Westerbeke 5.0Kw BCDR, 5.0Kw BCDBR, 7.0Kw BTDR, 7.6Kw BTDR Operator's Manual

-

OPERATORS

MOBILE

and

MANUAL

INDUSTRIAL

GENERATORS

5.0Kw

BCDR

15.0Kw

7.6Kw

B R

BCDBR

~

PUBLICATION

.

SECOND

APRIL

NO.

041283

EDITION

2006

..

WESIERBEKE

WESTERBEKE

MYLES

WEBSITE:

§JTAI'r

.u:_w

CORPORATION

STANDISH

MDtrber

INDUSTRIAL

WWW.WESTERBEKE.COM

NlIIltHffll

.150

PARK·

Mflrine

JOHN

HANCOCK

TAUNTON

Mfl"./lIdIIrm

MA

Assoclfltlo"

ROAD

02780

'A

WARNING

Exhaust colorless unconsciousness exposure

-Oizziness

-Nausea

-Headache

-

IF GET seek until

WARNING

'GGnerators

gasses

Weakness

YOU

OR

OUT

medical it

has

Produce

Regular

rry~~.!'!~~~

contain

gas.

Carbon

can

include:

and

ANYONE

INTO

THE

attention.

been

CARBON

Maintenance

and

Sleepiness

ELSE

FRESH

inspected

MONOXIDE

Required

Carbon

Monoxide

death.

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

- Inability

EXPERIENCE

AIR

IMMEOIATELY.

Shut

down

and

A

ANY

the

repaired.

WARNING WESTERBEKE bulkhead

near

WESTERBEKE CARBON

They at

MONOXIDE

are

your

local

inexpensive

an

and

of

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

unit

and

DECAL

and

your

also

hardware

odorless

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

is

provided

should

be

engine

persist,

or

recommends

DETECTORS.

and

easily

store

by

fixed

to

generator

installing

obtainable

a

PROPOSITION

Diesel

and

some

of

its

constituents

State

of

California

defects,

and

CALIFORNIA

65

WARNING

gasoline

to

other

reproductive

engine

areknown.to

cause

exhaust cancer,

harm.

and

the

birth

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual

caused

by

failure

precautions.

take the

personne4

PREVENT

A

.

while these

• Do not operate enclosures

• Shut off electrical power before equipment

• Use insulated equipment

• Make sure your clothing and skin are

(particularly shoes) when handling electrical equipment.

•

Remove electrical equipment.

• Electrical shock results from handling a capacitor. together.

PREVENT

Know

necessary

and

your

ELECTRIC

WARNING:

engine

is

connections!

and

wristwatch

Discharge capacitor

BURNS -HOT

corefuUy.

to

follow fundamental rules

when

dongerous

precautions

machinery.

Most

to

protect

accidents

conditions

yourself,

SHOCK

00

not

touch

AC

electrical

running.

this

covers in

mats

Lethal

voltage

machinery without electrical

place.

accessing

whenever wolring on electrical

dry.

and

all jewehy

by

shorting

when

ENGINE

and

exist

connections

is

present

electrical

not

damp

working

charged

terminals

are

and

your

at

on

• Do not operate Backfire

• Do not the engine/generator clean chances of

• Be aware - diesel

smoke

fuel

PREVENT

A

WARNING:

injury

Dr

death!

•

All

fuel

when

handling well-ventilated area equipment

• Do not fill the

• Shut off the

fuel

spill.

DO

sources servicing. the

•

Do

• Be sure

• Be certain

free

• Make properly Extinguishers rated for all

of

fuel not alter or modify

·of

leaks.

sure

applications

with

can

cause

or permit

system.

fire.

Keep

Wipe

BURNS -EXPLOSION

Explosions

vapors

are

and

out of the reach of

fuel

the

fuel

service

system.

all

Take

NOT

allow

fire

near

Ensure

proper ventilation

fuel

supplies

fuel

line

a

fire

extinguisher is installed

maintained..

the air cleaner/silencer

Severe

injury or death.

flames

or

sparks

the

compartment

and

free of debris

up

all spilled

fuel

will·bum.

from

highly

explosive.

storing

fuels.

away

from

tank(s)

while

valve care in any

smoking,

the

fuel

system

the

fuel

have

fittings

Be

familiar

ABC

by

encountered

fuel

vapors

Use

Store

spark-producing

children.

the

engine is

at

the

engine

catching

open

or

engine

exists

system.

a positive shutoff

are

adequately

with

the

NFPA

in

this environment

removed.

to

occur

and

the

to

minimize

and

engine

can

extreme

fuel

in a

running.

when

any

fuel

flames,

when

tightened

nearby

its proper

are

appropriate

near

the

oil.

cause

care

servicing

that might

or other

servicing

valve.

and

is

use.

A

WARNING:

exhaust

system

00

not

touch

components. A running

reryhot!

•

Always recovery

A

• In case of an engine overheat,

before touching

PREVENT

A

• Prevent sparks

pump,

vapors.

removing the

check the engine coolant level at

tank.

WARNING:

Steam

can

cause

the

engine or checking the coolant

BURNS -FIRE

WARNING:

to

or other potential

Use

Fire

can

flash

fires.

Do not smoke or permit

occur near the

a suitable container

fuel

line, carburetor, or

cause

carburetor,

sources

hot

engine

allow

injury

of spilled

to

engine

injury

the engine

Dr

fuel

line,

catch

fuel

parts

or

gets

the

coolant

Dr

death!

flames

filter,

fuel

all

fuel

filters.

to

cool

or fuel

when

Engines & Generators

ACCIDENTAL

A

WARNING:

Dr

death!

•

To

prevent accidental

generator.

• Disconnect the battery generator. it last

• Make certain

starting.

• Make re-installed

STARTING

Accidental

remove

Remove

all

personnel

certain

all

covers, guards,

before

the 8

the

starting the

starting

amp

cables

negative

are

can

cause

when

servicing the

fuse

from

the

before

servicing the engine/

lead

first

clear of the

and

hatches

engine.

control

and

engine

are

Injury

panel.

reconnect

before

i

SAFETY

INSTRUCTIONS

BATTERY

A

01

•

Do being highly explosive arcing equipment during

•

Never positive (+) connection terminal of the starter'solenoid.

Do

together. Ventilate accumulation

disturb the battery charger connections while the battery

is being

•

Avoid bums or wristwatch, the

•

Always the battery connections. Remove the negative lead

and

BATTERY

A

severe

•

When level, wear rubber gloves, a rubber protection. destructive.

off into caps.

A

EXPLOSION

WARNING:

death!

not

smoke

serviced.

or

servicing.

connect the negative (-) battery cable

not test the battery condition by shorting the terminals

contacting the terminals with tools, etc.,

battery.

reconnect it last

Battery

or allow an open

Lead acid batteries emit

by

lit tobacco products. Shut off all electrical

in the vicinity to prevent electrical

Sparks

any

compartment containing batteries

of explosive

charged.

sparks

rings, and

tum

the battery charger off before disconnecting

explosion

gas,

which can be ignited by electrical

could ignite battery

that could

any

when

can

cause

flame

near

hydrogen,

gases

gases.

To

avoid

cause

an

explosion.

other jewelry before handling

disconnecting the

injury

the

arcing

to

or

fuel

sparks,

battery.

battery

the

to

Remove

ACID

WARNING:

Injury

servicing the battery or checking the electrolyte

at

once

the

WARNING:'

Sultulic

01

death!

Batteries contain'sulfuric acid

If

it comes in contact with your

with

water.

eyes

inadvertently

Catbon

acid

In

batteries

Acid

may

when

monoxide

splash on

removing electrolyte

apron,

(CO)

Is

a

can

cause

and

eye

which

skin,

the

deadly

skin or

a

vapors.

prevent

do

prevent

first

is

wash

gas!

not

it

A

WARNING:

odorless nausea

•

AVOID

A

01

• Do

•

• Make

•

gas.

01

Do

not

use

fumes

can

systems.

tubing

copper

Do

not

install exhaust outlet

through Although

exhaust gas

is

present in diesel exhaust symptoms poisoning

Vomiting Dizziness Throbbing

MOVING

WARNING:

death!

not

service

situation

make

operating touching components.

Do

not

wear equipment; jackets, could be caught

sure

Keep

protective shields

places at Do

not

check the engine

HAZARDOUS

Carbon

Inhalation

death!

copper

rapidly

Exhaust sulfur causes rapid deterioration of

resulting in exhaust/water

vents,

or air conditioners.

diesel

fumes

from

or

signs

are:

in

temples

PARTS

Rota,tlng

the engine while it is

arises

in which it is absolutely

moving

loose clothing or jewelry

tie back

shirts,

sleeves,

all

attaching hardware is properly

all

times.

fluid

is

operating.

NOISE

monoxide

produces

tubing in

destroy

engine exhaust

copper

gasoline

of carbon

Muscular twitching

Intense

Weakness

parts

adjustments, use

parts and hot exhaust

long

hair

rings,

in

moving

and

levels or the drive belts

(CO)

f1u~lIke

diesel

exhaust

tubing

where

gases

engines,

fumes.

monoxide

headache

can

extreme

and

avoid

necklaces

parts.

guards

Is

in

exhaust

are

carbon

Some

inhalation or

and

sleepiness

cause

running.

necessary

system

when

wearing

or

in their

an

Invisible

symptoms,

systems.

exhaust

leakage.

can

not

Diesel

be drawn

as

toxic

monoxide

of the

Injury

If

a

to

care

to

avoid

servicing

loose

bracelets

respective

tension

that

tightened.

while

as

• Ensure that the exhaust system discharged regularly are attention

• Be sure

•

In

addition install a carbon monoxide detector. Consult your dealer for installation

for

securely

to

the

from

the

engine. Check the exhaust system

leaks

and

make

attached

the manifold unit and its surroundings are

to

and

routine inspection of the exhaust

of

approved

is

adequate

sure the exhaust

no warping exists.

and

exhaust

detectors.

to

Pay

well

expel

gases

manifolds

close

ventilated.

system,

Engines & Generators

• Never

•

ii

A

WARNING:

loss!

operate

Do

not

run an engine

removed.

Do

not

run

open.

A

WARNING:

mentally

01

High

an

engine without

engines

for long periods

Do

not

physically

noise

levels

can

its

with

the air intake

wolk

on

machinery

incapacItated

cause

muffler

(silencer)

with

by

fatigue!

healing

installed.

their

when

enclosures

you

are

TABLE

Parts

Identification

Introduction

Warranty Procedures ............................................ 3

Remote Panel ....................................................... 3

Diesel Generator

Description Description

Remote Panel ............................................... ' ..... ' ... 6

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

Fuel,

Engine

Control

Preparations

Prestart Inspections .............................................. 7

StartingJStopping Safety Generator

Shutdown

Break-In

The Daily Routine ..............................................

Maintenance Fuel

System

Fuel FilterlWater Separator ................................

Fuel Injection Pump ...........................................

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

Fuel Lift Pump Filter .........................................

Fuel Filter ...........................................................

Engine Fuel Filter ...............................................

Cooling

Changing Coolant. .............................................. 14

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

Air Intake Filter/Silencer ...................................

Engine

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

Remote Starter

Engine Engine

Drive Belt Adjustment ....................................... 22

Torquing The Cylinder Head Bolts .................... 22

Fuel Injectors ...................................................... 22

Valve Clearance Adjustment .............................. 23

Engine Compression .......................................... 23

Glow Plugs ......................................................... 24

Oil Pressure ........................................................ 24

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

System

Lubricating

Oil

Filter , .....................................................

Motor

Troubleshooting

Adjustments

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

Oil

and

Engine

Panels

of

Switches ....................................... 6

of

Gauges .......................................... 6

for

Initial

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

Start-Up

Procedure

Switches

....

Procedure

Schedule

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

Coolant..

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

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

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

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

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

Oil

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

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

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

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

OF

CONTENTS

.2

3

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

5 6

7

8 9

10 l0

12 13

13 13 13 13 13 13

14

15 15

16

17 18

20 Testing Exciter Windings ...................................

22

Engine

Alternator DC

Circuit/BaHery

Control

7.6

,

7.6

5.0

5.0 Remote Generator BT

Generator

7.6KW

7.6,KW

5~OKW

5.0KW

5.0KW GenRemote

Power Metric

Suggested

Adjustments

Injection Timing .................................................

Frequency Adjustment ....................................... 26

Fuel Run Solenoid .............................................. 26

Electronic Governor ........................................... 27

Testing/Troubleshooting

Battery Care ....................................................... 29

Panel

BTDR

Wiring

BTDR

Wiring

BTDR

Wiring

BTDR

Wiring

Stop/Start

Information

Troubleshooting

BT

Generator

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

No-Load Adjustment ......................................... .40

Residual Voltage Check ....................................

Bridge Rectifier .................................................. 42

Exciter RotorlField ............................................. 43

Measuring Resistance ........................................

Voltage Connection Terminal.. ..........................

BTOR

Generator

BC

Generator

BC

Troubleshooting

Dual Exciter Voltage Adjustment.. .................... .48

Single Exciter Voltage Adjustment .................... 49

Integral Controller ..............................................

Testing Battery Charging Circuit ....................... 50

Testing the Capacitor ..........................................

Testing Resistance Valves .................................. 53

BCDBR

Controls

Take-Off

Conversion

Spare

(cont.)

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

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

....

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

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

Diagram Schematic Diagram SchematiC

Panel

(#44743)

(#44742)

Wiring

.......................... 32

.......................... 34

(#44329)

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

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

Single

Phase

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

Specifications

Single

Phase

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

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

Generator

Systems

Specifications

(optional)

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

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

Data

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

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

22 25

.28

.30

31

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

33

...................... 35

....

..........

.36 .37 .38

39 39

.41

.44 .44

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

.45

46

.47

50

51 51

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

54

55 60 61

62

Engines & Generators

1

PARTS

IDENTIFICATION

RADIATOR PRESSURE

FAN

COVER

RADIATOR

FRONT

_...--l-.~-~-""t=

'FAN

COVER

CONTROL

FRONT

PANEL

___

FMFRf.:FNIr.V

SA

FUSE

'EXHAUST

LEFT

STOP

SWITCH

THERMOSTAT

.

HOUSING

SIDE

INSTRUMENT

POWER TAKE-OFF

GAUGES------£~~-.JI1I

GENERATOR HOUSING

CONTROL PANEL

START/STOP/ON SWITCHES

AC

CIRCUIT

BREAKER

PORT

REAR

INJECTORS

FUEL PUMP

LIFT

OIL

DRAIN

PRESSURE

AIR

INTAKE/SILENCER

HOSE

RIGHT

CAP

SIDE

Engines

2

& Generators

INTRODUCTION

This WES'IERBEKE WES'IERBEKE's technology. dependable Thank

In

order

is

important manual manual carefully throughout your nearest WES'IERBEKE dealer

This provided WES1ERBEKE equipment contact WES'IERBEKE'S installation

is

you

to

is

your

We

performance

for get

that

designed

Should

operators

and

a technical

WARRANTY

Your

WES1ERBEKE

folder.

If, after

you

form registering your

writing number

Customer

have

with

model

and

commission

Identification

Diesel

long

take

great pride

selecting

the

full

use

you

operate

to

help

and

observe

your generator

manual. A parts

dealer.

your

Generator

years

of experience

of our

engines

WES'IERBEKE.

and

benefit

and

you

do

all the

manual

If

you

are

WES'IERBEKE dealer

manual.

is

a product of

in

the

superior durability

and

from

maintain

this.

Please, read

safety

require

for

assistance.

catalog

is

available

planning

PROCEDURES

Warranty

60

days

of

not

received a customer identification

warranty,

information,

is included

submitting please contact

including

date.

the

Warranty the

Card

and

advanced

generators.

your generator it

it

correctly.

precautions

servicing, contact

is

also

from

to

install

for

in

a separate

factory

the unit's

I~'WESTERBEKE

J Engines & Generators

Customer Identification

MR.

GENERATOR

MAIN

STREET HOMETOWN, Model Expires

OWNER

USA

Ser.#

This

this

your

this

Registry

card

in

serial

and

.

PRODUCT

Product brochures WES'IERBEKE

WESTERBEKE CONTENT OF SUCH SOFIWARE, WARRANTIES THERETO, COMPLETENESS BE UABLE INCURRED

THE

OF

WES'IERBEKE time software WES'IERBEKE provided WES1ERBEKE or other suppliers, be relied the

respective

but

is WES'IERBEKE or to

determine

product

NOTES,

As

this

maintenance engine, CAUTIONS,

NOTE'

A

observed, your

SOFTWARE

software,

and

FURNISHING

span

between printings of WES1ERBEKE product

and

with upon

imperative that appropriate

software

CAUTIONS

manual

critical

An operating

.

CAUTION:

engine.

(tech

data,

parts lists,

catalogs), provided

are

not

within WES'IERBEKE's

CANNOT BE RESPONSIBLE

OR

REPRESENTATIONS

INCLUDING

FOR

ANY

IN CONNECTION

customers

the

unavoidable manuals.

WES'IERBEKE

exclusively

product.

the

accuracy

being

takes

schedules,

information

and

WARNINGS.

can

result

ACCURACY,

THEREOF

It not

the

AND

you

procedure

AND WIlL IN

TYPE

OF

OR

USE

should

existence of earlier

In

summation,

products,

as

the

only supplier consulted

and

currentness

in

WARNINGS

through

and

troubleshooting

will

be

essential

Procedures,

in

the

damage

DAMAGE

WITH

definitive

representatives

by

An

which

manuals,

from

sources

MAKES

WITH

TIMEUNESS

OR

ARISING OUT

OF

SUCH

also

keep

product

whether

must

not

authority

makes

good

question

of

the

customer.

the

operating

.highlighted

explanation

to

note .

if

not

or

destruction

other

than

control.

FOR

THE

NO

RESPECT

NO

EVENT

OR

INJURY

SOFIWARE.

in

mind

the

software from

and

cannot

on

sense

of

be

consulted

the

procedures,

of your

by

NO'IES,

follows:

marine

strictly

of

OR

A

WARNING:

followed,

Engines & Generators

3

can

Procedures,

result

in

personal

which

injury

if

not

or

properly

loss

of

life.

