is

in

operation.

alternator

cracks

the

drive

the

pivot belt.

down.

can

more than

adjust

and

of

be

on

pivot

belt.

on

the

is

the belt

the

board.

the

bolt.

frayed

1/2

edges.

TORQUING

After the initial break-in period (approximately 50 hours) and

every

re-torqued. Tighten the cylinder head bolts according

shown. Make

Before applying the specified torque

114

to procedure illustration

Bolts #1, 2 and 3; (12mm socket)

Bolts Rocketshaft Hold Down Rocker Cover Hold Down

,

.FUEL

In

case

injectors checked and

injection service center. Poor fuel

loss

of

in

injector faults. Since

clean room

injector

Before removing the old injector, clean the area around the base

of falling out easily the injector side-to-side with the aid

free it, and then

The injector seats washer. replaced

installed.

INJECTOR

40

± 4

THE

CYUNDER

500

hours

thereafter, the cylinder head bolts should be

sure

the engine is cold

1/2

of a

tum

and then

according

to

#4, 5, 6, 7, 8, 9, 10

to

the right

the numbered sequence shown in

CYLINDER

INJECTORS

of

severe vibrations

overhauled

positive fuel pressure

fuel

envir<;mment,

as

a spare should a problem

the injector

down

and

This washer should be

with

TO

CYUNDER

ft-lb

(5.5 ± 0.5

to

help prevent any rust or

into the injector

is held in by carbon build-up or the like,

lift

it

out

in

the cylinder head on a copper sealing

a new washer

.

HEAD

kgf·m)

HEAD

BOLTS

to

when

to

the bolt, loosen it

apply

the torque. Follow this

14-22

and

11

(14mm socket)

Bolts-

HEAD

it is best

nGHTENING

12mm

socket

Cap

Nuts-

(IOmm socket) (snug)

BOLT

PATTERN

and

detonation noise, have the

by

an

authorized fuel

quality,

to

the

injectors must

hole.

remov.ed

when

contaminant's

injection pump

be

to

carry at least one extra

occur.

If

the injector will not lift

of

the socket wrench

with

the

new

injector is

TORQUE

the sequence

this is done.

ft-lb

(54-

(11

-

can

serviced in a

debris

fiom

the injector

16

result

work

the

61

ft-lb)

and

to

and

ft-lb)

Engines & Generators

22.

ENGINE

ADJUSTMENTS

VALVE

NOTE:

engine's

BOLTS.

Pull off rocker shaft and valve assembly.

Remove the glow plugs from each the engine to be easily rotated by hand to position each cylinder for valve adjustment.

Valves are adjusted with adjusted stroke. Each cylinder order (1-3-2 for WESTERBEKE's three cylinder engines).

CLEARANCE

Retorque

valves.

A

WARNING:

engine

is

cold.

firing

order

of

bolts

to

the

specified

off

the air breather pipe from the rocker cover, and

the

rocker cover bolts

is

at TDC

ADJUSTMENT

the

cylinder head bolts

See

TORQUING THE CYLINDER

Adjust

the

valve

clearance

Valves

are

the

(top

adjusted

engine.

Tighten

torque

and

the rocker cover to expose

the

piston in the cylinder being

dead center)

is

adjusted following the engine's

by

the

before

adjusting

of

the cylinders to enable

of

its compression

VALVE

CLEARANCE

before

adjusting

cylinder

when

in

bead

the

HEAD

the•'

the

· ·

valves.

take

the

firing

#1

Adjust the valves in Proceed Rotate the crankshaft

rotation and adjust the next cylinder's valves order. the

Adjust each valve's clearance (0.25mm) feeler gauge between the rocker arm and the stem.

Re-install the glow plugs (use anti-seize compound on the threads) belts. manual.

to

the next cylinder in the firing order.

Rotate the crankshaft another 240 degrees and adjust

next cylinders valves in the firing order.

Make sure

and

assemble the rocker cover and rocker cover

See the TIGHTENING TORQUE SCHEDULE in

cylinder for both intake and exhaust.

240 degrees in normal direction of

in

the firing

by

inserting a 0.010 inch

to

adjust all valves while the engine is cold.

valve

this

Valve

adjustment

crankshaft slowly cylinder #1. Watch

piston

is

on it's intake stroke (the piston is moving down in the cylinder). Continue look for the intake

now starting it's compression stroke (the piston is moving in

the

cylindt'r towards TDC).

Align the TDC mark on the crankshaft front pulley with the timing marker on the front gear case cover when positioning the

#1

Piston at TDC of it's compression stroke. Confirm

by

rotating the crankshaft approximately 20 degrees before and after this point should not move.

beginning

and

observe the operation

for

the intake valve to open indicating

valve

and

with

cylinder

to

rotate the crankshaft slowly and

to close. This indicates the piston

the two valves for the

#1.

of

#1

Rotate the

the valves

cylinder

for

the

up

this

is

Engines & Generators

23

ENGINE

NOTE:

WESTERBEKE

ments be peiformed

is

below

provided

to

ADJUSTMENTS

recommends

by

a competent

assist

the

that

engine

mechanic.

the

following

mechanic.

engine

The

information

adjust-

Injection

If

your engine's fuel injection timing is not properly the engine will not operate properly, and start. well-established fuel injection follows:

NOTE:

fuel

do

this, side move

fully

1.

Remove No.

2.

Remove "0"

the

3. Reinstall only the delivery valve holder and reattach high pressure fuel line that pointing away line during the timing check.

Rotate rotation compression stroke.

Move

the electric (as viewed from the fuel (no crankshaft pulley should be directly aligned indicator

If

the specified injection timing (15° BTDC) cannot attained, adjust the timing by increasing or decreasing thickness of shim material under the injection pump's

mounting

Changing the shim thickness by changes advance To

retard

Refer

Pump

Have

the injection pump delivery rate checked

The

injection

delivery

unscrew

cover

to

the

fuel rack

to

the

left)

the

1 injector and

ring and remove the delivery valve spring

holder.

the

end that

the

engine's crankshaft in its normal direction of

to position piston

the

throttle lever to its

lift

line,

until the instant the fuel completely stops

drips).

At this instant, the

on

flange

the the

the

to

your Generator's

Timing

pump

position

the fuel shut off solenoid and

expose

to

secure

high pressure fuel line

the

No. 1

would

from

pump. Slowly rotate the crankshaft

front),

the front of the gear case ±

to

change the injection timing point.

injection timing by approximately one

timing, decrease the shim thickness,

timing, increase the shim thickness,

Adjustment

shop.

Adjust the injection

fuel

rack

needs

when

peiforming

the

injection pump fuel

the

full fuel delivery position

it in this position

the

No. 1 fuel delivery valve

fuel

delivery valve holder over

to

the delivery

connect

the engine fuel will

No. 1 at

full

catching the fuel

15°

Parts

List for shim part

this

then

from

to

the fuel injector

the beginning of

open position

BTDC timing mark

.5

0.004 inch

(Spill

may

be

to

be

spill

remove

rack.

proceed.

between

holder.

flow

from

with

degrees.

(O.Olmm)

Timing)

adjusted,

difficult

by

in

the

timing.

Mar,).~.ally

(move

holder.

beneath

Attach

from

its

and

operation

clockwise

the

flowing

the

be

degree.

as

required.

as

required.

numbers.

to

a

as

full

To

the

it

so is this

No.

on

the

timing

the

1

To

INJECTION

HOUSIMG

STOP

WIRE---..~

BRACKET

CONTROL

IT

MARK

ON

PULLEY

PUMP

RACK

PLUNGER

19"

VALVE

SPRING

TAPPET

.ROLLER

24

TIMING

POINTER

TIMING

MARKS

ENGINE

.

GLOWPWGS

The glow plugs are wired

When

PREHEAT

should

"click" on and the glow plug should begin to get

INSPECTION.

To

inspect

tions, then unscrew or unclamp each plug from tqe cylirider

bead. Thoroughly clean each plug's tip and threads

soft brush

oil"

deposits. While cleaning, examine the tip for

bum erosion;

TESTING·

An

accurate way to test glow plugs

..

one prod

Touch

to the body

other plug will have a 1.0 - 1.5 ohm used with the plug in or out

an multimeter to test the power

A

WARNING:

to

the

touch.

testing

the

·

through

is

pres$ed at

the

plug, remove the electrical

and

cleaning solution

if

it has eroded

to

-the

of

the glow

These

Be

careful

plugs.

too

glow plug's wire

plug,

of

glow

not

the preheat solenoid.

the

control panel tbis solenoid

tennina).

connec-

W,ith

to

remove

an

the c8rbon and

wear

much,

replace

is

with an ohmmeter.

as

shown. A good

resistance.

the

engine.

drain

(8

- 9 amps per plug).

plugs

will

to

burn

your

the

connection,.