INTRODUCTION

SERIAL

The engine are located time to enter

plate shown

when

parts.

NUMBER

and

on a decal

this

below,

seeking

technical

~~~~~~

LOCATION

generator

information

serial

numbers

on

the generator

on

the

as

this

will provide a quick reference

information and/or ordering repair

and

housing.

illustration of

model

Take

numbers

the

name-

..

NOTE:

A carbon

by

WESTERBEKE.

engine

room.

UNDERSTANDING

The diesel engine closely resembles since the mechanism are

arranged above a closed

the

same general type

diesel

engine

connecting Therefore,

same

preventive

most

important maintenance of Replacement of tin).e

periods contamination (that tem

is

also

the

same

designed specifically for diesel The

diesel engine however, carburetor component function

ORDERING

monoxide

has

the

rods

and

to

a great extent, a diesel

maintep.ance factors the

fuel

specified

essential, Another important factor

brand

of

high

does

in

its

method

and

ignition systems are replaced

the

fuel

of

both.

warning

Affix this

THE

is

same type of

lubricating

fuel,

and

is

injection pump -

decal

DIESEL

essentially

crankcilse;the

as

that of a

are proper ventilation

lubricating

is

a must, and

water,

detergent

differ from the gasoline of

handling

gasoline

system.

as

a gasoline

sediment,

diesel

engines.

PARTS

decal

has

in a visible

ENGINE

the

gasoline

the

same.

The

crankshaft

engine,

valves,

camshaft,

engine

requires

engine.

and

cooling

filter

elements at

frequent

etc.)

in

lubrication oil

and

firing

by

which

been

provided

position

engine,

cylinders

and

The

and

proper

systems.

checking

the

fuel

is

the

engine,

of

fuel.

a single

performs

in

the

is

of

the

pistons,

the

for

sys-

use

of

The

the

The engine serial number can engine block just above the injection serial number flat surface

An identification plate

the engine model and serial

is

stamped

on

the

left side of the

irito

on

the engine

also

be

the

generator generator.

number.

found

stamped

pump.

The

housing

manifold

generator

on

also

displays

into the

the

Whenever

generator serial plate located this

set.

number Parts because the

SPARES

Celtain WESTERBEKE

will See

accessories,

INSTALLATION

Publi.cation installing dealer.

replacement

model

number

information In

addition,

for

each

List).

Insist

will

fit or

same

specifications

AND

spares

assist

you

the

SPARE

see

#43400

generators

number,

as

they

on

the

generator end.

so

we

include a complete part description

part needed (see the

upon

generic

ACCESSORIES

will

be

engine.

in

preparing an inventory of

PARTS

WESTERBEKE'S ACCESSORIES

MANUAL

provides

and

parts are needed,

engine serial

appear

on

the silver

may properly identify

WESTERBEKE packaged

parts are frequently not

as

original equipment.

needed

to

support and

Your

local

page

in

this

detailed information for

is

available at your

always

number,

and

black

You

must

provide your

separately

maintain

WESTERBEKE

spare

manual.

For engine

WESTERBEKE

provide the

and

generator

name-

us

with

generator

and

part

furnished

parts

made

to

your

dealer

parts.

brochure.

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

FUEL

A

CAUTION:

rating

of

harm

to

your

Care

Of

The

Use only clean fuel! your fuel injection pump is very critical; invisible dirt

particles which might pass through the filter can damage these finely finished parts. and keep it clean. The best fuel can unsatisfactory facilities. To assure that the fuel going into the tank for your engine's daily use is clean and pure, the following practice is advisable:

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

metal bowl type filter/water separator between the fuel tank

and the engine.

ENGINE

Use an engine oil regular tion recommended for all operating conditions. Change the engine lube oil and filter after the initial operation and every 100 hours or less after.

of

OIL

CF

Only

use

unleaded

89

or

higher.

Leaded

engine

and

violate

Fuel

Supply

The

clearance

It

is important to

by

careless handling or improper storage

or

synthetic with an API classifica-

and/or CG-4.

An

oil viscosity rating

fuel

will

your

of

the components in

be

rendered

of

fuel.

of

warranty.

with

an

octane

cause

serious

buy

clean fuel,

of

15W-40 is

50

hours

of

break-in

operations there

ENGINE

WESTERBEKE recommends a mixture and chemicals that can corrode internal engine surfaces.

The

to run at proper temperatures the engine to the coolant.

cooling circuit from rust and corrosion.

antifreeze that contains supplemental cooling additives (SCAs') that keep the antifreeze chemically balanced, crucial to long term protection.

The water and antifreeze should poured into the cooling circuit.

NOTE:

antifreeze that is now available.

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

COOLANT

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

COOLANT

of

50% antifreeze

50%

distilled water. Distilled water is free from the

antifreeze performs double duty.

by

It

also lubricates and protects the

Use the new environmentally-friendly, long lasting,

RECOVERY

of

this recovery tank is to allow for engine

of

TANK

coolant and without introducing air into

It

allows the engine

transferring heat away from

Use

a good quality

be

premixed before being

of

-40°F.

A

CAUTION:

engine

oil

additives

to

produce

Do

to

mix.

Each

of

different

properties

not

allow brand

brands

harmful

two

or

more

contains

could

react

to

your

brands

its

own

in

the

engine.

of

additives;

mixture

Engines & Generators

5

GENERATOR

CONTROL

PANELS

DESCRIPTION

This

manually diesel generators engine control

All three following

PREHEAT:

preheating engine oil pressure switch. The

K2

relay.

the

pull

coil.

When

the panel lights, solenoid.

START:

The energizes the starter solenoid While the START begins PREHEAT pressure reaches 5 -

STOP:

providing opens flow To STOP switch noid The stops rotating

NOTE:

gauge last temperature will

switch engages

to

The

the

of

fuel

stop

1he

is

opened,

STOP

When

and

return

OF

SWITCHES

controlled series of WES1ERBEKE marine

is

equipped

panel

and,

optionally,

switches

functions:

The

the

PREHEAT

fire,

STOP power power circuit to

the

to

are momentary contact type

PREHEAT engine for

as

well

gauges

START

the

START

switch should not be released until

toggle

to

the

engine

engine, depress

is

depressed,

and

switch

should be depressed until the generator

the

engine

oil pressure

and

zero

once electrical power is

toggle

easy

as

supplies current

switch

is

and

meters

toggle

switch

is

the

start solenoid. When the engine

switch should be released. The

10

psi.

switch

the

K2

relay.

the

and

1he

the

fuel

flow

is

shut

gauge

oil

pressure

wi1h

toggle switches

at remote panels.

serves

two

starting and bypassing the

PREHEAT

depressed,

and

closes

and

activates the

still depressed, depressing the

is

a normally closed switch

Opening of

fuel

solenoid, stopping the

shuts

STOP

powe~

to

down,

will continue readings

function closes

to

the

the hold coil of

the

down

1he

switch.

feed

to

the engine

the

water temperature

displayed.

restored.

on

and

serve

purposes:

fuel"

solenoid

voltmeter,

the

Kl

relay that

starter.

the

oil

this

switch

engine.

When the

the

fuel

is

stopped.

to

register

1he

sole-

They

fuel

1he

the

EMERGENCY

stop switch is

normally

will

open panel switch is not performing

DESCRIPTION

Coolant

Engine coolant

1750 to

Engine

Oil

pressure

load

but

DC

Voltmeter

Indicates

13Vto

Hourmeter

Registers perform

REMOTE

For remote switches connected serve switch

.

serves WIRING

NOTE:

STARTING/STOPPING

DIAGRAMS

STOP:

The

on

1he

side

of

closed.

When

the

DC

circuit

and

shut the

engine

toggled

maintenance.

it

OF

GAUGES

can

Temperature

(water)

temperature

1950 F (800 to

Oil

Pressure

(psi)

should

1he

amount

14V.

elapsed

scheduled

900 C).

may

fluctuate

range

be~een

the

time

and

maintenance.

PANEL

operation

are

in

the

same

is

in

series

the

same

DIAGRAM

used.

parallel

of

The

with

functions

wi1h

function.

in

PREHEAT

the

GENERATOR

RELEASE

STARTER

PREHEAT

MUST

PRESS

For

additional infonnation on

~

r~)

1ST

~

WESTERSEKE

and

TROUBLESHOOTING

EMERGENCY

the

control

box,

depressed,

to

the

down.

be

battery

is

the

generator

the

as

in

gauge

There

this

manual.

it

control

As

the

used

when

should

depending

35

to

55

is

being charged

used

as a guide

system,

and

gauge panel's

the

gauge

panel's

is

a REM01E

6i

STOP

START

~~

{

,{1ft)

Control

PROCEDURE,

normally

on

psi.

START

switches

panel.

STOP

1

PRESS

2

ND

DC

GAUGES.

indicate

the

generator

should

show

for

when

to

the

same

three

switches The

switch

START/STOP

Panels.

are

and

STOP

and

Refer

WIRING

to:

Engines & Generators

6

PRESTART

Before starting prolonged

• Check the

• Check bowls

• Check and

NOTE:

the plastic coolant and then carefully

radiator.

antifreeze.

radiator.

mixture

way

•

Visually parts, threaded

• Check wiring

• Examine air inlet

•

Be load

INSPECTION

your

layoff,

check

the

engine

high

mark

on

the

fuel

supply

for

contaminants.

the

DC

electrical

battery cable

the

coolant

at

the

manifold.

After

the

engine's cooling

Ensure

If

not,

Replace

to

the

plastic coolant recovery tank

between "add" and "max".

examine

disconnected

connections.

loiui

leads

diagrams.

sure

no

other generator or utility power

lines.

generator

the

following

oil

level.

the

dipstick.

and

examine

system.

connections.

level

in both

initial

running

system

recovery

tank.

remove

that

add

the

for

and

the

radiator

mixture

pressure cap and

unit.

wires,

unattached

Search for

correct connection

outlet for air

PREPARATIONS

set for

the

first

time

or after a

items:

Add oil

Look for loose

to

maintain

the

fuel

filter/separator

Inspect wire connections

the

plastic recovery tank

of

the

generator,

should

be

purged

through

Allow

the

engine

pressure as needed

cap

on

is

completely full

to

fill

then

or

hoses,

any

leaks.

as

specified

flow

obstructions.

is

add antifreeze

to

missing

and

the

to

the the

fill it

connected

level

air

cool

of

to

check

in

FOR

at

in

the

half

the

to

INITIAL

•

Be the system requires, connected incomplete neutral voltage on unbalanced

A

recommended motors, up

to

This unanticipated prevent a cold

START-UP

sure that

neutral

CAUTION:

speed

precaution

in

power systems with a neutral line that

is

properly grounded (or

and

to

the load neutral.

or

open neutral can

When

that

all

be

switched

and,

in

will

operation

engine

that the generator neutral

AC

OFF

cold

prevent

from

starting

loads,

until

the

climates,

damage

of

the

AC

stalling.

ungrounded)

In

single

supply

the

loads.

the

generator,

especially

engine

starts

caused

machinery

phase

wrong

large

has

to

warm

is

properly

systems

it

is

come

by

and

will

as

the

line-to-

up.

an

SIDE

I

'-

RADIATOR

OIL

FILL

TOP

OIL

FILL

Engines & Generators

7

STARTING/STOPPING

PROCEDURE

THE

STARTING

Westerbeke glow

plugs illustration below cylinder. chamber When the The result

This circuitry depressed for while button

NOTE:

PREHEAT switch switch activates the PREHEAT intermittently plugs.

PREHEAT:

panel lights, gauges and meters HEAT following

The so

the

plug

glows

system

is

keeping

is

depressed

The

GLOW

switch should

SYSTEM

diesel

generators

for

both nonnal and cold weather starting. The

shows

a cross-sectional

glow

plug

is

located

that its

tip

is

in the injector nozzle's

glow

plug is energized

red

at the

tip

and

is

a rapid start with

is

common to

designed

the

time specified

the

PREHEAT

START switch will not

is

the

PLUGS

\'

-------

Depress the

chart:

WESTERBEKE

so

that the

to

crank the

depressed.

glow plugs

to

.

~~~~~~

PREHEAT

be

depressed

Temperatu

Abnospherlc

+41

+41°F(+5°C)

+23°F(-5°C)

limit

°F(

+5°C)

of

continuous

Temperatura

or

higher

to

23°F

(-5°C)

or

lower

usa

use

electric starters assisted

view

of

in

the

pre-combustion

by

the

PREHEAT

assists

in

igniting

less

wear

on

the

starter.

diesels. The start

PREHEAT

in

the

button

engine.

energize Depressing in

the

avoid overheating

switch.

will

in

button must be

preheat

engaged,

cylinder head

PRE-COMBUSTION

be

accordance

chart. the

unless

the

PREHEAT

CHAMBER

The voltmeter

activated.

eJPreheat

Preheating

Approx.

10

Approx.

15

Approx.

20

30

seconds

before

one

spray

button,

the

Then,

START

the

so

the

glow

The with

nme seconds seconds seconds

cranking

by

path. fuel.

use

and

PRE-

the

Should depressed for wait longer.

Remote

The remote start panel is the same

rpm.

the

engine not start when

10

to 20 seconds, release both switches

30

seconds; repeat the procedure above

Never

run

the

starter

Starting

start panel except that it has a green gauges. lights

since A.

B.

When starting at a remote location,

when

the generator is running at approximately

This

indicates when the

the

starting of the generator

When

the start/stop panel START engine this LED light will dim. the START for a few closes the oil pressure safety switch that path for The green LED will remain brightly illuminated engine

After released, the generator's starter will not crank unless PREHEAT

supplies voltage

Once proper oil pressure and battery charging light load temperature applying

NOTE:

Depressing the PREHEAT switchfor 10-15 second intervals will help stabilize the engine RPM until the operating temperature to

the

switch is depressed

LED

light will brighten signaling

switch. Continue to hold

seconds to allow oil pressure

12V

is

running.

the

generator

the

engine starts, check

to

the generator and

to

heavy loads.

Some unstable running may occur

engine.

Procedure

PREHEAT

B+

switch is operated

come

reaches

switch

the

LED light will illuminate.

to

the

is

started

to

the

up

to 140-1500 (60-66

the 140 - 1500 F and a load

the

START

for

more

than

as

the

LED

START

K2

START

switch can

may

not be

is

depressed at

and

the

starter

When

to

the

PREHEAT

run relay/fuel

and

the

START

first

because

switch.

the

engine's instruments for

voltage.

allow

the

engine's operating

switch

is

and

preheat

30

seconds.

engine-mounted

light

and

no

the

green

LED

600

be

released

audible.

the

remote

When

the

cranks

the

engine starts

release

the

depressed

to

build

up

which

is

in

the

series

run

solenoid.

while

switch

is

this

switch

Apply a

0

C) before

in

a cold

engine.

is

applied

the

START:

While still depressing

the

START Upon engine starting, release the release the

15

psi. oil pressure protective circuits remain energized

switch. This will engage

PREHEAT

Then

as

long

as

and

continue

12

I 14

~6

\

t::l

\"""

the

PREHEAT START

switch until

the high water

do

not

to

run.

VOLTS

the

oil

temperature

activate,

NOTE:

. A

voltage

when

is

depressed.

"'

switch,

starter

solenoid.

switch.

pressure

the

When

drop

the

preheat switch

depress

Do

not reaches and

low

engine

will

starting:

will

occur

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

STARTING

. Make sure

the prevailing temperature.

OIL section

The battery

drop .

.use a

Temperature!Preheat

STOPPING

1.

Remove allow stabilize

2.

Depress is

3.

Now

.

SAFETY

The engine switches.

without finding

UNDER

!he

lubricating

in

this

manual.

should

be

sufficient

amount of

PROCEDURE

the

AC

electrical load

the

generator to run for three

its

operating temperatures.

the

STOP

completely

release the

stopped.

STOP

SHUTDOWN

is

protected

Should shutdown

and

correcting the

COLD

oil

Check

fully charged

prehea~

chart elsewhere

switch

SWITCHES

by

three automatic shutdown

heading "Engine Stops" in the section

. The following

switches:

of

this manual.

is

a description of these automatic

CONDITIONS

conforms

and

occur,

with

the

ratings for

the

table

in

the

to

minimize

to

aid

in

this

from

the generator

to

hold it until

.

do not attempt

cause.

voltage

starting. See the

section.

five

minutes

the

Refer

TROUBLESHOOTING

ENGINE

and

to

generator

to

restart

to

the

shutdown

Remote

To the circuit. generator comes to a complete stop and the goes

Low

A

low engine's oil gallery. Normally open in a static switch's sensor monitors the engine's oil engine's interrupting the DC voltage to the K2 off

Stopping

stop

the

generator, depress the

normally

out.

Oil

the

closed

The STOP switch must be held

Pressure

oil pressure shutdown switch is located off

oil

pressure fall to 5-10 psi,

engine.

Procedure

B+

path for voltage

Switch

STOP

this

.

switch

to

open

pressure. switch

relay,

the

which

engine's

until

the

green

the

state,

will

thereby

opens

LED

this

Should

open,

shutting

run light

the

Coolant

A high water temperature switch housing. Nonnally closed,

coolant's operating temperature (99°C), will open relay,

195°P (107°C).

Temperature

and

interrupt

thereby shutting off

Switch

this

the

engine.

THERMOSTAT ASSEMBLY

is'

located

switch, should the

reach approximately

the

DC

on

voltage to

Tins

switch

the thermostat

fresh

2100P

the

K2'

resets

water

at

OIL

GALLERY

OIL

PRESSURE

SWITCH

Engine

The generator's engine manual draw wiring event relay

source breaker and restart

Circuit

reset circuit breaker (20 amps

or electrical overload anywhere

or engine wiring will cause the breaker

the

generator will shut down

is terminated.

of

the

Breaker

is

protected

If

this should

problem. After repairing

the

generator.

by

in

and

occur,

OIL

WIRED

.

AUDIBLE

an

engine

DC).

Excessive

the

instrument panel

to

the

voltage

check

and

the

fault,

PRESSURE

FOR

mounted

current

trip.