This meth04

You

can also use

become

fingers

·plug.

very

when

and

~d

·glow

can:

ADJUSTMENTS

OIL

PRESSURE

To

test the

oil

pressure,

install

a mechanical

hot

a

the

hot

·

be

wanning read

Oil

,

LOW

. A

ings. A rapid failure. ings,

the

oil

Pressure

OIL

gradual

For

see

the ENGINE

up

the

pressure

35-

551biin•

PRESSURE

loss

of

loss

additional

remove the oil pressure

oil

pressure gauge

engine,

set the engine speed at

gauge.

{2.5-

3.8

kg/em')

oil

pressure usually indicates a

of

oil

pressure indicates a

information

TRO_UBLESHOOTING

TESTING

on

low

OIL

PRESSURE

sender,

in

it's

place.

1800

·

worn

specific

oil pressure read-

.chart.

·

OIL

then

After

·

rpm

and

bear-

bearing

.

GALLERY

, .

:

·

GLOW

PLUGS

Re-install the plugs in the engine and

plugs should get seconds. circuit When comp9und

A

than

GLOW

If

WARNING:

30

PLUG

very

hot (at the tetminal end) within 7 to

the plugs don't heat

reinstalling

on

the threads.

Do

not

seconds.

TIGHTENING

1.0-

1.5

TORQUE

M-KG

(7

up

quickly,

the

glow

plugs, use anti-seize

keep a glow.plug

-11

FT-LB)

test

them

check for a short

on

·

USING

A

·TEST

UGHT

agaiil.

for

mare

The

15

OIL

PRESSURE

The

oil

pressure

front

of the

l/8npt that

pressure

engine

gauge

operation.

engine.

will

allow

when

SWITCH

safety

shut-down

Adjacent

checking for proper

to the switch is an

for

the

connecting of a

switch

is

located at the

access

mechanical

oil

pressure

port

oil

during

/-.y-/WESTERBEKE

l

!Engines.

~

Generato.rs

25.

ENGINE

TROUBLESHOOTING

ELECTRONIC

The

Electronic Control Unit aspects programmed

ECU

injection

If engine operating must DC NOTE: requires software

ECU

of

is

monnted

an

operating fault

and

be

breaker on the control panel

manufacturer:

CONTROLLER

the

drive engines operation.

and the programming

on

the

pump

and

controls

occurs,

illuminate

fault

re-set

to

Engine

ECU

software

and

communication cable

the

has

been investigated

re-start the

shutdown (check engine

Woodward,

PROBLEM

LOW

OIL

PRESSURE

HIGH

COOLANT

TEMPERATURE

BATTERY (HIGH

VOLTAGE

DC/LOW

DC)

ENGINE

(ECU)

SHUTDOWN/CHECK

monitors

can

The

not

and unit be

altered.

engine block just adjacent

the

The

injection

ECU

pumps

will

shutdown

Check Engine LED.

and

corrected,

engine.

for

proper troubleshooting.

To

OFF,

is

Inc./

Aerospace.

re-set the

then

ON.

LED

available

illuminated)

from

CHECK

PROBABLE

1.

Oil

level

low/oil

leak.

2.

Lack

of

oil

pressure.

3.

AGround

4.

Faulty

5.

Faulty

1.

Check

2.

Sea

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

Check

3.

Check

4.

tau

connection.

oil

pressure

control

system

water

pump.

water

temperature

connection.

control

alternator charge battery

tty

battery.

switch.

module.

coolant

pump

drive switch.

module

drive

voltage.

connections.

controls all

is

factory

The

to

the

fuel

operation.

the

When

the

The

ECU

ECU,

turn

the

This

ECU

the

ENGINE

SHUTDOWN

ENGINE/LED

CAUSE

level.

belt.

(ECU).

belt..

ENGINE

IS

ILLUMINATED

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

LIGHT

ELECTRONIC

PN.8404-1021

WOODARD

VERIFICATION/REMEDY

Check

oil

level,

add

oil

Test

oil

pressure.

inspect

oil

Check

ground

Check

sensor/replace.

Inspect

all

Add

coolant.

Inspect

impeller/pump/replace.

Adjust

belt

Check

sensor/replace.

Check

ground

Check

plug

Adjust

tension/replace

Check

excitation.

Check + and -cables

Load

test

If

OK,

filter,

inspect

connection.

the

plug

in

Check

for

tension,

battery.

replace

circuit.

connections/replace

Replace/repair

CONTROLLER

AEROSPACE

.

and

repair

leak.s.

test

oil

pressure

sendor,

oil

pump.

connections/replace

leaks.

belt.

if

worn.

from

battery

ECU.

alternator.

to

engine.

GENERATOR

Overs

peed

Underspeed

HIGH

EXHAUST

(External

No No Software

diagnosis

Note: Refer

Fault)

shutdown

LED

needed

FREQUENCY

to

the

Table

1.

2.

3.

4.

5.

1.

2.

3. 4

5.

of

Contents

•.

Check

engine

speed.

Check

fuel

supply. Amperage Crank

(underspeed Generator

(underspeed Check

Faulty Ground Sea Faulty

load.

cycle

with

Shut-down.

sea

water

exhaust

connection.

water

pump.

fire

suppression

for

addztzohal

fault) fault)

no

start.

flow.

temperature

. .

switch.

system.

T/WliBLESHOOTING pages m

Engine11_

26

~

Generators

1.

Check

speed

setting.

2.

Inspect

filters/replace

3.

Check + and -cables

4.

Check

cause

for

5.

Check

MPU

(voltage

(Check

MPU-

1.

Inspect

thru

hull

as

needed.

2.

Test/replace.

3.

Check

ground

4.

Inspect

impeller/replace.

5.

By-pass

system/check.

thzs

manual .

no

coil

resistance)

fitting,

circuit.

filters.

Test

from

battery

start.

cranking.

hose

and

fuel

pump

to

engine.

strainer.

operation.

Correct

ENGINE

The following troubleshooting chart describes certain problems relating to engine service, the probable causes these problems, and the recommendations to overcome these problems.If the engine shuts down

is illuminated), refer to

manual.

ECU

Troubleshooting Chart in this

(Check Engine/LED

TROUBLESHOOTING

NOTE:

The

of

engines ampere manual reset circuit breaker. The preheat solenoid mounted on the same bracket.

electrical system

is

protected by a 20-

is

PROBlEM

Engine

can

Starting

battery

Engine

slows

Engine

overheats

shuts

down.

Preheat

switch

No

panel

indications

electrical

Start

switch

No

starter

not

be

stopped.

not

being.

and

stops.

and

depressed

fuel

pump.

depressed

activation.

or

1.

Faulty

DC

1.

DC

charge

2.

Alternator

1.

Fuel

starvation.

2.

Contaminated

3.

Exhaust

restriction.

1.

Antifreeze

1.

Battery

switch

2.

20

Amp

breaker

3.

Emergency

4.

7.5

amp

fuse

5.

Blocking

6.

K2

Relay

1.

K1

Relay

2.

Faulty

starter

3.

Low

DC

battery

4.

Poor/loose

PROBABlE

alternator.

circuit

drive.

fuel.

coolant

off.

tripped.

stop

switch

faulty.

diode

open.

faulty. faulty.

solenoid.

charge.

battery

faulty.

not

circulating.

open.

cable

connection.

CAUSE

1.

Remove alternator.

1.

Perform alternator

2.

Check

drive

output,

1.

Check

fuel

2.

Check

filters

3.

Check

for

build

up

1.

Loss

of

2.

Air

in

system.

Check

recovery

3.

Thermostat

1.

Check

switch.

2.

Check/re-set

3.

Check/close

4.

Check/test

5.

Test

diode.

6.

Check/test

1.

Check/test

2.

Test

solenoid.

3.

Check

battery

4.

Check

connections.

VERIFICATION/REMEDY

Exc/R

connection

DC

voltage

section

belt

tension,

excitation

supply,

for

contaminates/water.

blockage,

in

water

injected

coolant.

Check

Expel

circuit.

stuck

20

amp

switch.

fuse. K2

Relay.

K1

Relay. charge

off

alternator.

check

of

charge

in

this

manual.

loose

connections,

voltage

present

filters,

tank

vent.

collapsed

air.

closed.

exhaust

system

for

Add

coolant

Check/test/replace.

breaker.

state.

at

Exo/R

elbow.

leak.

Repair

circuit.

hose,

as

needed.

See

DC

voltage

terminal.

carbon

TROUBLESHOOTING

If

the gauge reading

by the gauge when the instrument panel

is

to check for 12 volts DC between the ignition (B+)

step

and the Negative (B-) terminals Assuming that there is

instrument panel energized and perform the following steps:

1.

Disconnect the sender wire at the gauge and see

gauge reads zero, which situation.

2.