In

to

the

repair the

reset the

SWITCH

OPTIONAL

ALARM

this

K2

Engines

& Generators

9

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine hour of test operations at assembly procedures operated life of your engine operated

Breaking-in a piston and

scored,

break-in period.

Your

conditioning operation to Perform

following:

Start

section. water

reach

AFTER

Once the generator

tion

between

properly,

and

rings

smoky

operation indicate that the cylinder

which

new

engine requires approximately 50

maximize

this

the

engine according

Run

pump,

its

full

START-UP

and

then

20%

serviced during

new

to

the conditioning

the oil pressure, battery charging)

rated speed

encourage a fast

and

has

were

a break-in

is

dependent upon

engine basically

the cylinder

is

caused

performance and service life of the engine.

engine

has

60%

experienced a minimum of one

the

factory to

followed and that

time

its

walls.

by

overloading the engine during the

to

break in each

carefully,

to

the

while

checking that all systems

are

signs

been started, check for proper opera-

warm-up.

of

full

load for the

make

sure accurate

the

engine

is

required. The service

how

the engine

initial hours of

involves

Excessive oil consumption

keeping in

STARTING

of

moving

an

overload.

Run

seating the

hours

PROCEDURE

are

the

first

is

use.

walls

are

of initial

part in order

mind

the

functioning.

generator

10

hours.

(raw

After the load can be increased periodically

Avoid smoky Monitor it within the generators' rating.

1800 control of the generators engine break-in current drawn from the generator.

NOTE:

current amperage amperage.

GENERATOR

Once

governor adjustments required for engine speed (hertz) during

the

period (see ENGINE

ENGINE

also

ment

first

10

hours

of

the generators operation, the

to

the full-load rated output, then

vary

the load.

overload at all times. An ovefload

exhaust with reduced output voltage and

the

current being drawn from the generator and keep

Since the generator operates at

rpm

to

produce 60 hertz, or

Be

aware

of

motor starting loads and

drawn

required for starting motors.

draw

can

be 3

to

5 times normal running

See

GENERATOR INFORMATION

at

1500

is

signaled by a

frequency.

to

produce 50 hertz,

is

governed

the

This

high

starting

in

this

by

the

manual.

ADJUSTMENTS

the generator has been placed in operation, there

engine's break-in period (first 50 hours) or after this

SPEED (HERTZ) ADJUSTMENT under

ADJUSTMENTS. A no-load voltage adjustment

be required in conjunction with the engine's speed adjust-

(see

GENERATOR

INFORMATION).

may

be

CHECK

Follow

• Check that

• Record the hourmeter reading in your

•

• Check the oil level (dipstick).

• Check the coolant level in the coolant

• Check your

• Check the starting batteries (weekly).

• Check the

CHECK

• Check

•

LIST

this

checklist each

all

generator circuit breakers

the

off position before starting.

to

the

maintenance schedule).

Visually

blow-back sounds. Confirm

When When the engine When

inspect the engine

fuel

supply.

drive

belt

WITH

THE

ENGINE

for

abnormal noise

exhaust

the the engine

engine

smoke:

is is is

for

cold - White warm overloaded -

day

before starting your generator.

for

fuel,

oil,

wear and proper tension (weekly).

RUNNING.

such

as

knocking, vibration

Smoke.

- almost

Smokeless.

some

THE

(power

log

(engine hours relate

or water

recovery

Black

DAILY

panel)

leaks.

tank.

Smoke.

are

and

ROUTINE

NOTE:

Some

This

condition should abate as normal operating temperature

is

reached and loads

in

A

CAUTION:

periods

generator.

STOPPING

Remove the generator temperature, then generator safety precaution.

unstable running may occur

are

applied.

Do

not

operate

of

time

without a load

THE

GENERATOR

the

AC

loads

from

the generator

to

run for

3-5

minutes to stabilize the operating

turn the

is

shutdown, close

key

to

down

in

a cold

the

generator

being

placed

the

off position. Once the

all

circuit breakers

one

for

on

at a time.

engine.

long

the

Allow

as

a

Engines & Generators

10

A

WARNING:

running. use

the

servicing

NOTE:

Many

difficult

and

Wear

correct

any

of

the

may

MAINTENANCE

Never

attempt

the

proper

tools

for

the

engine's

following maintenance jobs

require

the

safety

each

DC

expert

to

perform

equipment

job.

Disconnect

electrical

krwwledge

SCHEDULE

any

such

equipment.

are

of a service

service

the

as

goggles

battery

while

and

terminals

simple but others

mechanic.

the

gloves,

engine

when

are

more

is

and

SCHEDULED MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visuallnspeclion

Fuel

Starting

Engine

Generator

Fuel/Water Electronic

(If

applicable)

Exhaust

Engine

Oil

Level

Belts

Filter

Batteries

011

System

Hoses

Separator

Level

(and

filter)

Separator

Governor

of

Engine

Control

CHECK

EACH

DAY

0 0

0

weekly

0

weekly

HOURS

OF

OPERATION

50

100

250

NOTE:

Please will

inhibit

cool.

keep

the

and

oil

remain

0 0 0

500

engine

engine's

750

surface

ability

0 0

1000

clean.

to

0 0 0 0 0 0 0

0 0 0 0

0

0 0 0

0 0

1250

Dirt

0

EXPLANATION

Diesel

No.2

Check

for

water

if

necessary).

Oil

level

should

dipstick. Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

fuel,

and

electrical

Check

for

loose

Initial

change

Every

50

operating

and

make

sure

excessive Initial

change Check

with

for Change Check

required as NOTE:

adjustment

Initial the

secure.

properly

vibration

Hose

spongy.

corrosion.

engine

both

that

no

chafing.

additional

every

and

(hertz)

needed.

These

check

system

Ensure

supported

or

should

Check

MAINTENANCE

rating

of

and

dirt

indicate

tank;

if

needed.

proper

tension

if

needed.

Check

oil

and

connections.

belt

tension.

at

50

hrs,

hours

connections

oil & filter

every

100

AC

connections

See

GENERATOR

information.

200

hours.

or

adjust

the

and

the

adjustment

during

or

at

50

hrs.,

and

that

connections

that

the

and

chaffing.

be

hard & tight.

and

tighten

OF

SCHEDULED

45

cetane

or

in

fuel

(drain/replace

between

if

empty,

(3/8"

to

belt

edges

water

leaks.

Keep

then

change

check

electrolyte

are

very

change

at

hours.

are

clean

no-load

regulator

are

not a warrantable

after

the

unit's

then

every

muffler

and

not

being

Replace

all

hose

higher.

MAX.

and

check

at

manifold.

1/2"

deflection)

for

wear.

Inspect

wiring

bolts & nuts

every

250

levels

tight.

Clean

50

hrs.,

then

and

secure

SECTION

speed

in

the

board

adjustment

break-in.

250

hrs.

are

tight

and

piping

are

affected

by

if

soft

clamps.

filter

LOW

on

tight.

hrs.

off

panel,

Inspect

or

Engines & Generators

11

NOTE:

engine

Use

hours

MAINTENANCE

the

engine

by

running

hour meter

time.

gauge

SCHEDULE

to

log

your

engine

hours or

record

your

SCHEDULED MAINTENANCE

Coolant

System

Electric

Fuel

(ift

Pump DC

Alternator

*Fuellnjectors

*Starter

*Preheat

Motor

Circuit

*Englne

Cylinder

Compression

*Torque

Cylinder

Hold-down

*Adjust

*Radlator

the

bolts

Valve

Head

Clearances

CHECK

EACH

DAY

HOURS

OF

OPERATION

100

250

500

750

1000

1250

50

D D

D D D D D D

D D D

D

D D

D

EXPLANATION

Drain,

flush,

appropriate Periodically

Check

DC

charge

bracket;

tighten

Check

and

adjust

spray

condition

Check

solenoid

and

lubricate.

pinion

drive.

Check

operation

clean

glow

plugs;

Check

compression

(see

ENGINE

At

first

50

hours,

(see

ENGINE

Adjust

Valve

(see

ENGINE

Remove, tested.

have

OF

cooling mix.

wiring

alternator.

connections.

opening

ENGINE

for

and

lubricate

solenoid.

resistance

and

every

500

SCHEDULED

system

connections

ADJUSTMENTS).

cleaned

MAINTENANCE

and

refill

antifreeze check

the

from

electrical

injection

(see

and

motor

Clean

of

preheat

check

pressure

ADJUSTMENTS).

then

ADJUSTMENTS).

Clearances

ADJUSTMENTS).

professionally

with

Check

pressure

corrosion.

the

starter

Remove

(4-6

ohms).

timing

hours

and

..

mounting

and

Remove

motor

and

pressure

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

12

FUEL

SYSTEM

DIESEL-

Use Do not

FUEL

The

manufactured and they must receive clean diesel fuel, free from water must pass through at least two separator clean, and change these filters according schedule in this manual.

FUEL

A primary installed between the water and other contaminants from the be carried

The owner/operator fuel reaching the engine's impurities. maintaining a proper fuel filter/water separator between the fuel tank and the generator/engine.

. a

FUEL

The fuel injection pump

the diesel engine, requiring the utmost caution in handling. The and the owner-operator it. authorized attempt

shims

The only adjustment the servicing mechanic should the fuel injection pump is the adjustment for running speed

ENGINE APJUSTMENTS).

FUEL

Periodically check the fuel and make are tight and

pump's mounting bolts should be clean

the mounting bolt

When energized purge air from the

of

FUEL

No.2

diesel

fuel

with

a cetane rating of

use

kerosene or home heating

FILTERS

fuel

injection pump and the

and

dirt.

To

ensure this

fuel

and

the engine's spin-on

WATER

10

micron

INJECTION

fuel

If

it requires servicing, remove it and

to

with the injection

LIFT

fuel

as

SEPARATOR

fuel

filter of the water separating type must be

fuel

tank and the,engine

to

the fuel system on the

is

responsible

injectlQn

This

process

filter

be

is

accomvij.shed

used.

PUMP

is

the most important component of

injection pump

fuel

injection pump service

disassemble and repair

(see

has

been thoroughly bench-tested

is

cautioned not

pump,

leave on

IDLE

SPEED ADJUSTMENT under

PUMP

connections

sure

that

no

secure.

to

thru

fuel

the engine

leakage

The DC ground

ensure proper

the preheat

is

system and

running.

45

or

fuel.

fuel

injectors are precisely

flow

of clean fuel, the

filters, a fuel

fuel

filter.

fuel

engine.

for

making

equipment

by

Westerbeke

to take

facility.

it.

Do

not

to

present

and

connection

and

pump

circuit,

the

provide a continuous

water

VIsually

to

the maintenance

to

remove

before they can

certain the

is

free

installing and

recommends

attempt

it

to

Do not

send

engine.

the

engines

aud

out

that

the

at one of the

well

secured by

operation.

fuel

lift

higher.

inspect,

of

to

service

an

the timing

make

of

the

pump

fittings

pump

flow

fuel

to

will

ENGINE

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

Changing/cleaning

1. Shut off the fuel

2.

3. Remove

4.

FUEL

FILTER

after the

MAINTENANCE

the

supply.

Unscrew the retainer ring that holds the filter bowl housing and allow the bowl to come housing,

and

replace

Replace the sealing

to the housing. Thread the retainer ring

so

as

not

to

cross thread. When retainer contacts the

"0"

ring, tighten

supply and run the engine to inspect for leaks.

THE

O-RING ONLY REPLACES SIGNS

GASKET

NEEDS

IF

OF

AGING.

TO IT

the

"0"

114 -112

BE

SHOWS"

SCHEDULE.

filter

element

filter element and clean the

ring and reassemble the bowl

turns by hand. Open the

first

away

on

FUEL FILTER

bowl

50 hours

from

the

carefully

for

to

the

bowl.

fuel

LIGHTLY

WITH

CLEAN

WIPE

FUEL

INLET

To in-line fuel filter connected filter should

FUEL

ensure clean

be

FILTER

fuel

into the fuel lift

to

the

replaced every 250

fuel

hours

pump,

lift

there

is

a small

pump

elbow.

of operation.

This

Engines & Generators

13

FUEL

LIFT

PUMP

COOLING

CIRCUIT

DESCRIPTION

Westerbeke diesel engines are designed and equipped fresh water cooling. Heat produced in the engine combustion and friction which circulates throughout the engine. This circulating fresh water coolant cools the engine block and its internal moving parts and the engine oil.

Fresh water coolant is pumped through the engine by a circulating pump, absorbing heat from the engine. coolant then passes through the thermostat into where it is cooled, and returned to the engine block suction side

FRESH

NOTE:

recommended antifreeze and water mixture to be used as the

fresh water coolant.

of

WATER

Refer to

the circulating pump.

ENGINE

is

transferred

COOLING

CIRCUIT

COOlANT

to

fresh water coolant

section

for

by

the

for

The

radiator

via

the

When the engine is started cold, external coolant vented by the closed thennostat (although some coolant is

bypassed around the thermostat to prevent the engine from

As

overheating). ally opens, allowing full flow unrestricted

Coolant

A coolant recovery and contraction during engine operation, without any significant loss the cooling system. This the engine manifold level and should be easily accessible.

CHANGING

The engine's coolant must

MAINTENANCE

become contaminated, it

A

CAUTION:

critical; a substantial traced

Drain the engine coolant the

manifold and opening the manifold pressure cap. Flush

the

system with fresh water, then start the refill process.

the engine warms

to

the external portion

Recovery

Tank

tank

of

coolant and without introducing air into

COOLANT

SCHEDULE.

Proper

back

to

cooling

allows for engine coolant expansion

tank should be located at or above

be

can

cooling

number

system

by

up,

the thermostat gradu-

of

the engine's coolant to

of

the cooling system.

changed according

If

the coolant

lead to overheating problems.

system

of

engine

corrosion.

removing the drain plug under

flow

is

flow

to

the

is

allowed

maintenance

failures

can

pre-

flow

to

is be

A

WARNING:

Wear

protective

Refilling

Re-install the engine block drain plug. Close the drain

pluglpetcock on the radiator. Pre-mix your antifreeze and add it

to

Start the generator and continue to add the antifreeze mix air As opening

When the remote recovery

Inspect the system for any leaks. the system recovery tank should be drawn into the engines cooling system. level between the add and max marks.

the

the radiator until the system is visibly near full.

is

expelled. Observe

the temperature nears 180°F. The thermostat should be

and

all the air

pressure cap, now add more antifreeze mixture to the

to

Add enough coolant to the recovery

Beware

of

the

hot

engine

coolant.

gloves.

Antifreeze

flow

through the radiator observed.

is

expelled, top

tank

cool down. Coolant in the plastic coolant •

Coolant

the

engine operating temperature.

until half full.

System

off

the radiator and install

Stop the engine and allow

tank

to place the

as

Engines & Generators

14

TO

COOLANT

;

RECOVERY

FROM RECOVERY

NOTE:

pressure cap. Ensure that the

are in good condition and

TANK

COOLANT

TANK

COOLANT

Periodically check the condition

and

closes tightly. Carry a spare

ENGINE

COOLANT

RETRACTION

upper

check

that the vacuum valve opens

cap.~

EXPANSION

of

the radiator

and

lower rubber seals

__

COOLING

CIRCUIT

THERMOSTAT

A thermostat, located near the the engine's coolant temperature, as the coolant continuously flows through the engine's engine is first started and the thermostat is closed, engine coolant by passes the thermostat to provide proper circulation and cooling via a by-pass ing pump and below the thermostat. reaches operating temperature,

opens to allow coolant to flow through it. accessible and can needed. Carry a spare

To

Replace

Remove the cap screws housing as shown. When installing the new thermostat and gasket, apply a thin coat

gasket before pressing cap screws.

Roo the engine and check there are no leaks at the housing.

be

checked. cleaned

thermostat

the

Thermostat

and

it

front

of

the engine, controls

closed

hose

of

into

for

cooling system

located between the circulat-

As the engine coolant

the

thermostat gradually

The

or

replaced

and housing gasket.

disassemble the thermostat

sealant

place.

normal

on

both sides

Do

not over-tighten the

temperatures and that

..

When the

thermostat is

as

of

the

RUBBER

.

AIR

INTAKE

There is a replaceable

inspected every 100 hours quently filter can

pressed ment/filter

NOTE:

T9 continuous volume and

black exhaust smoke

intake.

AIR

INTAKE

SILENCER·

FILTER/SILENCER

in

dusty operating conditions. Contaminants in the

be

shaken

air. However,

must

be

operate efficiently a diesel

paper

intake filter that should

of

unit

operation or more fre-

out

or

removed

if

this

can

replaced.

of

clean air. Hard starting, an erratic idle,

are

with the aid

not be accomplished the ele-

~ngine

must intake a

all symptoms

~--AIR

of

be

of

com-

a restricted air

SCREEN

.

FILTER

~_.-.,-.rfiJ

III

II

,

COOLANT TEMPERATURE. SENDER

GASKET

SEAL

WITH

HI-TACK

15

ENGINE

LUBRICATING

OIL

LUBRICATION

OIL SENDOR

OIL

PRESSURE

SWITCH

ENGINE

1.

OIL

Draining the Oil Sump. Discharge the

sump

while

the

replace

DIAGRAM

PRESSURE

-~-:ItlIIIIDoii""

CHANGE

drain hose (attached

engine

i~

still

warm.

the

hose

in

its bracket,

securely.

NOTE:

Thread

size

the

to

the

front of the

Drain

the

and

replace the end

oil

drain

used

hose

oil

through

engine)

oil

completely,

cap

capped end

is

2.

Replacing the Oil Filter. When

filter,

you

may

find

it helpful and cleaner

in

the upper and lower portion of

from

oil to should be helpful

NOTE:

filter

Place filter

(Oil cooling old

it into a container before

lessen spillage. A small style automotive

in

removing the old

Do

not punch this hole without first

to

make

certain it can

some

paper towels

when

unscrewing it to catch

or

any

other fluid on the engine

ability.

Please keep your

oil

filter

as

it

is

removed

be

and

sealing gasket came off with the old rubber sealing gasket remains sealed against block,

gently

remove it. .

.

removing

the

removing

removed!

a plastic

any

reduces

engine

to

make

oil

1!!!II'iZ!1oI-IJ--1"-

old

oil

bag

oil

clean.)

sure

filter.

,

to

filter

filter.

left

SEALING

COAT

the

used

oil

punch a hole

to

drain

it.

Thls

filter

wrench

loosening

around

the

in

the

engine's

Inspect

that

the

rubber

If

this

the

engine

GASKET

WITH

WHEN

INSTALLING

the

helps

the

filter.

the

CLEAN

OIL

'

NOTE:

During this

engine,

procedure,

have a suitable

7/i1l!tl'!'il~

tray

under

airiin-11/16"

:SOCKET

1W~NPT-

fuel and

the

oil

may

engine.

spill

When gasket's sealing surface apply on filter

from

the

NOTE:

, material standards dr diameters

generic parts.

rWl

that

3. Filling the Oil Sump.

cap After checking

around

stop lube the

Engines & Generators

installing the new

a thin coat

the

new

nipple,

Generic

of

oil

filter.

and then tighten the

filters

parts might be entirely

Immediately after

the

engine

to

make

there

are

no oil leaks around

on

the

top

of

the engine or

refilling,

the

oil

dipstick,

run the engine for a

the

oil pressure. Make

the

new

oil filter or from

engine.

Then check

dipstick. Fill to, but not

should the engine

oil

filter

on

the engine block

clean engine

Screw the

are

not

recommended,

an

oil filter

sure

the

Add

new

the

require

element,

oil

to

filter

onto

filter

of

important

different

change

oil

pressure

the

new

oil

through

few

sure

there

the

oil quantity over

the

wipe

free

the

rubber gasket

the

threaded

firmly

by

as

items

from

genuine

and oil

is

oil

filter.

the

side

moments

is

no

drain

system,

of

oil

high

mark

additional

the

filter

of

oil

and

oil

hand.

the

on

fill,

normal and

oil

filler

oil

fill..

while

leakage

and

with

the

on

oil.

16

INSTALLATION

This

popular

filter

from

an

engine compartment.

NOTE:

manual for instructions

APPLY A THIN INSTAlliNG TIGHTEN CONTACTS

the

Refer

COAT

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

accessory

engine

to

the

ENGINE OIL CHANGE page

OF

CLEAN

THREAO

3/4

is

used

to a more

on

OIL

TO

THE

KIT

TURN

AFTER

REMOTE

to

relocate

convenient location

removing

ON,

O-RING

THEN

THE

O-RING

the

WHEN

HAND

the

oil

engine's

filter.

OIL

oil

such

in

this

FILTER

To

install,

WESTERBEKE'S remote

as

install Contact

NOTE:

incorrect installation

A

correct/yo by-pass from

failure. immedialety

(OPTIONAL)

simply

remove

this

kit

with

your

WESTERBEKE

Westerbeke

CAUTION:

If

the

oil

valve

in

reaching

If

there

the

is

and

the

engine

oil

filter kit

the

oil

filter

facing

dealer for

is

not responsible for

of

the

Renwte

It

is

vital

to

install

flows

in

the

filter

assembly

engine

causing

;'0

oil

pressure

check

the

hose

oil

filter

and

as

shown.

down

as

more

engine

Oil

Filter.

the

oil

lines

reverse

direction,

will

prevent

an

internal

reading,

shutdown

connections

FASTEN

SECURELY

(SCREWS

V

thread

on

Always

illustrated.

information.

failure

due

the

oil

engine

TO A BULKHEAD

ARE

OWNER

SUPPLIED)

to

NOTE

ON

THE

REMOVED

,

Will

THE

OUT

CONNECTION

MUST

ATTACH CONNECTION REMOTE

OIL

AT

FILTER.

THE

"IN"

AND

ADAPTER

FOR

INSTAlLATION

BE

RECONNECTED

HOSE

TO

THE

IN

THE

"OUT"

WHEN

MARKINGS

THE

HOSES

SO

THEY

CORRECtlY.

ARE

APPLY A THIN TER

GASKET

FIlTER

CONTACTS

ADDITIONAL

COAT

WHEN

THE

3/4

TURN.

OF

CLEAN

BASE,

OIL

TIGHTEN

INSTALLING.

TO

THE

AFTER

THE

IT

AN

FIL-

Engines & Generators

17

DESCRIPTION

STARTER

MOTOR

The starter high-speed internal-reduction starter. The pinion shaft is separate pinion shaft. A reduction gear is installed between the motor shaft exposed outside the starter smoothly-without becoming fouled with dust motor shaft lever mechanism, switch and overrunning clutch inner circuit are identical

is

a new

type,

small, light-weight and

from

the motor shaft; the pinion slides only on

and

a pinion shaft. The pinion sliding part

so

that the pinion may slide

is

supported

to

TERMINALS

MOTOR

conventional ones.

--~

at

both ends

is

not

and

grease. The

on

ball bearings. The

SOLENOID

called a

the

TYPICAL STARTER

REFER DIAGRAM

MOTOR

TO

THE

IN

WIRING

THIS

MANUAL

TROUBLESHOOTING

A

WARNING:

procedures Sparks

could

must

cause

The

not

be

an

following

used

with

explosion

emergency

gasoline

and

fire.

starting

engines.

SOLENOID

r-...----(M)

IGNITION

TERMINAL

To

test the ignition circuit, locate the ignition(s) terminal (it

the

is one of circuit).

from that ignition terminal

terminal

If

the starter cranks, the fault lies with the ignition

circuit.

If

the solenoid clicks

motor

small terminal studs

Use a screwdriver, don't touch the blade,

on

the solenoid.

but

is

probably faulty.

and

is wired

to

the positive battery connection

nothing happens, the

to

the ignition

to

starter

~

SOLENOID

TERMINAL

jump

Prior

to

testing, make certain the ships batteries are at full

charge

and

that the starting system wiring connections (terminals) are clean the ground wire connections

To

check

the seconds, never more than hand along the wires that indicate resistance. Repair or replace

Using a multimeter, test terminal stud on the start solenoid (ground).

If

you read 12 volts, the starter is faulty.

and

tight.

Pay particular attention

on

the engine block.

wiring, try cranking the starter for a

10

seconds at a time, then run your

and

terminals looking for warm spots

the

voltage between the positive

and

the

few

any

trouble spots.

engine block

to

IGNITION

TERMINAL

~

If

nothing happens current.. Check the battery isolation switch and inspect the wiring connections. it defective.

A

WARNING:

fly

when

jumping

space

is

free gasoline, materials

and

stored

at

all, the solenoid is

is

also possible that the solenoid is

There

terminals.

of

potentially

that

there

nearby.

will

be explosive

are

arching

Be

certain

NO

flammable

not

and

sparks

the

engine

fumes,

solvents

getting

will

especially

or

Engines & Generators

18

STARTER

MOTOR

· A

WARNING:

,

position

!

the

,

other

yourself

engine

crew

In

members

...

'iGNITION

TERMINAL

Test

again

by Screwdriver screwdriver blade would

blade finnly between the

cause a

When safely

case

jumping

to

touch

short.

perfonning

away

the

engine

of

the

two

the

these

procedures,

from

the

moving

starts-up.

Also

danger.

~-.:----(M)

large tenninal

studs.

solenoid

or

studs.

Do

starter

parts

wam

TERMINAL

Hold

not

allow

casing,

of

the

this

EMERGENCY

Corrosion

can

cause

time

but not

will

need

is

however,

It starter lightly with a small

With

the

starter/solenoid casing

START

to

the starter brushes and/or the solenoid contacts

the

sporadic problem of the engine starting one

another.

to

be rebuilt.

battery switch off

If

corrosion is the problem, the starter

sometimes possible

as

to

get started by taping the

hammer.

and

no ignition,. tap lightly on the

shown, then try

to

start the engine .

TAP

\

.

INDICATED

LIGHTLY

WHERE

A

WARNING:

starting

the

If

the

if

the

current

screwdriver.

starter starter

There

should

be

spins,

the

solenoid

fails to spin,

will

be

arching

nowlng

the

motor is probably faulty.

is

faulty.

thru

as

the

full

blade

of

.tt no arching occurred, there is no juice reaching the

solenoid.

NOTE:

In

the

that

engages

using

a screwdriver

will

run

pre-engaged

Starter motors

the

motor without engaging

are

either inertia

model,

the

starter motor

to

bypass

solenoid

to

the

flywheel

the

solenoid

the

type

or

also

moves

on

flywheel.

pre-engaged.

an

arm

of

the

engine.

such

a starter

If

that

fails,

turn the battery switch on member with contact the starter will need

turn

the

hammer.,

to

the ignition

start the

This

may

engine.

to

be repaired.

on

When

SERVICE

WESTERBEKE serviced center,

If

certified USCG dealer.

TO

1.

2.

3.

4.

5.

or rebuilt at

replacing

for

standards.

REMOVE

Disconnect the negative battery

If

necessary,

to

the

starter

Label

and

allow

wires Remove Remove

starter obstructions,

uses

the

starter

marine

FOR

remove motor.

disconnect

to

the

starter

the starter

will have

a standard starter motor which can be

any

starter motor automotive service

motor,

use.

Automotive starters

If

in

doubt,

SERVICE

any

the

touch,

tape over the terminals). mounting from

to

be turned

and

have a crew and off rapidly loosen the brushes and

you

make certain the new motor

Gontact

cable.

components

wiring

from

bolts.

the

engine.

to

a different angle

as

you tap

allow

reach a repair

do

your WESTERBEKE

to

gain full

the

In

some cases the

not meet

starter.

facility,

(Do

to

again

is

access

not

clear

Engines & Generators

19

The

following

ENGINE

troubleshooting table describes certain

TROUBLESHOOTING

problems relating to engine service, the probable causes of the

problems,

and

the

recommendations to overcome these

problems.

Note:

manual of

the

The

engine s electrical system is protected

reset

circuit breaker located on a bracket at

engine.

by

a 20

the

amp

rear

Problem

PREHEAT no fuel

START engagement.

fuel

switch

panel

indications;

solenoid

SWITCH

START

switch

indications

solenoid

Generator start,

Engine Battery

Battery

fuel

can't

runs

not

engine

solenoid

or

OK;

not

be down.

charging

depressed:

electrical

fuel

DEPRESSED,

is

depressed;

starter

solenoid

functioning.

cranks,

but

energized.

stopped.

pump

no

panel

OK

does

starter

not

1.

Battery Emergency

2.

3.

20-Amp

4.

K2

relay

5.

loose

1.

Connection

2.

Faulty Faulty

3.

4.

loose low

5.

6.

Kl

relay.

1.

Poor

2.

Defective

1.

Faulty

2.

Preheat Faulty

1. Oil

1.

High

2.

3. low

4.

Poor

5.

DC

1.

2.

Alternator

Probable

Switch

stop

circuit

battery

connections.

to

switch. solenoid.

battery

battery.

connections

fuel

solenoid.

fueling

system.

solenoid

DC

alternator.

Pressure

switch.

resistance

battery

connections.

alternator

charge

not

circuit

drive.

Cause

not

on.

switch

off.

breaker

tripped.

solenoid

faulty.

connections.

to

fuel

solenoid.

faulty.

leak

to

ground.

leak.

charging.

faulty.

1.

Check

2.

Check

2.

Reset

circuit Check

3.

4.

Check engine

1.

Check Check

2.

Check

3.

4.

Check

5.

Check

6.

Check

1.

Check

2.

Check

fuel

1.

Check

la.

Switch

1

b.

Replace

le.

Check

1

d.

Change

2.

Check Remove

1. Observe

1. is

Check

2.

lines.

after

Check

3.

Check

4.

corrosion. Check

5.

DC

Perform

1.

DC

Check

2.

for are

Verlflcation/Remedy

switch

and/or

emergency

breaker;

if

and

check

K2

relay.

(+)

connection

ground

stud.

connection. switch

with

that

12

volts

battery

connections.

battery

charge

K1

relay.

connections. that

12

run

not

ELECTRICAL

loose

present

volts

solenoid.

that

fuel

valves

to

combine

batteries.

fuel

lift

pump.

inlet

fuel

solenoid.

"R"

connection

if

gauges

running.

Test

wiring.

Insert

Do

not

start

short

is

located.

all

wires

cable

connections

connections,

D.C.

voltage

drive

belt

connections.

at

the

battery

connections.

stop

switch

position.

breaker

trips

again,

check

circuit

for

shorts

to

starter

battery

present

are

open. and

at

alternator,

panel

lights

oil

pressure

Remove

at

battery

belt

of

Alternator

Check

terminal.

solenoid

at

start

(0 -.25

rise

tension.

generator

output

Check

ohmmeter.

are

state.

are

house

filter.

and

the

sensitive

engine.

for

temperature

check

SYSTEM/ALTERNATOR.

check

SYSTEM/ALTERNATOR

tension.

Exc.

preheat

to

ground.

and

cable

connections.

the

solenoid

the

(+)

connection

batteries.

repair

are

activated

switch.

amp)

connections

to

locate

for

loose

test

charging

in

should

voltmeter.

solenoid

(-)

connection

connection.

on

alternator.

when

engine

meter

in

battery

and

replace

the

fault.

connections,

alternator.

this

turn

circuit.

manual.

freely.

Ensure

See

Check

12

to

the

See

volts

Engines & Generators

20

ENGINE

TROUBLESHOOTING

Generator

Generator Low

oil

pressure.

Exhaust

smoking

Engine

starts,

Engine

starts,

Problem

engine

stops.

engine

overheats/shuts

engine

shuts

problems

runs

and

runs

at

down,

shuts

idle

down.

down

1.

Fuel

2.

Switches or

disconnected.

3.

Fuel 20

Amp

4.

5.

Exhaust

6.

Water

7.

Air

intake

1.

Coolant

1.

Loss

Oil

pressure

2.

1.

Blue

2.

White

3.

Black

Oil

1.

2.

Water

1.

Electronic (optional

Probable

feed

pump

and/or

starvation.

circuit

system

in

fuel.

obstruction.

not

circulating.

of

oil.

switch.

smoke.

pressure

switch.

temperature

governor

system)

Cause

strainer

wiring

breaker

is

restricted.

switch.

system

is

dirty.

loose

tripping.

faulty

VerificationJRemedy

1.

Clean

strainer

2.

Inspect

wiring

Inspect

switches

3.

Check

fuel

supply,

4.

Check

for Ensure cause

5.

Check

6.

Pump bleed

Check

7.

1.

Thermostat -remove

Replace

1a.

Loss

for

1b.

Broken

1

c.

Air

bleed

1.

Check

oil Replace

2.

1.

Incorrect

1a.

Crankcase

through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel insufficient exhaust

3b.

Improperly

3c.

Lack ventilation.

3d.

Overload. Check

1. Check

2. Check

1.

high

breaker

tripping.

for

blockage

water

from

fuel

system.

air

intake

thermostat.

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add

dipstick,

drain

hose

oil

pressure

grade

is

overfilled

the

exhaust).

is

running

injector

grade

burn

incomplete

air

system;

timed

of

air -check

oil

pressure

water

temperature

governor

(32

KW

only).

for

short

circuits

and

for

proper

fuel

valves,

DC

amperage

is

not

overly

or

collapsed

fuel

tank(s);

filter

cartridge.

and

hoses,

belts -tighten/replace.

run

engine

coolant

as

needed.

look

for

oil

connection.

switch.

of

engine

oil.

with

cold.

or

incorrect

of

fuel.

due

proper

check

injectors

air

switch.

system

to

combustion

air

intake.).

intake

switch.

components.

for

operation.

fuel

feed

draw

during

sensitive

muffler.

change

test

in

hot

hose

and

open

leaks

at

oil

engine

oil

injector

timing.

high

back

or

valves

and

air

loose

connections.

strainer.

operation.

to

heat

filters

water.

clamps,

the

pressure

filter

and

(oil

is

pressure

(Check

or

poor

filter.

Check

which

would

and

drain

plug,

cap

to

at

blowing

out

in

exhaust

for

restrictions

compression.

for

proper

etc.

or

in

Engines & Generators

21

ENGINE

NOTE:

WESTERBEKE recommends ments be performed by a competent engine mechanic. The information below is provived to assist the mechanic.

ADJUSTMENTS

that

the following

enginE!

adjust~

DRIVE

For

equipped with belt guards that cover over the belt(s) front guard is advised that proper inspection, service, and required.

Excessive drive belt tension can cause rapid wear

and reduce the service life A slack belt or the presence

slipping, resulting in high operating temperatures. The drive belt is properly adjusted

deflected inch (12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span belt. A spare belt or belts should always be carried on board.

Adjusting

1.

2. Loosen the pivot belt that holds the idler sheave and

3.

4.

S. Tighten the pivot bolt and

6. Replace the guard. Operate the generator for about 5

7. Remove the guard and recheck the belt tension.

8. Replace the guard.

BELT

ADJUSTMENT

your safety, WESTERBEKE generator models come .

of

the engine. ("Out

NOT installed for that purpose.) Operators are

no

less than 3/8 inch (lOmm) and no more than lI2

A

WARNING:

drive

belt's

Remove the belt guard.

loosen the adjusting bolt. With the belt loose, inspect for wear, cracks and frayed

edges. Pivot the idler sheave to the left

loosen or tighten.

minutes and then shut the generator down.

tension

Belt

Never

while

Tension

(FAN

BELT)

of

sight - out

of

the fresh water pump's bearing.

of

oil on the belt can cause belt

attempt

the

the adjusting bolt.

if

the belt can be

to

check

engine

or

right

of

mind." The belt

maintenance is

of

or

adjust

is

in

operation.

as

required, to

PIVOT

on

the belt

of

the

BOLT

the

TORQUING

After the initial break-in period (approximately 50 hours) and every re-torqued.

Tighten the cylinder head bolts according to the sequence

shown. Before applying the specified torque to the bolt, 114

to

procedure according to the numbered sequence shown in the

illustration

Bolts Bolts Rockershaft Hold Down Bolts - 12mm socket

FUEL

In case

injectors checked and overhauled by an authorized fuel injection service center. loss

of in injector faults. Since fuel injectors must clean room environment, injector as a spare should a problem occur.