Remove the wire attached to the sender on the engine

and ground it to the engine. The gauge in the panel

should register full scale, which situation. DC voltage at the oil and temperature sender to ground when the engine

(10-

11

VDC) and will fall as the oil pressure rises and

coolant rises. This DC voltage will generally stabilize in

- 7VDC range depending on what your engines

the 5 normal oil pressure and coolant temperature are.

is

other than what is normally indicated

of

the gauge.

12

volts

as

required, leave the

is

the normal reading for this

is

first started will be high

WATER

is

energized, the first

normal for this

Engines & Generators

TEMPERATURE

if

the

27

AND

OIL

PRESSURE

If

both

of

the above gauge tests are positive, the gauge is

OK

undoubtedly conductor from the sender to the gauge or with the sender.

If

either

of

probably defective and should be replaced. Assuming the gauge is

sender to the sender terminal at the gauge for continuity.

Check that the engine block is connected to the ground. Some starters have isolated ground terminals and battery is connected to the starter (both plus and minus terminals), the ground side will not necessarily be connected to the block.

and the problem lies either with the

the above gauge tests are negative, the gauge is

GAUGES

OK, check the conductor from the

if

the

ENGINE

TROUBLESHOOTING

PROBLEM

Generator but

does

not

Starting looses

Engine

Low

Smokey

battery

charge.

shuts

oil

pressure.

exhaust.

engine

start.

down.

cranks

1.

Faulty

preheat

2.

Faulty

fuel

3.

Fuel

supply.

4.

Fuel

filter(s)

1.

Faulty

battery.

2.

Oil

pressure

3.

DC

alternator

1.

Loss

of

oil.

2.

Oil

pressure

3.

Contaminated

1.

Blue

smoke.

2.

White

smoke.

3.

Black

smoke.

PROBABLE

circuit.

pump.

contaminated.

switch

stuck,

faults.

switch.

oil.

CAUSE

closed

contacts.

1.

TesVcheck

2.

Test

fuel

3.

Check

fuel

4.

Inspect

1.

Load

test

2.

Panel/fuel

3.

Check

alternator

1.

Locate

leak

2.

TesVreplace.

3.

Change

1.

Crankcase

2.

Incorrect

1.

Engine

running

2.

Faulty

injector.

1.

Lack

of

air,

2.

Incorrect

3.

Valves

need

4.

Low

compression.

VERIFICATION/REMEDY

circuit

components.

pump

operation.

ON.

all

filters.

battery.

pump

and

oil,

locate

overfilled.

grade

cold,

check

fuel

grade.

adjustment.

activated

charge

correct.

of

after

rate.

source

of

oil.

thermostat

intake/air

shutdown.

contaminates.

stuck

filter.

open.

Engine

starts,

then

shutsdown.

(stays

running

Preheat

Engine horsepower.

depresed).

has

loss

runs

with

of

1.

Safety

MAP

sensor

shutdown

(manifold

switch

absolute

faulty.

pressure).

1.

Check

safety

exhaust)

1.

TesVreplace.

shutdown

switch

(oil,

coolant,

Eng_ines

28

&

Generatof'~

ALTERNATOR

TESTING

DESCRIPTION

The charging system consists

engine

regulator, an cuit

breaker

the use.of integrated circuits (IC's) the electronic voltage ulator back of

and a battery with connecting cables. Because

is

very

the

alternator. ·

110

B+OUTPUT

To

114

DC

compact and is mounted internally or on

RED

starter

motor

PURPLE

of

an

alternator with a voltage

wiring

harness,

50

AMP

ALTERNATOR

,

a mounted DC

TROUBLESHOOTING

A

WARNING:

hot.

Do

not

This troubleshooting section is exists with the charging circuit or with the alternator. determined

best

to

have a qualified technician check it

The alternator charging circuit charges the starting battery

and the service or

a battery selector switch is usually mounted in the circuit to isolate the batteries along with the starting battery service battery

A

WARNING:

that

everyone

sheaves

and

A failed

touch

that

the alternator or voltage regulator is bad,

battery.

service

but

not

charging

Before

is

clear

belts

alternator

until

the

alternator

An

isolator with a diode, a solenoid,

so

the service battery is not discharged

battery.

If

the service

circuit

and

starting

of

moving

during

test

can

bas

to

determine

the

alternator

battery,

the problem is

not with

the

engine

parts!

Keep

procedures.

become

cooled

if

out.

is

the

make

very

down.

a problem

If

it

charging the

in

alternator.

certain

away

from

cir-

the

is

it

reg-

is

the

of

Testing

1.

2.

3.

the

Alternator

Start the Engine.

After

a

few

minutes of running measure the starting

tery voltage at the battery

on

DC

set

The

the alternator is working.

If

the

after

problem exists

a.

Turn Ensure connections

A

switch

b.

,If

ensure

c:.

Thrn

d.

Check the battery voltage. condition

volts.

voltage should be increasing

TESnNG

BArnRY

(ENGINE

the

starting

engine

off

the

that

THE

STARTING

·ALTERNATOR

RUNNING}

battery

is

with

engine.

the battery terminals

are

CADnON:

charging

a battery selector switch is.in the charging circuit,

circuit,

when

the

that

it

is

on the ignition switch, but

the

reading should

texminals

toward

Thrn

to

voltage remains around

started and

the alternator or

tight and clean.

To

never

engine

on the correct

run

Inspect all

avoid

damage

shut

is

mnnlng!

If

your battery

be

for

wiring

and

off the

setting.

do

12

MULTtMETER

using

a multi-meter

14

volts.

Step

4.

12

volts

a few

minutes,

the

charging circuit.

and connections.

the engine ground

to

the

battery

engine

battery

not

start

the

engine.

is

in

good

to

.13

volts.

If

bat-

it is,

a

A

WARNING:

-.

.D.C..and_jJ_C.J:Jn:u.lt$JLI'JtfJ1lmJJJJix.IHI.JD.get/ulr

applications. Isolate before made

DC

perfonning

without

Always

and

proper

AC

Molt/meters

disconnect converter.s DC

testing.

knowledge

and

No

DC

sllore

shut

AC

of

AC

Circuits:

power down

tests

should

clrt:lllts.

ln.

marine

cords,

generators

be

En!:Jines

TESnNG BATTERY

& Generators

29

THE

STARnNG

•

ENGINE

OFF

,STARTING

BA11ERY

e.

Now

check

the

voltage between the alternator output terminal voltage tery, age will be between the alternator and the

connections cuit.

(B+)

and ground.

at

the alternator should

or

if

an

isolator is

zero.

If

-look

not, a problem exists in the circuit

for

ALTERNATOR

If

the circuit

be

in

the circuit the alternator volt-

battery.

an

opening in the charging cir-

is

good, the

the same as the bat-

Check all the

TESTING

Alternator

4.

Check the voltage of the service should have a engine is running.

battery charging circuit Troubleshoot the service charging circuit the solenoid,

is

Working

voltage

by

isolator,

battery.

between

If

not,

checking the wiring and connections,

battery switch

there

13

and

14

is

a problem in the service

and

This battery

volts

when

battery

the battery

the

itself.

.

STARTING

·

f.

Start the engine again. Check the voltage between the

alternator output and ground .

The voltage reading for a properly operating alternator should be between 13.5 tor

is

able service shop.

NOTE:

a voltmeter

present at

showed only battery voltage at

If

12

the

wiring

BAlTERY

TESTING BATTERY· (ENGINE

over-

THE

STARTING

ALTERNATOR

RUNNING)

or

under-charging, have it repaired at a reli-

Before renwving

to

ensure that

the

EXC temzinal if

volts

are

not

presenJ

lookiJzg

for breaks and poor connections.

and

14.5 volts.

the

alternator for

12

volts DC excitation is

the

previous test

the

B output tenninal.

at

the

EXC

tennina~

..J_L-4t=---'·

If

your alterna-

repair;

use

trace

ENGINE GROUND

A

charging Megger).

ALTERNATOR

When and and the alternator wire wiring

Turn Depending on when

. brushes may need

send it to a service

MULTIMETER

CAUTION:

.

circuit

You

can

When do

not

damage

INSPECTiON

rebuilding the

inspected. The

brush. Make

connections that connect

the rotor pulle:?by

engine.

housing

terminal

certaip

the

replacing.

shop

SERVICE BAmRY

TESTING BATTERY

pedorming

use a high

the

alternator

The alternator should be cleaned

can be wiped off with a s?lvent

studs should

those studs are

to

the wiring harness.

hand.

It should turn smoothly.

alternator was last

If

the alternator

for

testing and overhaul.

THE

(ENGINE

tests

on

voltage

diodes.

be

cleaned

tight.

se~ced,

SERVICE

the

alternator

tester

Also clean

1s

at

all

RUNNING)

(i.e.

With

a

the

·

suspect,

30

DC

CIRCUITJBAnERY

BAnERY

The

generator's reviewing the DC The engine's DC wiring circuits: start, run and

The engine shown when troubleshooting or system

A

charging

switch

battery

·

when

CHARGING

DC

Circuit functions to start, operate and stop the

engine. The circuit

Wiring

has

a

12

volt

on

the Wiring

or

the engine.