Before removing the old injector, clean the area around the

of

base falling down into the injector hole. out easily and is held the injector side-to-side with the aid free it, and then lift

The injector seats in the cylinder head on a copper sealing washer. This washer should replaced with a new washer when the new injector is installed.

INJECTOR

40

± 4

fI-lb

THE

CYLINDER

500

hours thereafter, the cylinder head bolts should

Make

sure the engine is

112

of

a turn and then apply the torque. Follow this

to

the right.

#1,2,

and 3, (12mm socket) 14 -

#4,5,6,

7, 8, (14mm socket) (54 --61

CYLINDER

HEAD

BOLTS

cold

when this is done.

22

BOLT

PATTERN

ft-Ib

ft-Ib)

lom;en it

(11

- 16 ft-lb).

INJECTORS

of

severe vibrations and detonation noise, have the

Poor fuel quality, contaminant's and

positive fuel pressure to the injection pump can result

be

serviced in a

it

is best to carry at least one extra

the injector to help prevent any rust or debris from

If

the injector will not lift

in

TO

CYLINDER

(5.5 ± 0.5

by carbon build-up

it

out.

be

.

HEAD

TIGHTENING

kgf-m)

removed with the injector and

TORQUE

or

the like, work

of

the socket wrench to

be

WHEN

THE

ENGINE

IS

KEEP

CLEAR

ENGINE

OF BELT.

AND

THE

FAN

RUNNING,

Engines & Generators

22

ENGINE

ADJUSTMENTS

VALVE

NOTE:

engine's

BOLTS.

Pull off the air breather pipe from the rocker cover and take off the rocker cover bolts and the rocker cover to expose the rocker shaft and valve assembly.

Remove the glow plugs from each

the crankshaft

cylinder

Valves·are adjusted with the cylinder

adjusted stroke.

order (1-3-2 Valve adjustment beginning

crankshaft slowly and observe the operation cylinder #1. piston the cylinder). Continue to rotate the crankshaft slowly and look now starting it's compression stroke (the piston is moving in the cylinder towards

Align the timing marker the by rotating the crankshaft approximately and after should not

CLEARANCE

Retorque

valves.

A

WARNING:

engine

is

cold.

ing

order

of

the

to

the

specified

to

for

valve

at

Top

Dead Center

Each

cylinder

for

Watch

is

on

it's intake stroke (the piston

for

the intake valve to close. This indicates the piston is

IDC

mark on the crankshaft front pulley with the

on

#1

Piston at

IDC

this

point and the two valves

move.

ADJUSTMENT

the

cylinder head bolts before adjusting

See IDRQUING THE CYLINDER HEAD

Adjust

the

valve

clearance

Valves

are

adjusted

engine.

torque

be easily rotated

adjustment.

WES1ERBEKE three cylinder engines).

the front gear case cover when positioning

Tighten

before

(IDC)

is

adjusted following the engine's firing

with

for the intake

IDC).

of

it's compression stroke. Confirm this

by

cylinder

the

cylinder

adjusting

of

by

valve

the

the cylinders to enable

hand to position each

in

the piston being

of

its

compression

cylinder #1. Rotate the

of

to

open indicating the

is

moving down in

20

degrees before

for

the

when

the

in

the

head

bolts

valves.

the valves for

#1

cylinder

the

fir-

up

Re-install the threads)

bolts. See TIGH1ENING TORQUE SCHEDULE

manual.

ENGINE

Check the compression pressure.

remove shut-off solenoid the injector hole or tester

on motor until the pressure reaches a maximum this process for each cylinder. Look

matically (at least 20%) lower compression of

the others. Compression pressure should not differ

more than 35.5 psi

Standard

IT

a weak cylinder

is

either valve or piston related. Check the for the weak cylinder, adjust cylinder is still

cylinder to seal the rings and repeat the test.

comes up - the rings are Abnormally high readings

carbon accumulations, a condition that might

accompanied

NOTE:

In

cause may be fuel injector

mRS.

fuel pressure faults.

When re-installing the

glow

plugs (use anti-seize compound

and

assemble the rocker cover and rocker cover

COMPRESSION

To

do

this wann

all

fuel

injectors, or

wire,

glow

the adapter and crank the engine with

(2.5

compression

case

Poor fuel

pressure

is

low,

apply a small amount

by

high

of

severe

quality,

to

the

injection pump will result

glow

plugs, disconnect the

and install a compression adapter

plug

hole.

Connect a compression

for

cylinders

kglcm2)

flanked

pressUres

vibrations and detonation

glow

at 280

rpm.

398

Ib/iR'

at

280

rpm

by

healthy cylinder, the problem

valve

as

needed and test

of

faulty.

on

all

cylinders indicates heavy

and noise.

problems,

contaminates and

plugs use anti-seize compound.

see

FUEL INJEC-

value.

than

(28.0

oilmto the

If

compression

be

loss

in

on

the

in

this

the

engine,

fuel

the

starter

Repeat

with

dra-

the average

by

kg/em')

clearances

again.

If

noise,

of

positive

injector

in

the

~,,,~=.mnn~

~

I

~

Adjust the Proceed Rotate the crankshaft 240 degrees in

rotation order. Rotate the crankshaft another the

Adjust each valve's clearance by inserting a (0.25mm) feeler gauge between the rocker arm and the valve stem. Make sure to adjust all valves while the engine is cold.

valves

in

to

the next cylinder in the

arid

adjust the next cylinder's

valves

of

the next cylinder

#1

cylinder for both intake and exhaust.

firing

the

valves

240

in

the

firing

VALVE

CLEARANCE

0.25

mm

(0.010

COLD

order. normal direction

in

the firing

degrees and adjust

order.

O.OlOin

in)

ENGINE

Engines & Generators

of

23

COMPRESSION

ADAPTER~

TESTER

,~r-

~~

_____

INJECTOR

GLOW

OR

PLUG

HOLE

GLOW

PLUGS

The

glow

plugs

are wired through the preheat

When

PREHEAT

should "click"

is

pres~ed

on

and the glow plug should begin

INSPECTION

To

inspect

the

plug, remove the electrical tenninal

tions,

then

unscrew or unclamp each plug

head.

Thoroughly clean each plug's tip

soft

brush

and

cleaning solution

oit"

deposits.

bum

While cleaning, examine the tip for

erosion;

if

it has eroded

TESTING

An accurate

Touch'one prod to other

plug will have a used an

multimeter

A

to

the

testing

way

to test glow plugs

,the

to the

body

of the glow plug,

1.0 -1.5

with

the plug in or out

to

test the power

WARNING:

touch.

the

Be

plugs

These

careful

•.

glow plug's

ENGINE

solenoid.

at the control panel

and

to

remove all the carbon

too

much,

replace the

is

with

wire

connection,

as

shown.

ohm resistance. This method

of

the

engine.

drain

(8

- 9

glow

plugs

will

not

to

burn

your

this

from

the

threads

wear

an

ohmmeter.

A good;

You

can

amps

per

become

fingers

solenoid

to

get

connec-

~ylinder

w,ith

plug.

and

also

very

when

ADJUSTMENTS

OIL

PRESSURE

To

test the

oil

hot.

a

and

the

glow

can

use

plug).

hot

install a warming

read

011

LOW

A ings. A rapid failure. ings,

be

mechanical

the

oil

Pressure

OIL

gradual

For

see

up

PRESSURE

loss

the

pressure, remove the

oil

pressure gauge

the engine; set the engine speed

pressure gauge.

35·55

(b/io'

(2.5 -3.B

of

oil

pressure usually indicates a

loss

of

oil

pressure indicates a specific

I;ldditional

ENGINE

information

TROUBLESHOOTING

TESTING

oil

pressure

in

kg/cm')

on

low

OIL

PRESSURE

it's

at

oil

pressure

sender,

place,

1800

worn

chart.

then

After

rpm

bear-

bearing

read-

and

GLOW

Re-install the plugs

should get

seconds. circuit. When reinstalling the compound

A

WARNING:

than

GLOW

PLUG

,__--"I.--=-_

plugs

If

the on

30

seconds.

TIGHTENING

1.0·1.5

in the engine

very

plugs don't heat

the

threads.

00

M-KG

TESTING AN

OHMMETER

.

'PREHEAT

PLUGS

and

hot (at the

not

TORQUE

(1-11 FHB)

WITH

terminal

up

glow

keep a glow.p/ug

II

.

;,

~.

ON

test

them end)

quickly,

plugs,

check

use

TERMINAL

USING

TEST

again.

within 7 to

for

anti-seize

on

for

more

END

A

LIGHT

The

15

a short

OIL

PRESSURE

There

are

two

automatic

to protect

pressure. The other oil pressure switch is available for connecting

an alarm engine

Note the off.

the

(optional)

(before

down).

that

this

engine

this

occurs

SWITCHES

oil

pressure switches. One is wired

shutdown

is

circuit

(see

safety shutdown switches)

engine

from

a sudden loss of oil or very low oil

audible alarm that would sound a low pressure

the

shutdown switch activates and shuts the

audible

started

as

the

alarm

will sound momentarily when

and

sound

again when the engine

oil

pressure

drops below

10

to

psi.

the

is

to

shut

+

Engines & Generators

24

NOTE:

be

ments below

is

ENGINE

WESTERBEKE

ADJUSTMENTS

recommends

performed by a competent

provided

to

assist

the

that engine

mechanic.

the

following

mechanic.

engine

The

information

adjust-

Injection

If

your engine's fuel injection timing

the engine start. Have well-established fuel injection follows:

NOTE:

fuel delivery position

do

this, side cover move

fully

1. Remove

No.

2. Remove "0" the

3. Reinstall only the delivery valve holder high pressure fuel line to the delivery that the

pointing line during

Rotate rotation compression stroke.

Move

the

electric

(as

viewed fuel (no crankshaft pulley should be directly aligned indicator on the

If

the attained, thickness mounting Changing changes To

advance required. required.

numbers.

Pump

Timing

will not operate

the

The

injection

pump

PTm1P

when

unscrew

the

to

the

1 injector and the

ring

holder.

the engine's crankshaft

to

the

line,

drips).

specified injection timing

adjust

the

the fuel shut off solenoid

to

expose

the

injection

fuel rack

end

position piston

throttle levet

from

until

At

of shim material under

flange

the

To

Refer

to

thefullfuel

left)

secure

it

in

the

high pressure

No. 1 fuel

the

No.

1 fuel delivery

and

remove the delivery

that would connect

away

from the engine

the timing

lift

pump.

the

this

front

the

to

shim thickness by 0.004 inch

injection timing

the

timing, decrease

retard

to

check.

to

Slowly rotate

front),

instant

the

instant,

of

the

timing

change

the

timing,

your Generator's

Adjustment

is

not properly adjusted,

properly,

fuel

performing

this

the

its

full

catching

the

gear case ±

by

the

by

and

may delivery rate checked shop.

Adjust

rack

needs

this

pump

fuel

delivery

position

fuel

in

No.

fuel

0

11

(11

increasing or decreasing

injection timing point.

approximately

increase

then

line

from

delivery

valve

holder.

to

the

fuel

will

its

normal

1 at

the

open

position

the

crankshaft clockwise

the

fuel

completely

BIDe

timing

.5

0

BIDC) cannot be

the

injection pump's

the

shim

the

Parts

(Spill

Timing)

be

difficult to

the

injection

to

be

in

the

spill

timing.

and

remove

rack.

Manually

position

(move

proceed.

between the

valve

holder.

holder over

spring

beneath

and

reattach the

Attach it

fuel

injector

flow

from

direction of

beginning of

and

operate

from

the

stops

flowing

mark

with

the

degrees.

(O.Olmm)

one

degree.

thickness,

shim

thickness,

List for

shim

by

a

as

full

To

the

is

this

its

No.1

on

timing

the

as

part

so

the

as

INJECTION

STOP BRACKET

CONTROL

PUMP.

WIHt--

RACK

.....

Engines & Generators

25

TIMING

POINTER

MARKS

ENGINE

ADJUSTMENTS

GENERATOR

Once

the

there

may during this

period.

required

are

These

mal

break-in

Frequency indicated

When the generator output frequency

When the generator

output

Therefore

speed

must

perfonn the

1.

With the connections change These tion

A

certain away

FREQUENCY

diesel

generator set

be

adjustments

the

engine's break-in period (first 50 hours) or after

A no-load voltage adjustment

in

conjunction with the engine's speed adjustment

not

warrantable adjustments

and maintenance.

is

a direct result

by

the

following:

is

frequency

to

the

AC

connections are shown in the

of

is

change the generator's

be

changed.

following:

engine stopped, connect the

tenninal block

diagram specified for your generator

the

Hertz circuit connection

this

manual.

WARNING:

that

everyone

from

pulleys

ADJUSTMENT

has

been placed in operation,

required

is

run

60

Hertz.

is

run

50 Hertz.

To

accomplish the frequency change,

in

Before

and

for engine speed (Hertz)

may

as

they

relate

of

engine/generator speed, as

at

1800 rpm,

at

1500

.

accordance with the

starting

Is

clear

belts

during

the

rpm,

the AC voltage

frequency,

AC

output leads

to

the capacitor.

GENERATOR

the

engine

of

moving

test

parts!

procedures.

(HERTZ)

also

be

to

nor-

AC voltage

the engine

AC

voltage

set,

and

sec-

make

Keep

to

FUEL

RUN

SOLENOID

The

fuel

run solenoid

engine's block just aft of and below the engine's

tion

pump.

Proceed

or

new

fuel

run

1.

Visual

access needed. cover and gasket just below the

2.

Thread the locknut onto the solenoid and small amount solenoid.

3.

Thread the solenoid into the hole

observe the solenoid plunger through the

Allow the plunger into the injection push the plunger into the solenoid.

4. Back the solenoid out position with the locknut.

Locknut

5.

Properly connect the three electrical leads noid. and the third inboard threaded hole with

6.

Reassemble

certain

To

Torque

Two

that

is

mounted in a threaded hole

as

follows when installing a replacement

solenoid.

to

the fuel injection pump's

obtain this, remove the small square side

fuel

of

Teflon

sealant

to

the

on

to

contact the

pump.

Do not thread further

114

Value

of the connections plug into the engine hamess

the

grounds

cover

unit

stops

28.9 - 36.2

to

the engine block

and

when

-

112

an

gasket

the

fuel

of

ft-Ib

8mm

and

a turn

(4.0 -5.0

solenoid

fuel

injection

then

threads

the engine and

cover

rack and

and

m-kg)

from

at

bolt.

test

run

is

on

the

fuel

injec-

rack

is

pump.

apply

a

on

the

opening.

move

fully

so

as

to

secure it

an

the

de-energized.

the

sole-

adjacent

unit.

Make

in

-

2.

Start

the

engine and adjust the engine's speed to obtain

the

frequency adjusting the against these stop bolts to either increase or decrease

engine no-load speed

3.

To

arrive

speed

of the engine/generator with a tachometer, or mon-

itor

the

method

THROTILE

CONTROL

LEVER

,

STOP

BOLT

SPEED

FACTORY

ADJUSTMENT.

ADJUSTMENT!

SET

corresponding

stoP

bolts and positioning the throttle ann

to

adjust the Hertz produced.

at the appropriate

frequency

being the more precise

with a frequency

frequency,

to

the voltage selected

either monitor the

meter,

of

the

two.

by

the latter

.

FUEL

RUN

SOLENOID

Engines & Generators

26

0.3937:t (1o:t0.5

0.019

mm)

in

ENGINE

ADJUSTMENTS

ELECTRONIC

The Electronic Governor regulates the engine sensing the engine's flywheel. the engines speed and if there

GOVERNOR

RPM

(OPTIONAL)·

speed

with a magnetic pick-up at

by

the

The governor's controller continuously monitors

is

any discrepancy, the controller signals the actuator and the actuator adjusts the engine

to the desired speed electronically.

ENGINE

MOUNTING

SURFACE

Actuator

The following instructions are the actuator.

1. Shut-off the DC power to the generator.

Disconnect

2.

the

actuator

3. Measure the distance between the actuator and the engine

mounting surface

as

wires

shown.

for

adjusting

from

the

wiring

or

replacing

harness.

4. Back-offthe 1 7/16" jam nut and

5. Apply a small amount

of

teflon sealant to the replacement

unscrew

actuator and screw the actuator into the engine's

mounting

boss.

Maintain the same distance

actuator and the engine mounting surface

measured Secure the actuator's position with (The standard distance is 13/16" to 7/8").

6.

Reconnect the actuator wires and test the

SCREW

IN

ORIGINAL

NOTE:

For additional information

Troubleshooting, refer to

TO

MEASUHE

your

~---13!16"

and

Electronic Governor

WESTERBEKE Service Manual.

the

actuator.

between

as

previously

the

jam

unit.

STANDARD

TO

the

nut.

7/8"

ACTUATOR

MEASURE

REFERENCE

FOR

ENGINE

MOUNTING

.

SURFACE

-JAM

NUT

Engines & Generators

21

7.6KW

BTDR

GENERATOR

ONLY

ALTERNATORS

DESCRIPTION

The following information applies that are supplied with Generators.

NOTE:

The

5.0KW BCl)R generator

belt driven

/'

lty a battery

generator. the 30

amp

DC

charge

This

engine's starting

buss

fuse.

WESTERBEKE'S Engines

alternator.

circuit supplies

Battery

circuit that

battery.

NOTE:

is up

This

SEE FOR

TO

OPTIONAL

FOR

CORRECT

REFER

TO

THE

to

the standard alternators

and

is

not equipped

charging

an

to

circuit

is integral a 17

amp

is

protected by a

accomplished

part o/the AC

charge

TESTING/TROUBLESHOOTING

WIRING

DIAGRAM

WIRE

CONNECTIONS

WIRING WIRING

with

a

to

ALTERNATORS

HARNESS DIAGRAMS

VOLTAGE

The integral voltage regulator is device which senses the system voltage level the voltage applied to the system voltage.