CAUTION:

circut,

while

switch,

working

Diagrams.

To

avoid

never

the

engine

however,

on

the

stop.

is

best understood by .

Diagram

is

designed with three simple basic

DC

when

shut

is

engine's

and Wiring Schematic.

electrical control circuit that is

Refer

to

these diagrams

servicing the DC electrical

damage

to

off

the

engine

running.

avoid

Shut

electrical

the

battery

off

circuit.

battery

the

engine

shorts

SPECIFICATIONS

The

minimum recommended

the engine's t2Atolt DC control circuit is 600-900 (CCA).

capaCity

of

the battery used in

TESTING

If

the starting battery is not being charged. Verity

output from the alternator's

·there is excitation voltage at the alternator's ''R'' terminal.

Check battery cable connections the engine and at the

BATTERY

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

• Check the electrolyte level and specific gravity with a

• Use only distilled water to bring electrolytes to a

• Make certain that

• Keep your batteries clean and

THE

CIRCUIT

B+

starting battery.

MAINTENANCE

hydrometer.

level.

battery

cable connections are clean and

tight to the battery posts (and

De

voltage

output terminal. Check that

DC + and DC

to

your engine).

free

of

corrosion.

-both

proper

at

Engines & Genef'lltors

31

:

I

[

..

_

..

_

..

_____

..

_

..

____

NT

1 4 T ,

_,_,_,_,

..

,_

___

,

fREOUEIICY

POWER

LIN£ AC

FOR

SPEED

TBI-&

TO

ENGINE

CONTROLS

CONNECTED

8

ECU

GOHz

I.

NOTES:

~

IN

.•

.

I . · I

! , \

!

DSl

EG

COIINECTION.

TBI·8

5.5,1.6

TO

SYSTEM

CONNECTED

8

HARIIESS,GENSET

JUMPER

SUPPRESSION

•

Pill

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Engines &

~nerstors

34

SPECIFICATIONS

•

5.5/5.0KW

EG

GENERATOR

Engine

Type

ASpiration Governor Combustion Bore & Stroke

5.5Kw

Piston

5.5Kw

Firing Direction Maximum Compression Dimensions

Weight Fuel

5.5Kw

Inclination

Compression

Valve

Engine

Valve (Engine

Injector Engine

5.5Kw

General Oil Sump

(not

Operating (engine

Oil

Chamber

Displacement

Order

of

Rotation

Torque

Ratio

Consumption

Pressure

liming

Seat

Angle

Speed

Clearance

Cold)

Pressure

liming

Filter

Capacity

mcluding

Oil

Pressure

hot)

Grade

ENGINE

TUNE-UP

(Spill)

SPECIFICATIONS

Diesel, water-cooled, mechanism

Naturally Centrifugal Swirl

2.99 x 2.76

58.00

1 .

3.

Clockwise, 27

fHb 21:1 Height:

Width: Length:

3361bs

0.54

Continuous Temporary

SPECIFICATIONS

398

psi

(Limit

47.2 Intake

Intake Exhaust

Exhaust Intake

Exhaust 1800

1500 Intake

1968 ± 142 15°

BTOC±

LUBRICATION

Pressure Full

flow,

3.2

filter)

U.S. 35 -55 API

Specification

better.

four-cycle,

(9.2

aspirated

type

inches

cubic

inches

2

when

(3.4

kg-m)

19.9

inches

16.0

inches

27.2

inches

(152.4

US

gph

14°

25°

(28

kg/em')

of

Difference

psi

(3.0

Opens Closes

45°

rpm

60

rpm

50

and

Exhaust

psi .5

fed

system

paper

Qts

(3.031iters)

psi

(2.5 -3.8

SAE

10W-40

three-cylinder,

vertical

in-line

Hp

at

1800

(76 x 70

(0.952

liters)

viewed

from

at

1800

(505.5

(406.4

mm)

(690.9

kgs)

(2.011ph)

kg/em')

19°

Hertz Hertz

(BCDB:

(not

to

at

between

BTDC

51°

ABOC

51 • BBDC

19°

ATDC

0.098

(140 ± 10

approximate

14")

exceed

280

inches

kg/em')

SYSTEM

by

geared

element,

spin--on

kg/em')

CF,

CF-4,

or

15W-40

fresh

overhead

rpm

maximum)

mm)

the

front

rpm

mm)

30

min.)

rpm

limit

cylinders)

(0.25

pump

type

CG-4,

CH-4,

valve

mm)

Cl-4

or

General Fuel Fuel

Injection

Pump

Fuel

Injection

timing)

Filter

Combustion)

Battery

Capacity

Aid Cranking Charging

Regulator

Temperature

Water

Flow,

rpm

Capacity

water)

liming

Amps

Pump

(Spill Nozzle Fuel Air

cleaner

Air

Row

(Engine

Starting Battery Starter Starting DC DC VoHage

General Operating

Fresh Raw

at3600 System

(fresh

AC

Single

Phase

VoHage -Single

Voltage Frequency Rating

.5.5Kw

Generator Ambient Recommendations

Electromagnetic Interference

Generator Air

Requirements

Phase

Regulation:

(Volts/Amps)

Compartment

Temperature

level

Cooling

FUEL

SYSTEM

Open

flow,

self No. 2 diesel In-line 15° ± 5o

Throttle Cartridge Plastic

25.6

30.2

ELECTRICAL

12-Volt, 600 -900 12-Volt, Glow 175-200 51 Capacitor

COOLING

Fresh controlled

1700 Centrifugal

6.5 • 7.0 before

4.0

GENERATOR

Brushless, Self-exciting, excitation. design.

120 220

±5% .5

Hertz

60 50

120°F

NOTE:

to

maintain

temperatures

Exceeds telephones CE

175 -200 (60

oil

plunger

BTDC

type

intake

cfm

(0.7

cfm

(0.6

SYSTEM

(·)

ne_gative

Cold

reduction

plugs,

sheathed

Amps

Amp

IC

13-14

SYSTEM

water-cooled

-1oo· F (77"-

type,

US

gpm

discharging

qts

(3.791iters)

(Single

four-pole,

capacitor

Pre-lubricated,

120

volts,

Volts -60 Volts • 50

no

load

to

(6%)

Hertz

(1800

Hertz

(1500

(50°C)

Forced

generator

requirements

and

(Certified

Europe)

cfm

Hertz)

at

1800

silencer -cleaner

maximum

below

bleeding -self (cetane

rating

(Bosch

type)

(Before

Top

cmm)

BCD,

cmm)

BCD

ground

Cranking

Amps

type

(engine

cold)

volts

DC

block,

sa•

C)

metal

impeller,

(24.6 -22.5

into

exhaust

Phase)

revolving

saturated

single

phase

Hertz Hertz.

full

load.

no

load

to

full

rpm)

120

rpm)

220

ventilation

should

compartment

120°F

for

standard

televisions.

requirements

(4.95 • 5.66

rpm

priming

of

45

or

higher)

Dead

Center)

BCDA,

BCDB

5.5

Kw

(CCA)

(in

generator)

thermostatically-

belt-driven

lpm)

(measured

elbow).

field.

field

single-bearing

load.

Volts/45.8 Volts/21.7

most

be

(50"C)

marine

cmm)

Amps Amps

provided

radio

Meets

NOTE:

Increase

air

I.....,.I§I'ERBEKE

t

Engines & Generators

35

supply

15%

for

50

Hertz

operation

@1500

rpm

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The power required to start more

than

is required to keep it running after it

Some motors require much more current to start them than

- others. Split-phase under similar circumstances, than other types.

monly used on easy-starting loads, such

machines; or where

started, such 7 times avoided, whenever possible, if the electric motor is ven

by motors require from 2 to run. The current required to start load connected to compressor, for example, motor

In

general,

to

medium

MOTOR

*NOTE:

more for

fo.r

this

rnaile-in

Because motors is be

damaged if it can bring the motor seconds. off

all

on

the

Required

Run

the generator's capacity, and finally loaded to its indicted on should be checked periodically the generating plant voltmeter or ampere meter is not installed

and load, check it with a portable meter and amp probe.

NOTE:

contains AC equipment

the

that

vide

one

panel.

as

much current

a small generator. Capacitor and repulsion-induction

to

which

the

cwrent

starting

SIZE

(HP)

116 1/4 1/3 1/2 3/4

1

In

the

above

some

is

that

Zcfrger

-

the

heavy

required·

If

difficulty

other electrical loads and, if possible, reduce the load

electric

Operating

generator

the

When

the

generator's AC terminal block be

120

volt AC hot

This

will

MOTORS

an

electric motor is considerably

is

started.

(AC)

motors require more current to start,

They

are com-

as

washing

loads

are applied after the motor is

small power

it.