The regulator design thick-film assembly techniques. After the voltage adjusted encapsulated possible

50

AMP

ALTERNATOR

CONNECTIONS

IN

THIS

TO

MANUAL.

REGULATOR

to

the proper regulating valve, the entire circuit

to

protect the circuit

damage

due

THE

ALTERNATOR,

an

field

in order

utili~s

all-silicon semi conductors and

to

handling or vibration.

electronic switching

and

switches

to

maintain a proper

has

and

the components from

been

is

ELECTRICAL

The charging system consists regulator, circuit breaker and a battery with connecting cables. Because of the use of integrated circuits (IC's), regulator back of the alternator.

It

is

desirable voltage regulator) using the wiring loads

that are a permanent part of provide the technician with charging system electrical

ALTERNATOR

CHARGING

an

engine DC wiring harness, a mounted

is

very compact and

to

test the charging system (alternator

as

well

system.

CIRCUIT

of

an

alternator

the

is

mounted internally

harness

the

system

an

operational test of

as

the major components of

DESCRIPTION

w~th

a

Voltage

DC

electronic voltage

or

on

the

and

electrical

and

will

then

the

ALTERNATOR

Use this troubleshooting section exists with the charging circuit or determined that the alternator or voltage regulator have a qualified technician check

LOW

BATTERY/FAULTY

If

the starter only moans or makes a clicking sound instead of spinning the engine faulty connection in the starting problem.

A simple test dims

significantly or goes out, the battery

remains bright, look for a poor connection in the starting

circuit.

A

WARNING:

altemator altemator

TROUBLESHOOTING

to

determine

with

it.

CIRCUIT

to

life it is likely a

c~uit

is

to

try starting again lights

A

can

until

working

become

if

has

altematorlUns

very

hot.

cooled.

00

not

the

alternator.

low

and not

on,

is

dead.

touch

if

a problem

If

is

faulty,

battery or a

an

alternator

if

the

light

If

the light

hot. A failed

the

it

is

Engines & Generators

28

ALTERNATORS

PRELIMINARY

Before starting the actual alternator and voltage regulator, testing the following checks are recommended.

1. Make certain your alternator is securely mounted.

2. Check the drive belts for proper tension. Replace the

if

it is worn or glazed.

3. Check that all terminals, connectors and plugs are clean

and tight. Loose or corroded connections cause high resistance and this could cause overcharging, undercharging corroded battery cables could prevent the battery from reaching a fully charged condition.

4. Check the condition A low or discharged battery may cause false or misleading readings in the tests.

INSPECTION

or

damage to the charging system. Badly

of

the battery and charge

TESTING/TROUBLESHOOTING

~lt

if

necessary.

3.

'fum

off

the

engine. Ensure that the battery terminals and the engine ground connections are tight

s.

'fum

on

the

ignition

6. Check the battery voltage. condition the reading

Inspect

and

clean

switch,

If

should

all wiring and connections.

but

do

not

start

your battery is in good

be

12

to

13

volts.

the engine.

TESTING

A

certain

away

1.

2. After the engine has run for a few minutes, measure the

THE

ALTERNATOR

CAUTION:

that

from

Start

the

starting battery voltage at the battery terminals using a multimeter set on

a.

If

the voltage is increasing toward

alternator is working.

b.

If

the voltage remains around exists with either the alternator or the charging circuit; continue with Steps 3 through

Before

starting

everyone

sheaves

Engine.

MUlTIMETER

'ij~~~~~~

~

is

clear

and

belts

DC

volts.

~ir!j-

the

of

moving

during

12

8.

~-,.

engine

test

parts!

procedures.

14

volts, the

volts, a problem

MEASURING

BAlTERY

-

YOLTAGE

ENGINE

make

Keep

RUNNING

MEASURING BATTERY

(IGNITION

ENGINE

TESTING

1. Connect the positive

2. Wiggle the engine

3.

4. Repeat the same measurement, the negative probe to

S.

THE

OUTPUT

connect the negative the alternator.

voltmeter. The meter

battery voltage, and

or

if

obtained, output circuit for loose damaged wiring.

Start

the

the positive probe voltage reading should

If

your alternator is

repaired at a reliable service shop. If

the

prev~ous

terminal B, use the terminal. inspect the wiring Jump

12

battery) and operate

13~14

is

the

engine.

test reads only battery voltage at

If

12

volts is

volts from a 12 volt source (such

volts,m then

CIRCUIT

probe

to the output terminal B and

probe

to the ground terminal E on

wiring

reading

to B with

for

harness while observing the

should

over

meter

the

indicate the approximate

not vary.

varies, check the alternator

or

dirty connections

the engine running. The

be

between 13.5 and 14.5 volts.

or

under-charging, have

to

measure the

not

present at exciter terminal R,

breaks and poor connections.

alternator.

the

alternator is OK.

If

no reading is

DC

If

the voltage output

VOLTAGE

OFF)

or

excitation

ad

the

ON

it

E,

Engines & Generators

29

ALTERNATORS

TESTING

OUTPUT

ENGINE

TESTING/TROUBLESHOOTING

THE

CIRCUIT

RUNNING

TO

STARTER

SOLENOIO

,

I

\\

\ \

.

BATTERY

\ \

~'==rl~J

TESTING

1. Connect the positive (+) multimeter probe to the

2.

3.

4.

THE

EXCITATION

excitation terminal R

(-)

lead to the ground terminal E on the alternator.

Tum

the

ignition

the multimeter reading. The reading should be 1.3 to

2.5 volts (see illustration).

If

the

reading

rotor field circuit probably is shorted or grounded.

If

the

reading

field circuit probably is open

switch

is

between

is

between

CIRCUIT

on

the alternator and the negative

to

the

on

position and note

.75

and

1.1

volts, the

6.0

and

7.0 volts, the rotor

5.

If

no

reading alternator-excitation the regulator. Disconnect Connect the positive lead and the negative terminal approximate battery defective and must indicated, check the connections

ALTERNATOR

If

tests indicate a failed alternator, it will need to be disassembled and repaired. Any do the job.

NOTE:

WESTERBEKE'S service Manual has detailed

instructions

standard alternators.

is

obtained,

E.

If

the

multimeter

or

damaged wiring.

voltage,

be

excitation

an

lead

or

in the excitation circuit

the

multimeter

inultimeter

replaced.

REPAIR

good

alternator service shop can

for

the disassembly and repair

open

exists in the

lead

from exc terminal

probe to the excitation

probe to ground

now

indicates an

the voltage regulator is

If

no voltage is

circuit for loose

___

-.-_

of

their

or

dirty

of

R.

BATIERYCARE

The minimum recommended capacity

the engine's 12 volt Cranking Amps (CCA).

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

• Monitor your voltmeter engine operation.

• Check the electrolyte hydrometer.

• Use only·distilled water level.

• Make certain that battery cable connections are clean and

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

DC

control circuit is 600 - 900 Cold

and

house batteries.

for

level

to

bring electrolytes to a proper

of

the battery used in

proper charging during

and specific gravity with a

SPECIFICATIONS

The minimum recommended capacity the engine's l2-volt

Engines & Generators

29A

of

the battery used in

DC

control circuit is 600-900 (CCA).

DC

CIRCUIT/BATTERY

BATTERY

The generator's engine. The circuit reviewing the The engine's circuits: start, run and

The engine

shown

when

system or the

A

charging switch battery

when

CHARGING

DC

Circuit functions

DC

wiring

has a 12

on

the

Wiring

troubleshooting or when servicing the DC electrical

engine.

CAUTION:

circut,

while

the

switch,

working

however,

on

to

start, operate and stop the

is

best understood

WIring

Diagram and Wiring Schematic.

is

designed with

stop.

volt

DC

electrical control circuit that

Diagrams. Refer

To

avoid

damage

never

shut

off

engine

is

running.

to

avoid

the

engine's

elect(ical

to

the

engine

Shut

electrical

three

these diagrams

by

simple basic

battery

off

the

shorts

circuit.

engine

SPECIFICATIONS

The minimum recommended capacity of the battery used in

DC

the engine's 12-volt

BATIERY

NOTE:

belt driven

by

a bauery generator. the

engine s starting

30

amp

NOTE:

purpose than maintaining baUery.

Additional information

BC

CHARGING

The

5.0KW BCDR generator

DC

alternator.

charge

This

circuit supplies

buss

fuse.

This

charge circuit should not

GENERATOR

control circuit

circuit that

bauery.

on

section of this manual.

CIRCUIT

Bauery charging

This

the

engine dedicated starting

this

is

600-900

is

not equipped

is

an

integral part

up

to

a 17 amp charge

circuit

is

protected by a

be

used for any other

charge circuit

(CCA).

with

is

accomplished

of

the

is

found in the

a

AC

to

is

TESTING

If

the battery circuit, remove the fuse and test with a voltmeter between the running, it should indicate 13-14 volts. voltage battery.

BATTERY

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

• Check the electrolyte level and specific gravity with a

• Use only distilled water

• Make certain that battery cable connections are clean and

•

ALTERNATOR

The alternator should be cleaned and inspected. the housing can be wiped off with a solvent and the alternator terminal studs those studs are tight. Also clean the wiring connections that connect

'fum the rotor pulley by hand.

Depending

brushes may need replacing.

send it

THE

CIRCUIT

is

not charging, check the

fuse

holder connection and the ground.

is

indicated, check the terminal connections at the

fuse.

To

test

With

If

only the battery

MAINTENANCE

hydrometer.

to

bring electrolytes

level.

tight

to

the battery posts (and to your engine).

Keep

your batteries clean and

INSPECTION

should be cleaned with a wire brush. Make certain

to

the wiring harness.

on

when the alternator

to

a service shop for testing and overhaul

free

of corrosion.

(7.6

BTDR)

It

should tum

was

If

the alternator

last serviced, the

to

smoothly.

is

at

the

the engine

a proper

all suspect,

Eng/nes

30

It

Generators

NOTE:

located

CONTROL

MANUAL

The

engine

control

on

the

engine

PANEL

STARTER

system

as

close

DISCONNECT

is

protected

as

possible

TROUBLESHOOTING

to

by

the

(TOGGLE

a 20

amp

power

source.

manual

SWITCHES)

reset

circuit breaker

PREHEAT

fuel

preheat

START

engagement.

NO

NOT

BATTERY

depressed,

solenoid,

solenoid

SWITCH

IGNITION,

CHARGING

RUNS

Problem

no

electric

cranks,

panel

fuel

not

energized.

DEPRESSED,

does

BATTERY

DOWN

indications

pump

no

not

and

starter

start.

1.

Oil

2.

20

amp

3.

K2

1.

Connection

2.

Faulty

3

..

Faulty

4.

Loose Low

5

6.

K1

Faulty

1.

2.

Check

3.

Faulty

1.

Faulty

1.

Oil

2.

High

3.

Low

4.

Faulty

Probable

Pressure

circuit

relay

faulty.

switch. solenoid.

battery

battery.

relay.

fueling

for

air

fuel

lilt

alternator

pressure

resistance

alternator.

Cause

switch.

breaker

to

solenoid

connections.

system.

in

the

fuel

pump.

drive.

switch.

leak

to

leak

to

tripped.

faulty.

system.

ground.

Check

1.

Reset

2.

circuit

Check

3. Check

1.

2.

Check Check

3.

4.

Check

5.

Check Check

6.

1.

Check Allow

2.

Replace

3. Check

1.

turns output regulator

Observe

1.

engine Check

2.

lines alter

Check

3. Alter a good

4.

If

leakage

replace.

Verification/Remedy

switches

breaker.

switch that

for

system

freely.

the (Do short

all

and/or

If

run

with

12

volts

connections. charge

fuel.

to

fuel

lilt

drive

Check

a

voltmeter.

terminal.

if

the

gauges

not

running.

wiring.

NOT

start

is

located.

wires

battery

stops.

it

circuit

bleed.

pump.

belt

Insert

for

Remove

and relay. connection.

battery battery relay.

the

with

is

opens

for

ohmmeter.

are

state.

and

for

and

Test

engine).

temperature

charging,

battery

again, shorts

present

its

tension.

loose

connections.

Ensure

panel

the

oil

sensitive

Remove

disconnect

alternator

connections.

check

preheat

to

ground.

at

the

solenoid

Be

sure

are

present

are

activated

pressure

amp)

connections

to

locate

alternator

and

bench

Check

switch.

12V

lights

(0-.25

rise

solenoid

connection.

the

alternator

the

at

when

meter

and

the

fault.

at

test.

Repair

the

in

battery

replace

output.

the

or

TROUBLESHOOTING

If

the gauge reading is other than what is nonnally indicated

by

the gauge when the instrument panel is energized, the first step is to check for 12 volts and the Negative (B-) terminals

DC

between the ignition (B+) of

the gauge.

WATER

TEMPERATURE

Assuming that there is 12 volts as required, leave the instrument panel energized and perfonn the following steps:

1.

Disconnect the sender wire at the gauge and see

if

the

gauge reads zero, which is the nonnal reading for this

situation.

2. Remove the wire attached to the sender terminal at the gauge and connect scale, which is the

it

to ground. See

nonnal

reading for this situation.

if

the gauge reads full

Engines & Generators

AND

OIL

If

both

of

the above gauge tests are positive, the gauge is

undoubtedly

PRESSURE

OK and the problem lies either with the

GAUGES

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

If

either

of

the above gauge tests are negative, the gauge is

probably defective and should be replaced. Assuming the gauge is

OK, check the conductor from the

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

if

the battery is connected to the starter (both plus and minus terminals), the ground side will not necessarily be connected

to the block.

31

BATTERY SWITCH

r~~-----

7.6BTDR

GXD

~

0

~

.

~

-----'~

~J

START"ER

=

~

MOTOR

tl2

RED

tl2

RED

IIZY[lIRED

WIRING

.eJJ!Q.S.

=

~

=

Q

W

;:;

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to

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w/out

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Switch Switch

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GENERATOR

USE

OF

ELECTRIC

The power required

is

more than Some others. Split-phase under similar circumstances, than other types. They are commonly used

. machines, or

started, such

7 times

avoided, whenever possible, ven by a small motors require to run. The current required load connected

compressor, for

motor

In

general,

to

medium

MOTOR

"

*NOTE:

more for some small motors than for larger

for this is that the hardest starting types (split-phase)

made

Because the motors be damaged seconds. off all other electrical loads on the electric

REQUIRED

Run the generator generators indicted on the generators data should be checked periodically

the generating plant and the appliances it supplies. If voltmeter or ampmeter load, check it

required

motors

on

where

as

much current

to

which

the

starting

SIZE

(HP)

1/6 1/4

1/3 112

3/4

1

In

the

in larger

heavy

is

required for only

if

If

difficulty

OPERATING.SPEED

capacity,

MOTORS

to

start

an

electric motor

to

keep it running after it

require

much

more current

(AC)

motors require more current

easy-starting loads, such

loads

are applied after the motor is .

small power tools. Because they require 5

to

start

as

to

run, their use should be

if

the electric motor generator. from 2 to

to

example,

no

current

above

sizes.

At

can bring the motor up

motor.

with

Capacitor and repulsion-induction

4 times

it.

An electric motor connected

load

is

required

loads

will

AMPS

(AMPERES)

table the maximum

surge of current needed for starting

is

experienced in starting motors, turn

first

with no load applied, then at half the

and

finally

is

a portable meter and amp probe.

as

much current

to

start any motor varies with the

will require more current

connected.

to

start

115-

be

approximately

FOR

RUNNING

3.2

4.6

5.2

7.2

10.2 13

an

instant, the generator will not

and,

if possible, reduce the load

loaded

plate.

The output voltage

to

ensure proper operation of

not installed to monitor voltage and

is

considerably is

started.

to

start them than

as

washing

is

to to

Volt

motors as

follows:

AMPS

STARTING

.

tAMPERESJ

6.4

to

22.4-

9.2

to

32.2-

10.4

to

72.8-

14.4

to

29.2-

20.4

to

40.8-

26

to

Amps

for Starting is

ones.

The

to

speed in a

to

its full capacity

to

than

connected

FOR

52

to

be dri-

start an

air

reason

are

few

an

start,

a

AC

INFORMATION

to

as

not

as

Generator

• Maintaining reasonable cleanliness Connections of terminal boards and rectifiers corroded, and insulation surfaces may start conducting salts, build excessive heating and reduced life of

• For unusually severe conditions, thin rust-inhibiting

petroleum-base coatings, should be sprayed or brushed over

• In addition

inspected for tightness overheated terminals and loose or damaged

• The drive discs

checked periodically and should not accelerate cracking. The bolts which fasten to

8,

comers of the head

• The rear armature bearing is lubricated and maintenance is required. noisy or rough-sounding, have it replaced.

• Examine bearing at periodic intervals. of motion wear.

will

CARBON

WESTERBEKE recommends mounting a carbon monoxide detector

small amounts is deadly.

The presence of carbon monoxide indicates from elbow/exhaust are leaking

If carbon monoxide is present, ventilate the area with clean

air and correct the problem immediately!

Maintenance

dust,

engine exhaust, carbon, etc.

up.

Clogged ventilation openings

all

surfaces

for

any

the generator shaft must be hardened steel identified

shaft should be detected

is

Repair must

rub

and

to

periodic cleaning, the generator should be

on

evidence of incipient cracking

be

allowed

by

6 radial marks, one at each of

detectable, inspect the bearing

cause major damage

MONOXIDE

in

the living quarters. Carbon Monoxide,

the engine or generator or from the exhaust

hose,

in

your

area.

is

important.

may

are

allowed

may

cause

windings.

reduce rusting and

of

all connections, evidence of

single bearing generators should

if

possible for tightness of

to

become rusty because rust

..

However,

when

be

made quickly or major components

corrosion.

wires.

failure.

the

drive

SAE

the

sealed;

if the bearing becomes

No

side movement

force is applied.If side

and

shaft for

to

generator.

'DETECTOR

an

exhaust leak

or that

fumes

from a nearby generator

become

to

be

screws

Discs

may

grade

6

no

even

if

disc

in

NOTE:

When

the

area

in

which

the

generator contains that the generators

provide one 120 volt

This will generator.

AC

equipment

AC

ensure

good motor starting

of

120 volts

terminal block be configured

AC

hot leg for

only, the

response

is

installed

it

is

recommended

to

distribution panel.

from the

Engines & Generators

37

This

troubleshooting chart

problems which

may

generators operating

Owing

to

the simplicity of the equipment and controls, troubleshooting between

cause

is

relatively

and

7.6KW

is

designed to give insight into

be encountered with BT brushless

on

compound transformer regulation.

easy,

effect

is

understood.

BT·

GENERATOR

once the relationship

WESTERBEKE recommends that the troubleshooting and repair of

with

.the

generator

be

performed by a qualified technician

a thorough knowledge of electricity and the safety

procedures necessary when dealing with high voltages.

TROUBLESHOOTING

Only a few These are hand tools: an amp probe and a quality volt-ohmmeter capable of reading less than one ohm precision required in reading component winding resistances.

Before attempting any repairs, get a clear the problem witnessing the problem. light a problem which rather than equipment fault. Have basic repair parts available,

such found in one of these easily replaceable parts, repairs can be made

basic tools are necessary for diagnosis and

due

to

an

explanation of

as

possible, preferably from

In

some cases, this

is

as:

diodes and a bridge rectifier, so that if the problem

an

individual

may

bring

the method of operation

efficiently.

repair.

the

to

is

High

voltage

correct

voltage

(115

-120

High

voltage

Low

voltage

growling

noise

engine

speed

Generator

is 0 volts

at

Low

voltage

load

is

applied,

Voltage

correct

loss

of

engine

Problem

(125

when

volts).

at

NIL

(0

-5 from

when

does

not

NIL.

(60 -100

voltage

at

rpm

-135

volts)

loaded

and

F/L.

volts)

at

generator

load

is

excite;

volts)

drops.

NIL,

but

(hertz).

at

NIL

with

and

applied.

voltage

at

NIL,

not

at

FIL

with

loss

is

when

with

of

1.

Generator's

1.

Generator's

2.

Short

windings

1.

Main

2.

Compound 0-1,0-2.

1.

Generator's

2.

Short transformer.

3.

Shorted

1.

Oiodes(s)

2.

Rotating

3.

Exciter

4.

Exciter

1.

Generator

2.

Rotating

3.

Generator's

Probable

engine

in

compound

0-3.

stator

windings

transformer

engine

in

the

main

Posi-resistor.

in

rotating

field

windings.

rotor

windings.

stator

windings.

overload.

diode

failing.

engine

Cause

speed

(rpm)

speed

(rpm)

transformer

shorted

windings

speed

is

stator

windings

exciter

speed

is

high

high. auxiliary

C-1, C-2.

shorted

slow.

or

(B-2)

shorted.

low.

at

NIL.

1.

Check

1.

Check

2.

Check

1.

Check and

2.

Check

1.

Adjust

2.

Check

3.

Test

1.

Check

this

2.

Check

3.

Check

4.

Check

1.

Monitor

2.

Check

3.

Check

VerificationJRemedy

NIL

speed

and

adjust

NIL

rpm

and

adjust

continuity

connections.

continuity

the the

Posi-resistor.

B-1

section.

for for for

the the

engine's diodes

and

short. short short.

the

load. diode. governor

and

and and

B-2

a,

speed

as

in

b,

shown

operation.

connections

resistance resistance

the

c.

NIL

voltage.

NIL

voltage.

values values

and

adjust

in

this

rotating

of

0-3

of of

NIL

manual.

exciter

windings.

C-1,

C-2

0-1,

0-2

voltage.

as

explained

windings

windings.

in

4.

Low

Unstable

voltage.

Residual

Voltage

(18 -22

volts)

1.

Engine's

1.

2.

3.

Transformer

4.

power

Bridge Exciter

Main

stator

load

rpm

fluctuating.

rectifier. stator.

windings.

sux.

factor.

windings.

Engines & Generators

38

4.

Check regulator

1.

Check See

1.

Test

2.

Test

3.

Test

4.

Test

the

type

board.

the

engine

ENGINE

ADJUSTMENTS.

rectifier.

winding

for

winding

for

winding

for

of

load

operation

open. open.

open.

applied.

and

Consider

the

fuel

use

of

system.

optional

7.6KW

.

DESCRIPTION

This generator

which requires

AC

duce stator are responsible for the self-exciting feature of this generator.

The magnetic field produced causes

be

induced into the related exciter rotor windings during rotation.Diodes located in the exciter rotor rectify this voltage DC

and supply it creates windings of supplied parallel produced main

stator and is,

tifier.

The rectifier produces a

the exciter stator windings,

. a rated

AC

is

a four-pole, brushless, self-excited generator

only

the driving force of the engine

output.

The copper and laminated iron in the exciter

to

the windings of the rotating

an

electromagnetic field which rotates through

the

main stator, inducing

to a load.

to

the

in

A step down transformer

AC

output

of

the main

the

auxiliary windings of the transformer

in

turn, supplied

~nabling

output.

DC

to

voltage

BT

GENERATOR

to

pro-

an

AC

voltage

field.

This

the

an

AC

voltage which is

is

connected

stator.

An

AC

voltage is

and

a full-wave bridge rec-

to

further excite

th~

generator to produce

to

in

to

the

SINGLE

Circuit

A circuit breaker is installed on all WES1ERBEKE generators. This circuit breaker will automatically disconnect generator power breaker can be manually shut off when servicing the generator to ensure the vessel.

NOTE:

add-on WESTERBEKE

WHITEN

Breaker

This

kit for

in

case of

no

AC

circuit

earlier

dealer.

breaker

PHASE

an

electrical overload. The circuit

power

is

coming

is

available

model

generations;

·CIRCUIT

BREAKER

from

as a WESTERBEKE

contact

the generator

your

to

INTERNAL

12

STUD

WIRING

BT

GENERATOR

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

A±

i 1 '00

:1=:

-

1-

I - I

L

_____________

ORANGE

L-

__________________

A.

EXCITER STATOR WINDING A-I

Exciter Stator Windings

B. EXCITER ROTOR

1.

Auxiliary Windings (A - B - C)

2.

Diodes

(6)

3. Rotating Field Windings

4.

POD

Resistor

C.

MAIN STATOR

1.

Main

Stator Windings

2.

Main

Stator Windings

3. Main Stator Auxiliary Wmdings

GREEN

and

FOR

8

1* 43:

2 I

J

G

+

DC

~

FIELD

-

,,-_oJ

AC

-K1-

ACr-

aLACK

YELLOW

BREAKER

r-------,

I C I I D I

i

~

PART

NO.

!:

i 1

42707

r-------,

....

..--:---t1--

!

:

~

I I I

I 3 I I 3 I WHT/ BlK

L - - - - - - J

__

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

i!!

~ L !l-.?~!--I-

z

~

o I

D.

COMPOUND TRANSFORMER

1.

Compound Transformer Windings

2. Compound Transformer Windings

3. Compound Transformer Auxiliary Windings

Resistance readings easily

for

the components in the exciter circuit

D-3

by

locating the color coded wires at the connection points shown on the winding resistance component's electrical connections.

G. BRIDGE REC'l'IF'ffiR

2

...

r-:--!1----

~F=

-:-

,_

and

above

values

WHT/GREEN •

voltage checks can

schematic. When checking

be

sure

I .

~

J

to

lift both of the

be

accessed

A,

6

5

9 M

1

0

3

2 7

8

•

G,

C-3

AC

T E

R

I

N

A

L B

L

0 C

K

@

S

T

U

D

and

Engines & Generators

39

7.6KW

BT

GENERATOR

SINGLE

PHASE

NO-LOAD

1. Voltage adjustment

2.

NOTE:

age nwmentary load should be applied

former and

generator after this nwmentary load load

3.

Generator

1. Frequency is a direct result

2. a. Configure the AC terminal block for the desired volt-

b. Start the engine, monitor voltage and adjust engine no-

VOLTAGE

being governed by the compound transformer. Operate the generator, apply a moderate load momentar-

ily and remove it. Note the voltage output from the generator's voltage should be between hertz (234 - 238 volts at 51.5 -

120 volt legeS) (230 volt

The

no-load voltage should be adjusted

produced by

ADJUSTMENT

is

made with the generator regulation

the

generator once started and a

then

renwved.

50

hertz). The no-load

121

- 124 volts at 61.5 - 62

52

hertz).

to

excite

The

voltage produced by

is

renwved

the

to

trans-

is

voltage.

To

raise or lower the voltage, shims (non-conductive material) are placed under the steel laminated bar on top transformer. The material used for shimming should not soften at temperatures in the small reduction in no-load voltage sometimes be accomplished by gently tapping the top the laminated steel bar to reduce the gap between the existing shims and the transformer core.

of

or

of

1760 F (80

(1

to 3 volts) can

varying thickness

removed from

the compound

0

C) range. A

Frequency

of

engine/generator speed:

1800 rpm = 60 hertz; 1500 rpm =

To

change generator frequency follow the steps below.

age frequency as shown below. Ensure that the case

ground wire is connected to the correct terminal block

neutral ground stud.

NOTE:

The

white/green ground

those

installations

neutral and ground

from

being

load speed. Adjust the throttle arm or the throttle stop

screw to produce engine speed desired. 60 hertz: no-load speed, 61.5 - 62.0 hertz.

50

hertz: no-load speed, 51.5 - 52.0 hertz.

where

a ground

circuit.

source

50

hertz.

wire

may

be

renwved

the

AC circuit has a separate

This

will prevent the unit

in

the vessel

the

no-

volt-

the

of

in

c. After the no-load hertz adjustment is made, the no-load

voltage may need to be readjusted. generator was producing the correct no-load voltage at the previous hertz setting, it would changed hertz setting.

In the event it needs adjustment, adjust the shim thick-

ness under the laminated steel bar 60 hertz: no-load voltage, 50

hertz: no-load voltage, 234 - 238 volts.

d.

Load the generator to the rated amperage output corresponding to the hertz speed Rated Loaded Speed 60 hertz: loaded speed, 58.5 - 59.0 hertz 50

hertz: loaded speed, 48.5 - 49.0 hertz Maximum voltage drop acceptable at full rated output (amps) 60 hertz: 108 - 110 volts 50

hertz: 215- 220 volts Should the voltage drop below the proper rate, loaded excitation can be increased to raise this voltage by repositioning the connection on the Voltage Connection Terminal.

TERMINAL

Winding

'~:~=~L1

BLOCK

WIRING

Connections

6 - 5 4 4 9

CONNECTIONS

Needed

To

Obtain

The

In most cases,

be

of

121

- 124 volts.

of

the generator.

Proper

Voltage

if

correct at the

the transformer.