An

no

load

required

loads

table

small motors

the

hardest starting types (split-phase)

tools.

Because

to

start

as

to

4 times

electric motor connected

is

will

AMPS

(AMPERES)

as

much current any

will

require more current than a

connected.

to

start

115-

be

approximately

FOR

RUNNING

3.2

4.6

5.2

7.2

10.2 13

the

maximum Amps

than

for larger

they

run, their use should be

motor varies with the

Volt

require 5

to

start

to

an air

motors

connected

as

follows:

AMPS

FOR

STARTING

(AMPERES)

6.4

to

22.4*

9.2to

32.2*

10.4

to

72.8*

14.4

to

29.2*

20.4

to

40.8*

26to52

for

Starting

ones.

The

are

sizes.

surge

of

current needed for starting

for

only an instant, the generator will not

up

motor.

to speed

is

experienced in starting motors, turn

in

a few

Speed

first

with

no

load applied, then at half the

full .capacity

generator's data plate. The output voltage

to

ensure proper operation of

and

the appliances it supplies.

vessel

in

which

of

120

leg

ensure

good motor starting

the

generator

volts

only,

for

the

vessel's distribution

to

it

configured

If

an AC

monitor voltage

is

installed

is

recommended

to

response

from

generator.

to

be dri-

as

reason

not

as

pro-

the

is

Generator

Frequency is a direct result

indicated by the following:

• When the generator output frequency is

• When the generator

output frequency is

Therefore, to change the generator's frequency, the generator's drive engine's speed must be changed. A reconfiguration of the AC output connections sary.

Generator

• Maintaining reasonable cleanliness is important. Connections

become corroded, and insulation surfaces

ducting

allowed cause excessive heating and reduced life of windings.

• For unusually severe conditions,

leum-base coatings, should be sprayed or brushed over surfaces suggested are Daubert Chemical Co. 410" and Ashland "Tectyle 506" or equivalent.

•

In

inspected for

of overheated terminals and

• The drive discs on single bearing generators should be .

checked periodically and for should not accelerate cracking. The bolts which fasten the drive disc to 8, ners

• The rear armature bearing is lubricated and sealed;

maintenance is required. However, noisy or rough-sounding, have it replaced.

• Examine bearing at periodic intervals.

of shaft should be detected motion is shaft Repair

rub

The

and

..

decal

·~generator

·

The$6

Frequency

Adjustment

of

engine/generator speed,

is

run at

1800

RPM, the

60

Hertz.

is

run

at

1500

RPM, the AC voltage

50

Hertz.

at

the

generator is also neces-

AC

Maintenance

of

terminal boards

if

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

to build

to

addition

any

the

generator shaft must be hardened steel SAE grade

identified

of the head.

of

bearing socket outside bearing has occurred.

n;tust be made quickly or major components

an4

cause major damage to generator.

generator's frequency

is

on

voltage

up.

Clogged ventilation openings may

reduce rusting and corrosion. '!ypical materials

to

periodic cleaning, the generator should be

(a}

tightness of all connections, (b) evidence

if

possible for tightness of screws .

evidence of incipient cracking failure. Discs

be

allowed

by

deteGtable,

rating

the

inside

end

that

to

6 radial marks, one at each

bearings

data

plate

of

the

of

the

includes

diagrams

and

rectifiers may

may start con-

thin

rust-inhibiting petro-

"Non-Rust AC-

{c)

loose or damaged wires.

become rusty because rust may .

of

the 6 cor-

if

the

bearing becomes

No

side movement

when

force is applied.

are

wearing or wear on

gives

the

voltage,rurrent,

generator.

louvered

the

are

also

AC

voltage

shown

An

AC

wiring

cover

at

the

connections.

on

these

as

voltage

all

no

if

side

will

pages.

I...,.,IWESTERBEKE

)

Engines_.&

Genei1#0TS

36

BC

GENERATOR

NOTE:

WESTERBEKE

and adjustments

recornrrzends

be

peiformed by a

SINGLE

that

the

qut:di.fied

PHASE

following generator tests

technician.

DESCRIPTION

The

BC

generator requires AC stator

is

induces

larger of

windings

capacitor(s) in a drawn equipment. 120 or SPECIFICATIONS ratings. and affixed end. A diagram

provided

output.

windings

started,

current

the

stator.

steady

off

volt

230

volt

The

frequency

to

only

residual

a current

in

quickly

voltage

the

AC

the

on

is

the

driving

The

stator

and

the

magnetism

in

the

in

the

exciter

the

four

reaches

and

a regulated energy

At

the

same

in

the

generator's

The generator is a single-phase, re-connectable

two-wire

AC

two-wire

section of

generator's data plate gives

rating

inside

of the louvered cover at

of

the

decal.

a brushless, self-excited generator

force

of

the

engine

to

produce

houses

two

sets of windings;

exciter windings.

in

the

four rotating

stator

which

then generates

windings.

rotating poles and

the

saturation point of

field

time,

this

regulated

stator windings

AC

terminals

at

60

at

of

the

various

hertz, or

50

generator.

115

hertz.

Refer

this

manual for generator

AC

voltage connections

When

This

mutual build

in

the

is

then

which

to

operate

volt

to

the

voltage, current

An

AC

the

poles

exciter ·

the

maintained

field

produces

can

_then

AC

two-wire

the

wiring

the

generator

generator an

decal

which

an

main

even

up

be

is

Circuit

A circuit breaker WES1ERBEKE generators. This circuit breaker

automatically disconnect generator power electrical overload. The circuit breaker can be manually shut power is coming into the boat.

NOTE:

add-on

WESTERBEKE

60Hz - 5.0 KW Circuit Breaker Part Number 42705

50

Breaker

is

installed

off

when

servicing the generator to ensure that

This

circuit breaker is available

kit for earlier model generators; contact your

dealer.

Hz

- 4.0 KW Circuit Breaker Part Number 42704

on

all single phase

as a WES'IERBEKE

in

will

case of

an

no

GENERATOR

INTERNAL

WIRING

A.

ROTATING

WITH

DIODES.

B.

MAIN

STATOR

C.

EXCITER

SCHEMATIC

FJELD/AUXILIARY

WINDINGS.

WINDINGS

AND

CAPACITOR(S).

r-

i l

I

I - - .

: t

WINDINGS

AC

TERMINALBLOCK

--

---

--

--- ---

CAPA~~TOR

t t

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t

Engines & Generatqrs

37

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

DUAl

---.J

EXCITER

CIRCUIT

-.

SINGLE

1.

2.

3.

EXCITER

Remove generator, the

capacitor(s).

Start

the

five

minutes

generator

current correct. Refer

connection Referring

check voltage meter. no-load voltage the proceed.

from

appliances).

the

across

Make

voltage output

NOTE:

and

adjustments be performed by a qualified technician.

NO-LOAD

the

louvered metal plate, at

covering

generator

is

change.

to generator's no-load voltage

the

and

so

the engine can warm

operating without

the

generator (that

Make sure

to

the

DC

the

AC

load connections diagram

the

neutral lead and

sure you record

is

115 is

higher or lower than specified,

VOLTAGE

AC

terminal connections

allow it to run for approximately

any

is,

the

engine's speed (Hertz)

Wiring Diagram

this

reading. The generator's

-

124

volts

BC

GENERATOR

WESTERBEKE recommends that the following generator tests

SINGLE

PHASE

ADJUSTMENT

the

back of

up. equipment drawing shut off

by

the

hot lead

at

60.5 -61.5

the

and

Make sure

all

electrical

for

the

ECU

below,

measuring

with

Hertz.

@)

the

is

the

AC

P8

a volt

If

A

WARNING:

age

adjustment capacitor any

wiring addition, ment

while

lingers

to

5. There

6. · H the generator's no-load

are

minal,

#7, #8, and #9.

low,

then disconnect

nect the plug with tor's no-load voltage is high, numbered plug number. tenninal may be

because the voltage

numbered plug is or the voltage-needs bered

p1ug

Genefator Troubleshooting Guide).

Do

not

attempt

while

the

generator

can

produce

can

produce a severe

attempting

the

generator

be

caught

tln·ee

Note that the

is connected, refer to the WESTERBEKE

a

400·500

to

make a no-load

Is

in

the

generator's

plugs grouped for the right capacitor

If

the

lower numbered plug and

the

connect

plug

any

one

of'the three

voltage

needs

already

connected

to

be lowered

to

make a no-load

Is

operating.

volt

charge.

electrical

shock.

voltage

operating

could

cause

rotor.

generator's no-load

higher

number.

then

disconnect the higher

the

plug

presently connected

cannot be adjusted

to

be

increased and the

and

with

plugs

to

the

If

the next

available.

right

lowest

volt·

The

Touching

In

adjust-

your

ter-

voltage

con-

the

genera-

lower

to

this

highest

terminal,

num-

BC

is

115V/50Hz

firl

l:dxJ

N

4. Shut off the

(60

Hertz #6, or

capacitor(s).

A

WARNING:

handling

tially

power

as

_lethal·

charge

source.

L1

230V/50Hz

generator.

50

Capacitors

they

store·

ll

I•

®

• •

L1

N_

Make sure the correct Hertz lead

Hertz #5)

electricity

even

is

plugged into the ·

must

when

disconnected

be and

GROUNDED

INSIDE

GENERATOR

discharged

can

pack a poten-

from

TO

OF

THE

CASE

before

their

THE

A

WARNING:

.

the

unused

with

each

housing.

I

BC

Make

leads

are

in

other

or

In

contact

GENERATOR

120V/60Hz

certain

place

and

with

BACK

END

the

insulating

are

NOT

in

the

generator's

NOTE:

THE SHOWN DEMONSTRATION THESE BE

SHOWN

#7

CONNECTED

CONNECTIONS

MAD£

covers

on

contact

WIRE

IS

AS

OF

HOW

CAN

A

NOTE:

Simply insulated any·excess

cross

(plastic

electricity.

the

capacitor's

handle)

two

screwdriver.

tenninals

This

will

with

an

discharge

EtJglnes

38

& Generl!tors

SINGLE

EXCITER

CIRCUIT

BC

GENERATOR

NOTE:

WESTER./JEKE

and

Cu:ljustnients

DUAL

EXCITER

These generators adjustment connectors at connectors available for

Hertz

selection, connectors, #7, #8, adjustment.

When

making Hertz-change or no-load voltage adjusunents

proceed

1.

2. Select

as

Shut

the generator down.

the

capacitor

RPM. The three other connectors at each capacitor, #7,

#8,

and

produced

group

can

will

increase or decrease approximately 8-10

between

achieve the prescribed no-load

CIRCUIT

have

60

and

follows:

appropriate Hertz connection

#60,

60

#9,

will

have

by the

generator.

be

plugged into each capacitor. No-load voltage

connectors used in any pair combination to

_.------..._

DUAL

MODEL

dual Hertz and no-load voltage

each capacitor. There are

for

each capacitor.

Hertz

or

#9,

are for no-load voltage

Hertz,

1800

an

effect on the no-load voltage

One connector from each

EXCITER

Two

50

Hertz,

RPM

or

volta~e

CIRCUIT

be performed by a qualified

connectors

and

three

to

plug into each

#50

Hertz,

AC

as

illustrated.

r_ecommends

five

are

1500

volts

SINGLE

that

the

PHASE

following generator tests

technician.

NOTE:

Simply

cross

the

capacitor's

insulated (plastic handle)

any

excess

electricity.

Shore

Power

If

the installer connects shore power to the vessel's AC cir-

cuit,

this

Switch. Set the transfer switch shown in the diagrams to the

OFF position. This switch prevents simultaneous connection

of

shore power to generator output.

A

CAUTION:

utility

shore

at

the

same covered liflity

to

120Volt/60

·-:Ganeratot

~._N~Gt"~

Connections

must

be

done by means

Damage power time.

under

the

make

sure

Hertz

screwdriver.

to

and

generator

This

type

warranty;

all

AC

Three

NOTE: Diagram

wfre.120·V'olt l'fstiim from the gener-ator,

with

'th.,..

...

w1re.120•Vott boat system.

two

terminals with

This will discharge

of

the Shore

the

generator

power

of

generator

it

Is

the

installer's

connections

Wire

show•

are

Configuration

connections for a

Power

can

result

are

connected

damage

responsi·

correct.

two-

an

Transfer

if

is

not

When

changing Hertz produced by

reference

connection

terminal blocks must be

must

frame ground

volts,

A

handling

tial/y

power

the

DC

change.

produced.

be

The

changed for 50 Hertz

wire

50 Hertz

to

WARNING:

as

they

lethal

charge

source.

Wiring

Hertz plug connection at

230

store

GENERATOR

Diagram for

The

AC output connections

be

selected for

(#5)

must be moved

volts,

50

Hertz.

Capacitors

must

electricity

even

when

disconnected

BACK

the

ECU

the

voltage and Hertz

the

or60

Hertz (#6).

when

changing from

be

diScharged

and

can

pack a poten·

•

230

Volt/50

L1

END

generator,

P8 on

the

to

capacitor

The

115

z

..

::!

"

before

from

their

1-.viWESTERBEKE

·l

Engines.~

Generators

39

Hertz

GENERATOR

GROUND

lL1

SHORE

220V

N

•

POWER

50HZ

Two

~

;:

..

N)

Wire

Configuration_

GENERATOR/SHORE

SWITCH

- SHORE

- GROUND

Shlp-to•Shcn'* Switch

PH

32008 PN32009 PN32010

PN32133

SHIP'S

LOAD

BC

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator tests

and adjustments be performed by a qualified technician.

SINGLE

PHASE

INTEGRAL

The

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

Charging (;barging

A separate group

btidge rectifier which converts the

I.1C. unit. The I.C. unit senses the needs

ahd

suppli~s

that the low), check the charging circuit and it's components as

d~cribed

deahliness and tightness including the ground before

irtg

.the

t(On:

produce a low charging rate. This charging rate will rise as

{fie generator is operated.

Tlhe Integral Controller is mounted inside the generator hous-

i~g

in the 12:00 position.

CONTROLLER

Voltage: 13.0 - 14.0 volts

Amperage: 0 - 10-

of

stator windings supplies

a

DC

charge when

I.

C.

unit is faulty (that is,

in

the following steps. Check all connections for

I.

C.

unit.

When the generator is first started, the L

EARLY

BCD

(I.C.)

amps

AC

current to supply the

cine

is needed. If you suspect

if

the battery's charge is

and

BCDA.MODELS

DC

of

the starting battery

INTEGRAL

AC

voltage

C.

unit will

to

replac-

Testing

1. Bridge Rectifier

a

2.

3. Testing

If the

the

Battery

Normal engine is operating at two illustrated).

AC

Normal DC) is measured across the two bridge rectifier; that is + and

DC voltage running from the bridge rectifier

(approximate):

AC Lift the two

measure, the resistance between these two leads with an ohmmeter. should exist between these two leads and the ground or

the main

the rectifier fails

AC

voltage running

AC

connections

voltage running to the bridge rectifier (approximate): No-load Full-load

No-load

Full-load

winding: 0.14

A. Set the meter B. Connect the positive ( +) lead from the meter to point

Taking the negative(-) lead, momentarily touch points #1, #3,

C. Remove the positive ( +) lead from point

#3. the

D. Leaving the negative (-) lead on point

E,

rectifier

off

DC

voltage running out

off

AC

It

AC

the

Bridge

. . . - ' . ' .

and

#5. There should

meter.

negative(-) lead

Ohm

each point

the positive ( +) lead. value. Place the

lead on point #3. value. Reverse these connections and the meter should register

no

as

Charging

1800 rpm)

on

the bridge rectifier. (As

the

generator

off

the

generator

the

generator

off

the

generator

ohm

wire leads off the bridge rectifier and

should measure 0.14.ohm. No continuity

stator windings

Rectifier (meter

on

Ohms scale.

to

it. Momentarily touch

meter should register an arbitrary Ohm value at

Circuit

to

the rectifier (while the

is

measured across the

16.0 volts

17.5 volts

of

the rectifier (in volts

DC

connections

-.

..

be

no Ohm value registered

17.0 volts

18.5 volts

used-

AC AC

FLUKE

#4

of

the

DC DC

multimeter).

and connect the

point~

#1,

it touches.

#4,

touch point #5 with

The

positive(+)

The

Ohm

value.

any

of

it

is defective.

meter should register

lead on point meter again should register no Ohm

the

previous tests B

#1

and the negative(-)

no

through

#4.

#2,

on

the

#2

and

Ohm

E, replace

+

-

GND

BLACK

YELLOW

GROUND

GENERATOR

TO

CASE

BRIDGE RECTIFIER

AC

En_gfnes & Generators

40

.#4.

BRIDGE

RECTIFIER

IF

THE

BRIDGE

RECTIFIER AIVY TESTS,

REPLACED

OF'

FAILS

THE

IT

SHOULD

ABOVE

·

BE

DESCRIPTION.

-

Oiiee~ttie

_

engiile,made

mOUiited

positiotfin

frOm

line

STEP

UPPER AS EXISTING

~lly~Pass

pJiun~l#.';fh'e-~

to

ifte

\Yater

~.1htWilter

in a

COftVeilient

relation

~heater

without

1:

UN-BOLT

ANO

LOWER

ONE

ASSEMBLY.

BY..PASS

to

lhe

any

loops

AND

THERMOSTAT

REMOVE

RXnJRE.

the

engmedm

whiclnmglit trap

REMOVE.