and

Frequency

110V

10

230V50

the

50

Hz

~~~~~~:,

5

6

44

9

10

~~:~12n~

~::±:::~'

6 N 5 4>4

yo

24n~

115V

50Hz

The

frame

ground

wire

be

moved from volts

50 nections

block,JJseJenninaIJlnds.for

1/4 accept wire

rating

nection. wire

green

between

and

when

115

volts

50

hertz

hertz.

From

to

inch

studs

multi-strand

sized

for

from

The

is

whtte

strip.

the

generator

the

frame

It

neutral

changing

and

1101220

to

230

volts

making

AC

terminal

that

will

copper

the

amperage

hot

lead

ground

or

white

connects

stud

frame.

must

con-

with

"'I-+.a:::::{<

a

,1-r-+--:_U

• •

230V50Hz

a=::D

ClRCUIT BREAKER

.

115/230V

0

N

L1 L1

~

Engines & Generators

a=::D

CIRCUn

BREAKER

40

50Hz

0

II-A-t-:;.-U

••

120V

o

N

CIRCUIT BREAKER

60

Hz

a=::D

120/240V/60Hz

L1

l~gCIRCUIT

L!!!

BREAKER

,....,.-+-:;;;:-I

• •

CIRCUIT BREAKER

7.6KW

BT

GENERATOR

SINGLE

PHASE

INTERNAL

12

r----

I 1 B :

SIDD

--

WIRING

FOR

BT

GENERATOR

--------.

I A I

: I

, B

1>1-

4

3,

I C I

, 2 I

I ,

L

_____________

, G

ORANGE

GREEN

RESIDUAL

1.

"Residual Voltage

NOTE:

generator can

the problemlfault may

1bis voltage is the

from measured between the load

The presence following generator components are

The fault lies nents

2.

1Welve

windings should cause the generator to produce between

125 -135 tral. (1\velve volts DC and (-) leads Correct voltage produced with twelve volts DC excitation

indicates the fault is

~omponents·B,·-D-or

125 -135

3. The absence fault with the main stator windings

the compound transformer windings failed components that output are the posi-resistor

more failed diodes in the exciter

VOLTAGE

The

anwunt

magnetism in the exciter stator

on

the generator running at its hertz.

1.

Exciter Rotor

2.

Rotating Field (B-3)

3. Main Stator

4. Compound Transformer

in

the exciter circuit:

A.

Exciter Stator (A-I) B. Bridge Rectifier C. Main Stator Auxiliary Windings (C-3) D.

Compound Transformer Auxiliary Winding (D-3)

(12) volts DC excitation

volts

volts AC, then include A and C. .

CHECK

18 -22

of

no-load voltage produced

be

an

indicator

lie.

AC

voltage produced by the generator

AC

of

residual voltage is an indication that the

(B-1

a,

(C-1"&

in

one or more

(G)

AC

between each hot lead and the neu-

is

applied between the lifted (+)

of

the bridge rectifier, + to + and - to

in

one or more

E. If·the generator doosnot proouce

of

any voltage from the generator indicates a

can

+

DC

-I<l-

volts

AC.

of

where in the generator

field.

neutral and hot

OK:

b,

& c) & (B-2)

C-2)

(D-1

& D-2)

of

the following compo-

of

the exciter stator

of

C-1

D-1

produce this same no-voltage

in

the exciter rotor and four or

rotor.

J

BLACK

AC

YELLOW

by

1bis

voltage

leges)

the above listed

and C-2 and/or

and D-2. Other

r-------.,

r-------,

, C I

'

i

; 1

D

....

!~!:

.

! 2

i~i!

I 3 I

I

L

______

the

4. Voltage output greater than residual and less than the

is

with no-

-.)

Engines & Generators

POSITIVE ORANGE

EXCITING

KEEP POLARITY DC+ DC-

J w

~

o

L-..

a. Apply

rated output indicates a fault in the exciter rotor/field B-2, B-3. Excitation paragraph 2 should produce a partial rise put original low output

12

ings

as

explained stator and/or compound transformer windings such short

will the shorted windings the excitation

and,

when removed, the voltage will return

JUMPER

--,

::'1-

(+)

I'

mE

GENERATOR

WITH

12

THE

to

Battery

to

Case

VOLTS

EXCITER

CIRCUIT

CORRECT:

at

Starter

Ground

....

I

===;7'..c=

I 3 r WHT/

L~l~~!--I--:-

" , _

__

volt DC excitation to the exciter stator

cause the generator engine

I T

....

in

paragraph

to

eventually produce smoke

is

continued.

of

the generator

START

MOTOR

SOLENOID

I'

.

/

I

,"

..

.j

BRIDGE RECTIFIER

NOTE:

rectifiers are configured differently, still located

AC

i'

r---+---1~

I !

6 l

9

~

I 0

BlK

•

~

...

J @

WHT/GREEN

2.

A fault in the main

as

.

FROM

DC(-)

I

Current

but

at

• S

to

load down and

explained

in

voltage out-

to

model

bridge

+ and - are

the

comers.

wind-

in

the

as

B-1,

U

D

a

41

7.6KW

BT

GENERATOR

SINGLE

PHASE

BRIDGE

The bridge rectifier windings transformer (D-3). The AC voltage measured across the AC terminals lows:

Diodes supply it through which the exciter rotor revolves. The measured across the fier during engine operation

Failure produced sent, due to the magnetism

cause the generator to produce residual voltage.

BRIDGE

POINT

RECTIFIER

is

supplied AC voltage from the auxiliary

in

the generator stator

of

the rectifier during engine operation

120

Volts

NIL

FIL

17 - 44 Volts AC in

the rectifier convert this AC voltage to

to

the windings

(+) and

120

Volts

NIL

FIL

8 -

17

Volts

DC

of

the bridge rectifier will result in a weak field being

by

the exciter stator windings. A weak field is pre-

RECTIFIER

POINT

#1

#4

«(::-3)

and the compound

; 120/240

NIL

. 17 -

of

the exciter stator to induce a field

(-)

is

120/240

NIL

: 8 - 17

in

Volts

FIL

44

Volts

AC

terminals

as follows:

of

the bridge recti-

Volts

FIL

(

Volts

DC

the exciter stator, which will

DC

is

as fol-

DC

and

voltage

Testing For

(Meter used: Simpson 260)

1.

2. Connect the positive

3. Remove the positive

4. Leaving the negative

S.

The

Bridge

Faults

Set the ohmmeter scale on needle to zero.

#4. Taking the ohmmeter's negative

ily contact points #1, #2, #3, and #5. The ohmmeter should register no deflection for any touched.

the negative lead, momentarily touch points #1, #2, and #3. The ohmmeter's needle should deflect when each point showing a passage the rectifier.

touch point #5 with the positive the needle should occur.

Place the positive (+) lead and the negative should not register any deflection

deflection indicates infinite resistance). Reverse these

connections and the ohmmeter should again register deflection. If

defective and should be replaced.

NOTE:

results from the above tests.

With

the rectifier fails any

Different style/model meters may produce opposite

Rectifier

An

Ohmmeter

(-)

lead to point

of

(-)

RXI

(+ DC) and set the

(+) lead from the ohmmeter to point

(-)

lead, momentar-

of

the points

(+) lead from point

#4

and, with the positive (+)

meter voltage through the diodes

(-) ohmmeter lead on point #4,

(+) lead. No deflection

of

the ohmmeter on point # I

lead on point #3. The ohmmeter

of

the previous tests

#4

of

the needle (no

and connect

(1

is

touched,

-4) it

in

of

no

is

Engines & Generators

42

7.6KW

BT

GENERATOR

SINGLE

PHASE

EXCITER

Auxiliary windings group a, b minal groups. and count off either Measure points A der occurs, unsolder and be

no

points

Auxiliary

ROTOR/FIELD

points

on

the exciter rotor for these auxiliary winding

Position

left

these

continuity

and

Windings

the exciter rotor

the

porcelain knobs from the

or

right

to

locate terminal points

the

resistance value between the pairs

&

B,

B &

C,

and C &

connections unless a faulty reading appears.

verify

the winding

found

between any

the

rotor shaft/case ground.

1.0 -1.2

Ohms

RED & WHITE

EXCITER

and

c. Locate the

as

shown in the illustration

12

o'clock point

a,

band

A.

There

is

no

need

fault.

There should

of

the three terminal

ROTOR

three

of

terminal

c.

to

ter-

unsol-

If

this

The diodes common automotive 12-volt high beam headlight bulb, jumper leads and the generator's

A short or above without having check it

NOTE:

will iary

When passes

Reverse voltage passing through it, or it

can

an

with

Attempting

give

erroneous

winding's

leads

are

through

the

leads across the

may

glow

be easily checked

open

in

a diode

to

unsolder and isolate each diode

an

ohmmeter.

to

check

diodes

readings

connections.

put

across

the

diode

allowing

and

faintly.

in

place with the use of a

12

volt starting battery.

can

easily be found with

in

place

with

an

on

the

diodes

due

to

diode,

as

illustrated,

the

headlight

diode.

The diode should block

the headlight should not

to

glow

ohmmeter

the

voltage

brightly.

HIGH

12

VOLT

GLOWS

some

the

to

auxil-

BEAM

BULB

BRIGHT

glow,

Rotating Field Wuulings.

rotor.

The

the exciter the (+)

and

(-) connections

the

Measure these unsoldered unsolder

With

to

the rotor

these

Diodes.

tify the

windings

rotating

RESISTANCE

INFINITE

BLOCKING

resistance value with your ohmmeter between

two

connection points. These connections need not be

unless

the

connection and verify the resistance reading.

these

connections lifted, there should

shaft.

field

windings.

Six

diodes are mounted on the exciter rotor;

AC

voltage produced by the

to

DC

field

VALUE

---1

windings.

field

a faulty reading appears.

This would indicate a short

voltages and supply this

tHJHMS

----------11

I

I-YL....

.....

__

INFINITE------

R~fer

to the illustration above of

winding connections

of

the red & white striped wires.

If

this occurs

be

no

to

three

groups

DC

voltage

TRROUGH-lRE

....--

____

DIODE

OHMS

.....

are

noted

as

continuity

ground with

they

rec-

of

auxiliary

to

the

HIGH

BEAM

12

VOLT

bulb not

bulb

glow

of

red

&

will

to

BULB

VERY

FAINT

glow

with leads connected

is

open internally.

with

leads connected

is

shorted internally.

the

diode should

values

of the rotating

the

resistors connected

white

wires

connected

as

shown

on

destroy the rotating

drop

to

zero.

DOES

NOT

GLOW/IS

a. Should

directions, the diode

b.

Should directions, the diode

In

Check the resistance and the integrity field

Rotating

between the

(-)

terminals.

Posi-resistor. (Infinite readings between

lifted

from

shorted posi-resistor

AC

the

both a

and b above,

windings.

Field

Windings 7.0-8.0 ohm. (Reading

two

of the exciter rotor

the (+) and (-) terminals

output voltage

be

replaced.

field

between

to

in

the

both

yellow

the exciter

field

in

both

in

both

windings

the

taken

the

(+)

and

illustration.)

leads

rotor.)

A

and

cause

Engines & Generators

43

7.8KW

MEASURING

Main

Stator

1.

Group

lifted lead fonner order lead

2.

Group

lifted lead fonner and lead order lead #2 should

Main

3.

Main Stator Auxiliary Wuulings are measured between

the double leads fier,

tral prong connection of the regulator plug.

Main

NOTE:

these

Compound

Group 1 measured between Lead #10 at the block

and

with lead

Group 2 measured between Lead #8 at the block

and with

along

Compound

RESISTANCE

Windings

#1.

The resistance value

#4

from

the insulated tenninal below the trans-

and

lead #6 lifted from the

to

totally isolate the stator windings

#5

should be lifted

#2.

The resistance value

#1

from

#3

to

totally isolate the stator windings of group #2,

be

stator

Windings

unplugged

Stator

No

winding

from

Auxiliary

continuity should

groups

from

the insulated tenninal below the trans-

lifted

from

20 -22

on

the

AC

the

Windings

or

Transformer

Lead

#4 at the junction box. Lift both leads along

#9

at the terminal block.

Lead

#4 at the junction block. Lift both leads

lead #7 at the tenninal block.

Transformer

Windings

0.019 -0.021

is

the tenninal block.

is

from

the

the tenninal block.

Ohms

tenninal of the bridge recti-

rectifier and the double lead cen-

1.5 -1.8

be

found

to

the

generator

BT

measured between the

AC

tenninal block.

of

group #1,

measured between the

AC

tenninal block.

Ohms

between

Ohms

case.

AC

either

terminal

tenninal

GENERATOR

In

of

SINGLE

A

three

connection voltage connection tenninal this circuit located just below the lower left. Isolate the three numbered #1, #2, white-striped wires coming onto each Lift the black and white-striped leads and the white-striped leads off of their connections nal

block.

Measure the resistance value between the lead lifted striped lead lifted from the

Transformer

VOLTAGE

The addition of the increase or decrease of full-load voltage load voltage terminal strip lead will supply a higher

full-load conditions, bringing the output voltage of the

atorup.

No-load voltage should the compound transfonner: hertz. The sating for incorrectly adjusting the generator's no-load age.

NOTE:

For

from

Auxiliary

above

engine

ADJUSTMENI'S

VOLTAGE

CONNECTION

REPOSmON

LEADS

PHASE

AC

the tenninal strip and the black

AC

tenninal

Windings

CONNECTION

three

fall

below

to connect the lead (red or

should not be used

speedlhertz adjustment,

in

this

LOW.

...-1"""

--."

...

-~-

..-

"'-~--

4.0 " 4.5

Ohms

TERMINAL

connection tenninal

108

volts, selecting a higher number

AC

voltage to the exciter circuit during

be

properly adjusted

121 -124

manuaL

TERMINAL

was

tenninal block at

and

#3

of

the

three

tenninals.

green

on

the

AC

and

block.

is

for the

output.

Should

red

and white)

by

shimming

volts

at

61.5

- 62.0

as

a means

see

ENGINE

of

compen-

added

the

red

and

tenni-

#1

white

gener-

volt-

to

and

red

full-

12

STUD

TERMINAL

BLOCK

BT

SINGLE

PHASE

·120/60

VOLT

CONFIGURATION

Engines & Generators

(12

HIGH

CIRCUIT BREAKER

STUD)

44

SPECIFICATIONS

•

7.6KW

ITO

GENERATOR

Engine

Type

Aspiration

Governor Combustion Bore & Stroke Piston Rring Direction Compression Dimensions

Weight Fuel Inclination

Generator

Compression (Limit Between

Valve

Spill Valve

Engine Valve

(engine Injector Emission

General Fuel Fuel Nozzle Fuel Air Air

(engine

Chamber

Displacement

Order

of

Rotation

Consumption

Power

of

Difference Cylinders)

TIming

(Static)

Seat

Angle

SPeed

Clearance

cold)

Pressure

Control

Injection

Filter cleaner Row

combustion)

ENGINE

Ratio

Take

Off

TUNE-UP

Pressure

System

Pump

SPECIFICATIONS

Diesel,

four-cycle,

water-cooled,

mechanism Naturally Centrifugal Swirl

type

2.99 x 2.76

59.09

cubic

1 - 3 -2

Clockwise, 21

: 1

Height:

20.4

Width:

16.0

Length: 3951bs

0.53

US

Continuous

Temporary

11

Horsepower

vertical

(11

Hp

aspirated

type

inches

when

inches

27.6

inches

(1797

kgs)

gph

(2

Iph)

15°

25°

(not

(maximum)

three-cylinder,

in-line

at

1800

(76 x 70

(0.952

viewed

from

(518.6

(406.40

(518.6

at

Full

to

exceed

SPECIFICATIONS

398

psi

(28

kg/cm2)

at

280

47.2

psi

{3.0

kg/cm'

Intake

Opens

17°

Intake

Closes

Exhaust Exhaust

11° ± 1.5 Intake

45°

Exhaust 1800

rpm

1500

rpm

Intake

and

1920 + 71

Smoke

FUEL

Open

flow,

No.2

diesel In-line Throttle Canister Paper

air

30.2

cfm

plunger,

BTDC

47°

ABDC

Opens

51 ° BBDC

Closes

13°

ATDC

45°

60

Hertz

50

Hertz

Exhaust

0.010

-0

psi

(135

puffer

limiter

SYSTEM

self

bleeding -self

oil

(cetane Bosch

type

filter

(0.85

cmm)

+ 5 -0

rating

type

fresh

overhead

rpm

maximum).

mm)

liters)

the

mm)

Rated

30

rpm

limit

inches

(0.25

kg/cm2)

priming

of

45

valve

front

Output min.)

mm)

or

higher)

Starting

Battery

Capacity

Battery DC

Charging

Alternator Starter Starting

Aid

DC

No-Load

Current

DC

Cranking

Current

General Operating

Fresh System

(fresh Radiator

General Oil Sump

(not Operating

(engine Oil

Temperature

Water

Capacity

water)

Air

Riter

Capacity

including

Oil

hot)

Grade

Pump

Row

filter)

Pressure

AC

General -Single

Voltage -Single Voltage

Regulation Frequency Rating

Air (60

Note: Engine Generator

Temperature

Regulation

(Volts

AC)

Requirements

Hertz@

1800

Increase

Combustion

Compartment

ELECTRICAL

12-Volt, 600 -900 51

Amp 12-Volt, Glow

plugs,

±

2%

175 -200

COOLING

Fresh controlled

170

-190°

Centrifugal

6.0

qts

695

cfm

LUBRICATION

Pressure Full

flow,

3.2

U.S.

plus

filter/cooler

35 -55 API

Specification

SAE

30,

GENERATOR

Phase

Brushless, lubricated Reconnectable with

solid

120

or

230

Volts -50

±5%

no

±0.05

7.6

KW -60

120

Volts

1201240

5.7

KW -50

230

Volts

GENERATOR

200

air

rpm)

supply

15%

30.2 120°F

Ambient

for

cfm

50 cfm

SYSTEM

(-)

negative

Cold

Cranking

rated,

belt

driven

reduction

of

sheathed

rated

Amps

gear,

Amps

(engine

SYSTEM

water-cooled

(5.5

(20

with

F type,

liters)

cmm)

(n

heat

-

metal

block,

88°

SYSTEM

fed

system

paper

element,

qts

(3.03

liters)

assembly

psi

(2.5 -3.8

CF

10W-30,

15W-40

(SINGLE

four-pole,

single

bearing

single

state

voltage

1201240

Volts -60

Hertz

load

to

full

Hertz

no

load

Hertz

(1800

166

Amps

Volts

63.3/31.6

Hertz

(1500

24.8

Amps

COOLING

(5.66

cmm)

Hertz

operation @ 1500

(0.85

cmm)

(50°C)

maximum

Temperature

ground

Amps

1.2

IWi

type

cold)

thermostatically-

exchanger.

C) impeller,

with

external

spin-on

kg/cm')

or

CG-4,

PHASE)

revolving

field

design.

phase

for

regulator.

Hertz

load

to

full

load

rpm)

Amps

rpm)

generator

(CCA)

belt-driven

relief

valve

type

sealed

1201240

volts

rpm

Engines & Generators

45

5.0KW

Be

GENERATOR

SINGLE

PHASE

DESCRIPTION

The

BC

generator

requires only

AC

output. The stator houses two sets of windings; stator windings and the exciter windings. When the generator is

started, residual magnetism induces a current in the stator which then generates larger current in the exciter windings. This mutual build

of current in the four rotating poles ings

quickly reaches the saturation point of

and

a regulated energy

At

the

same time, voltage the generator wire AC the ratings. The generator's data plate

in

the

generator's

is

or

120/240

two-wire or

SPECIFICATIONS section of

and

frequency rating of

affixed

to

the

end.

A diagram of provided inside the generators starting battery when For more information see DC

on

the

generator and supplies a continuous

CHARGER section

is

a brushless, self-excited generator which

the

driving force of the engine

in

the

four rotating poles

and

field

is

then maintained in the

this

regulated

stator windings which can then be drawn off

AC

terminals

a single-phase, reconnectable

voltAC three-wire, 230

volt

the

inside of the louvered cover

the

various

the

decal.

An

field

to

operate

at

AC

two-wire,

this

gives

generator.

AC

voltage connections

Integral Controller (IC) is mounted

the

INTEGRAL CONTROLLER

in

this manual.

to

produce

the

an

in

the

exciter

the

capacitor(s)

produces a steady

AC

equipment. The

120

volt

AC

60

hertz; or

at

50

manual

the

An

AC

at

generator

110

hertz. Refer

for generator

voltage, current

wiring decal

the generator

DC

charge

is

running.

an

main

even

up

windstator.

two-

volt

to

is

to

Circuit

A circuit breaker is installed on all single phase WESTERBEKE generators. This circuit breaker will automatically disconnect generator power in case electrical overload. The circuit breaker can be manually shut off when servicing the generator corning into

NOTE:

add-on kit

WESTERBEKE dealer.

60 Hz - 5.0 50

Breaker

of

to

ensure that no power

the

generator.

This circuit breaker is available as a WESTERBEKE

for

earlier model generators; contact your

KW

Circuit Breaker Part Number 42238

Hz - 4.0

KW

Circuit Breaker Part Number 42704

CIRCUIT

BREAKER

an

is

GENERATOR

SCHEMATIC

CHARGING

A.

ROTATING WITH

B.

MAIN

C.

EXCITER

D.

DC BRIDGE CONTROLLER.

FIELD/AUXILIARY DIODES. STATOR

WINDINGSAND

BATTERY

RECTIFIER

INTERNAL

WITH

WIRING

DC

BATTERY

CIRCUIT

r---------,

I I I I

I

I _ l

I

DIODE

I

AI

L

_________

r-----------------------------------------,

I J

I I

J I

I I

I :

II

~

,-

----"1----------------....1

------o'zS

-.,......----o~

J

~.::::::======~~.-J

I

I I

RECTIFIER

J

:oc

Co'

a:a

J

D

CONTROLLER:

B

AC

TERMINAL

r---------

I I

BLOCK

---

I

I I

WINDINGS.

CHARGING

CAPACITOR(S). CIRCUIT

AND

INTEGRAL

WINDINGS

WITH

CAPACITOR

t..-H-.J

'-

________

----....I

l

I r

!

t~

________________

V'PAr"

DUAL

---

EXCITER

CIRCUIT

---

I

t i

J

Engines & Generators

46

5.0KW

This

troubleshooting chart problems generators operating Owing troubleshooting is relatively between

WESTERBEKE repair of with procedures necessary

which

may

to

the

simplicity of

cause

and effect

recommends

the

generator be performed

a thorough

knowledge

be

encountered

on

compound transformer regulation.

is

when

is

designed

the

equipment

easy,

once

understood.

that

the

of electricity

dealing

with

BC

GENERATOR

to

give

insight into

with

BT

brushless

and

controls,

the

relationship

troubleshooting

by

a qualified technician

and

the

safety

high

voltages.

and

TROUBLESHOOTING

Only a few These

meter capable of reading

precision required

Before·attempting the

problem witnessing light a problem rather such found made

basic

are

hand

as

the

than

equipment

as:

diodes

in

one

efficiently.

tools

are

necessary for

tools:

an

amp

probe and a

less

than one

in

reading component

any

repairs, get a clear

possible, preferably from

problem.

which

and

In

some cases,

is

related to the

fault.

Have basic repair

a bridge rectifier,

so

of these easily replaceable

diagnosis

quality

ohm

due

winding

an

individual

this

may

method

that if

parts,

and

repair.

volt-ohm-

to

the

resistances.

explanation of

bring

to

of operation

parts

available,

the

problem

repairs

can

1]e

is

No

AC

Output

ReSidual

High

No

Load

Correct

No

to

60 -80

Correct

No

Unstable

Noisy

Generator.

Problem

at

voltage

Load

volts

when

Load

voltage

No

load.

(4

-6

Volts)

output.

voltage,

load

voltage,

output.

at

NIL.

voltage

applied.

high

voltage

..

drops

..

1.

Main

stator

1.

Faulty

2.

Faulty

3.

Engine

4.

Faulty

1.

Engine

2.

No

load

3.

Wrong

1.

Faulty

2.

Poor

governor

3.

Overload

1.

Engine

1.

Poor

governor

2.

Loose

1.

Rear

support

2.

Unbalanced

3.

Generator to

engine

Probable

winding capaCitor. electrical

connections.

speed

is

too

exciter

winding.

speed

is

too

voltage

tap

hertz

tap.

diode.

reaction.

on

generator.

speed

is

too

reaction.

electrical

connections.

bearing

load

rotor

connection

is

loose.

Cause

is

open

slow.

fast.

at

capacitor

fast.

faulty.

(1201240

or

shorted.

.

wired).

1.

Excite

1.

Perform

2.

Check

3.

Adjust

4.

Check Check

1.

Adjust

2.

Change

3.

Check

1.

Isolate

2.

Check Adjust

3.

Check Monitor

1.

Check

1.

Check

2.

Check

1.

Inspect

2.

Monitor

3.

Check

VerlflcationJRemedy

unit

with

12

VDC.

Check

capacitor

check.

all

electrical

connections,

engine

speed

to

correct

winding winding

engine

speed

tap

to

lower

to

ensure

diodes

and

engine

speed

or

repair

the

engine

amperage

engine

speed.

the

governor.

the

security

rear

bearing.

the

amperage

rotor

security.

resistance residual

governor

to number.

correct

check

under

speed.

draw

Adjust

and

draw

value.

voltage

correct

hertz

for

load.

as

with

cleanliness

the

ensure