~on

~i.e

locanen

ertgitle

THE

so

mE · HOUSINGS

i$

ifiStaUed

·coolant

·h~tet

shollld

either

in

a high or

that-the

run.·m•

eon:necting-hoses

a

~hably

air.

on

the

can~

be _

low

direct

-

·

INSTALLAnON

Follow

lower

the

Heater

The

· to connect

the

steps

1hetmostat

e:idslirtg

By-Pass

hoSe

spuds

to

as

housing~

by

..

pass

as shown itt STEP on the

518"

lD.

illustrated

'l1iiS

fixttfre

as

He"ater

hose,_

below.

Remove

will

allow

access

showll in STEP

2.

By-Pass

use the hose

are

adapters:

for

the

1.

3/8"

upper

to

remove

Install

I.D.

and tbe

bose,

STEP

SEALING

WA1ER

ANO

PARTSUSnNO

HEAtER

BY~PASS

-

SEALING

THERMOsTAT

HOUSING

HOSE

THERMOSTAT

HOUSINC

0-RING

(2)

LOWER

GASKET

ADAPTERs

(2)

GASKET

2:

ATTACH

O~RINGS

HEATER

ASSEMBLE

PN

042743:

PN

036937

PN

03701&

PN

302391

PN

03&956

THE

TWO

TO

tHE

8}(-PASS

AS

ILLUSTRATE!).

THERMOSTAT

HOUSING

.

STEP

HEATER

4:

HOSES

HEATER

INSTALL

TO

BY--PASS.

STEP

3:

HOUSING GASKEr

'TUII:DIIineTIIIT

GASKET·

iHE

7WO

THE

NEW

RE~NSrAU

ASSEMBLY

HOUSING

REMOVE

THE

THERMOSTAT

USING

THE

AND

NEW

DISCARD

41

DOMESTIC

HOT

WATER

HEATER

CONNECTIONS

WATER

Once the Heater By-Pass engine, plumbing

made

mounted in a convenient location either position in relation

from the

line

A

TO

HEATER

to the water heater.

heater

to

without

WA1FR

HEATER

CONNECTION

any

TANK

PY-PASS

INSJAUATIONS·.

~onnectionis

of

the erigine.antifreeze

The

water

to

tbe

engine

so

the engine

loops which

WATER

can

might

HOSEADAPrm 41302391

HOSE

HEATER

installed

coolant

heater

should

in

a

high

that

the

connecting hoses

run

in

a reasonably direct

trap

air.

- 3/ll"

TO

5/ll"

THERMOSTAT

ASSEMBlY

ClAMPS

CONNECTIONS

on

or

the can be

low

.

be

HEATER

When expansion tank convenient'location

NOTE:

ABOVE

the

water

heater

is

The expansion tank replaces the stanilard plastic

recovery tank and

and

fillpoint.

As

shown

in

the

fitting

at

connection B

.rise continuously

air to rise

.Remove .the plastic

.:

needed. manifold

to

the tank

Remove

and

plug

REMOTE

(REPLACES RECOVERY

EXPANSION!

COOLANT

1ANKJ

EXPANSION

PN0241TI

KiT

THE

ENGINE

is

located

above the engine, a remote

required. Install the expansion tank in a

above

the

water

heater.

wiU

now

serve as the systems

illustration, a

on

the

to

the

expansion

and

be

expeUed).

coolant

its

the

recovery tank fhat is no longer

attachment

opening

TANK

'

single

hose

water

heater. That hose must

tank. (This will allow

fitting

from

'with a 1/8npt plug.

is

the

check

teed

exhaust .

into the

point

any

Using

the

Heater

By-Pass

as

illusltirted

increase

HOT

HEATEfl

FILLING

Fill

the engine's cooling system with antifreeze thru the

pressure cap operating engine and monitor the coolant until noted.

antifreeze to the coolant recovery tank (mark).

m1tifreeze

fully functional.

below.

the

hose

size

WATER

THE

COOLING

Fill the manifold and install

circuit with its hot water heater should now

connection, install

Use

the

hose

from

adapters

3/W'

to

5/8".

HEATER

(PN302391)

BELOW

!ENGINE

SYSTEM

on

the exhaust manifold. Start the

good

circulation is

the

pressure cap. Add

hoses A and

to

CONNECTIONS

HEATER

BY-PASS

The

engine's

be

B

FROM

HEATER

FILLING

Ftll the

on pressure

expansion and expelled. stable the pressure engine

~k

engine's

the

engine's

cap

monitor

and

coolant

THE

add

HOT

WATER

HEATER

ABOVE

COOLANT

cooling

water

and

continue

tank.

Fill

the

coolant

good

circtilation

cap

on

the

level,

ENGINE

SYSTEM

system

jacketed

filling

t3Dk

level

to

maintain

is

remote

it

is

now

at

exhaust

the

to

about

hi

the

felt

tank.

done

(REMOTE

the.

pressure

manifold

system

~

frilL

remote this level. at

both

heater

When

at

the

remote

TANK)

cap

opening

Install the

at

the

remote

Start

the engine

tank. As air is

Once

the level is

hoses, install

checking

the

expansion

.

Engines & Generators

42

POWER

TAKE

OFF

SYSTEMS

POWER

A backend. engine

THE

PRODUCE

1800 FOR THE

TAKE·

power

take This

for a variety

BC

GENERATOR

9.0

RPM.

THIS

GENERATOR

POWER

TAKE-OFF.

OFF

ADAPTER

off

adapter

HP.

(APPROXIMATE)

HORSEPOWER

AC

allows

of

hydraulic

MODELS

OUTPUT

can

be

attached

access

to

and

electrical

IN

THIS

MANUAL

AT A CONTINUOUS

CAN

BE

OR

UTILIZED

FOR

EQUIPMENT

to

the

full

EITHER

FROM

the

generator

power

accessories.

.

of

the

POWER

KIT4#34786

TAKE

OFF

Contact

information.

your

WESTERBEKE

DISTRIBUTOR

for

additional

Engines & Generators

43

LAY-UP

&

RECOMMISSIONING

GENERAL

Many

owners

rely

on

their

boatyards to prepare their craft, including engines off-season or for

to

accomplish

The

procedures

lay-up

own

you

if

have

local

check list

These procedures

during a lay-up and maintenance

If

your provide assistance.

Propeller

The transmission

be

opened

out of

the

water or

storage

apply period of time.

recommended for

1bis

antifreeze, depending

Should amount

and cooling

in

the severe strain on the propeller shaft or coupling or the

boat

is taken out or put in the water.

has

shaft not in

Fresh

A

solution

mixture.

actually

to

small boats that are hauled out

use,

Water

50-50

solution

solution may

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine

sump.

Remove

with

new

oil.

ENGINE

oil

LUBRICATING

changing

pressure and

A

CAUTION:

in

the

sump

combustion

chemicals

internal

parts.

and

generators,

long

periods

lay-up preparation themselves.

which

follow

and

recommissioning,

others

do

the

procedures.

should

afford your engine protection

also

help

needs of your engine.

any

questions

servicing

Shaft

and

up and

the

cradle.

been

unless

they

Cooling

of

use

make sure

antifreeze the

engine

the

of

the

Now

regarding lay-up procedures, call

dealer;

Coupling

propeller half couplings should always bolts

moved

The

flexibility

bent by these strains. This does not

have been dry for a considerable

· ·

Circuit

antifreeze

in the coolant system at all times.

require

a higher concentration

on

the area's winter climate. Check the

the

antifreeze protection is adequate.

be needed, drain an appropriate

block and

engine

antifreeze

recheck

for lay-up during

of inactivity. Others prefer

will allow you

or you may use them

familiarize you with the

he ~ be more than willing to

[Propulsion

removed when the boat is hauled

from land to water, and during

[Propulsion

and

distilled water is

add

to ensure a complete circulation

concentration throughout the

the

antifreeze solution's

System

warm,

drain

all

the

and

replace

the oil filter and

Use

the

correct

grade

of

OIL

pages in this manual for the

procedure.

over

deposits

which

Run the engine and check for proper

make

sure there are no leaks.

Do

not

leavfl

the

iay-up

period.

combine

can

reduce

to

produce

the

life of

to

perform your

Engine]

of

the boat often puts a

In

some cases, the

of

the water when

a more concentrated

engine oil from

fill

oil. Refer to the

enginet

old

Lubficating

harmful

your

the

both, while

Engine]

of

strength.

the

the sump

engine

oil

and

englnet

as

oil

Fuel

System

Top

off your fuel tanks with unleaded

or

higher. stabilizer should be added. Change the element gasoline/water separator and clean and

make certain there are no leaks. Clean

a

fuel

Fuel

System

Top

off your fuel tanks with

additives should be

mix

With

Additives. such

be·

should condition the used are compatible with the separator used in the system. Change the element in your

primary fuel filter/water separator clean the separator

sediment Change the fuel filter elements

fuel system,

5 - 10 minutes to make sure no air is left

for

system. Check for any leaks that may have been created

the fuel system during this servicing, correcting

needed. Operating the engine for 5 - 10 minutes will help

allow movement equipment on

Raw

Water

Close the through-hull seacock. Remove the raw water intake

hose from the seacock.

gallon bucket check the zinc anode found in the primary heat exchanger on the engine any

zinc debris from inside the

zinc anode is located. Clean Start the engine and allow the raw water pump to

fresh water through the system. When the bucket stop the engine and refill solution slightly stronger protection in your area

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

as

providing corrosion protection.

Remove the impeller from your raw water pump

antifreeze mixture will accompany it,

Examine the impeller.

a cover gasket. Do not replace the impeller (into the pump)

until recommissioning, but replace

[Gasoline]

A fuel conditioner such

g~line

as

Sta-Bil gasoline

the

metal bowl. Re-install

of

in

up

any spilled

89

octane

your

[Diesel]

No.

2D diesel fuel. Fuel

added

prior

to

topping

the

fuel being

as

added at this time to control bacteria growth and

fuel.

bowl

as

needed. Start the engine and allow it to run

the

Cooling

of

and clean or replace it as required, and also clean

raw water system. Once the bucket

added

and fuel still in the tank.

Bio-bor and Diesel Kleen+ Cetane Boost

Care should be taken that the additives

primary

on

the engine and bleed

of

the treated fuel through the injection

engine.

CircuH

Place

the end

clean fresh

water.

heat,_exchanger

the

raw water strainer.

the

bucket with

than

needed for winter

of

this

Acquire a replacement,

off

to

ensure

fuel filter/water

the

in

the

fuel

them

as

of

this hose into a

Before starting the engine,

where the

draw

the

is

empty~

an

antifreeze

freeze

mixture to

so

the

cover and

be

drawn

is

empty,

as

well

(some

catch it in a bucket).

if

needed, and

gasket.

they

in

five

stop

l"ffV'lWESTERBEKE

l Engines & Generators

44

LAY·UP

&

RECOMMISSIONING

Starter

Lubrication and

if

battery connections the connections removed from the starter.

Cylinder

If

WESTERBEKE access

the cylinder walls. revolutions and

If

to

the

Intake

Clean cloth lightly

block

through-hull exhaust.port, Make a note

to

Cylinder

Remove the spray coat the intake,

Reinstall the

NOTE:

and

tions. attach

Motor

cleaning

access

to

the starter permits its easy removal. Make sure the

starter.

Take

care

Lubrication

you

anticipate a

recommends removal

to

the

cylinders.

re-install the glow plugs.

your

engine

does

be

removed.

injectors

and

Be

return

Manifold

the

filter screen in the flame arrester, and place a clean

soaked in lube oil around the flame arrester

any

opening.

start-up!

Lubrication

flame

fogging

gap

Re-install

oil

into

valves

flame

At

re-commissioning,

them.

Rotate

the

high

tension

of

the starter drive pinion is advisable,

are

shut off before attempting

in

properly replacing any electrical

[Diesel]

long

lay-up period (12 months Squirt some Marvel Mystery Oill into

Rotate

the engine crankshaft

not

have glow plugs, the injectors will have

sure

to have replacement sealing washers for

fuel line

as

needed.

[Gasoline]

Also

place an oil-soaked cloth in the

[Gasoline]

arrester and clean. Operate the engine

the intake stalling the engine. This will

and cylinders with a protectiqg

arrester.

remove

the

engine

by

spark

plugs

and

Zeds.

Batteries

If

batteries

make

to prevent them

. batteries will not

subjected

batteries·and store

environment

A

highly-explosive arcing smoke serviced.

ftl

Transmission

Check or change off the coating. additional

are to

sure that

they

from

to

severe environmental conditions, remove the

WARNING:

or

a lighted

or

allow

Shut

Pfll.ftlnt

grime

coupling

electrical

and,

grease

and

Check

that

information,

[Propulsion

be

left on board during the lay-up period,

are

fully charged, and

freezing.

remain

them

Lead

gas,

cigarette,

an

open

11ft

all

If

there is any doubt that the

fully charged, or that they will be

in a warmer, more compatible

acid

batteries

which

can

be

cigar,

flame

near

electrical

arcing

equipment

during

Engine]

the

fluid

in

the

transmission as

and touch up any unpainted areas. Protect

the

output flange with an anti-corrosion

the

transmission vent is open. For

refer

to

the TRANSMISSION SECTION.

tO

remove

or

more)

of

the glow plugs for

by

hand two

to remove cloths prior

the

spark plugs and

hand

two

complete

tighten

securely

will

emit

Ignited

or

pipe.

the

battery

hydrogen,

and firmly

remain

by

electrical

Do

not

beiilg

In

the vicinity

St!f!!cing.

required

to

and

oil.

clean

revolu-

that

a

Wipe

Spare

Lay-up time provides a good opportunity to inspect your · Westerbeke engine to see

or coolant hoses need replacement. Check your basic spares

kit and

during the lay-up, such

SPARE

Parts

order

items not on hand,

PART.S

section

as

of

Recommissioning

The recommissioning of your Westerbeke engine

·-seasonal

• those described in the PREPARAUONS section regarding preparation for starting However,. counteracted

1. Remove the oil-soaked cloths from the intake manifold.

2.

3. Reinstall the batteries that were removed during

way,

4.

S.

6. Start the engine

lay-up generally follows the same procedures

some

of

the lay-up procedures will need to be

before starting the engine.

Remove the raw water pump cover and gasket and discard the old removed

Install the raw water pump cover with a new cover gasket

lay-up, and reconnect the battery cables, making sure the

terminals are clean and that the connections are tight

Check to make sure that the batteries are fully

A

CAUTION:

and

eye

protection batteries can

be

Ignited

cigarette,

flame

near electrical arcing

during

Remove· the spark plugs, wipe clean, re-gap, proper tightness

Check the condition circuit and that

it is not necessary to flush the

solution from the raw water coolant system. When engine is put into operation, the system will self-flush in a

period

short advisable, service, to

heat exchanger and clear any and

area.

in

the PREPARAUONS FOR STARTING section of this

manual.

g~et.Jnstall

during

lay-up (or a replacement,

Wear

when

emit

hydrogen, a highly

by

electrical

cigar,

or

pipe.

the

battery

equipiiiBIIt

In

servicing.

[gasoline].

clean or replace the anode

of

time with no adverse

as

either

an

inspect the area where the

in

accordance with procedures described

if

external items such

or

replace

filters and zinc anodes. Refer

this manual.

the raw water pump impeller

rubber

gloves, a iubber

servicing

batteries.

explosive

arcing

or

Do

not

smoke

being

serviced.

the

of

the

end

vicinity

of

to

zinc anode in the

ant:ifreezelfresh·

season or recommissioning

all

as

those

FOR

STARTING

and

normal starts.

if

required).

gas,

a lightell

or

allow

Shut

og all

/ll'fiVIInf

as

needed. Note

affects.

zinc

is located

zinc debris

items

after

charged.

apron,

Lead

electrical

and

raw

It

drive

the

acid

which

an

open

install

water

is

from

belts

used

to

a

as

the

in

that

the

to

the

IW'IWESTERBEKE

l Engines &

Generators

45

SUGGESTED

SPARE

PARTS

CONTACT

THERMOSTAT

YOUR

WESTERBEKE

DEALER

~.

WESTERBEKE

ENGINE

AND A GALLON

RECOMMENDS

OIL

(YOUR

FOR

SUGGESTIONS

. .

BRAND)

OF

PREMIXED

FOR

AND

CARRYING

AN

COOLANT.

ENOUGH

OIL

CHANGE

ADDITIONAL

INFORMATION

'.·:

~~._..

WESTERB:aKE

each

packaged

Kit

"A" includes

Kit

"B" is

in

for

more extensive off-shore cruising.

KIT.A

ZINC

ANODES

DRIVE

BELTS

OIL

FILTER.

FUEL

FILTER

HEAT

EXCHANGER IMPELLER FUEL

SYSTEM

FUEL

PUMP

..

IN·UNE

RJBJWATER

FtLTER.CARTRiDGE

also

offers

two

Spare Parts Kits,

.a

rugged

hinged

toolbox.

the

basic spares.

GASKET

KIT

HARDWARE

INLET

FILTER

KIT

.BELTS

INJECTOR

SPARE

PARTS

KITS

IW"IWESTERBEKE

l

DRIVE

Engines·&

Get:Jerators

KIT

B

ZINC.

ANODES

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER

IMPELLER

KIT

INJECTOR OVERHAUL

GLOW fUEL

FUEL

GASKET

PLUG

SYSTEM PUMP

INLET

·MOLDED

HOSE

KIT

INA

CANVAS

CARRYING

GASKET

KIT

HARDWARE

ALTER

KIT

BAG

46

Engines & Generators

7/2016·1228

Westerbeke 5.5 EGCD, 5.0 EGCD Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual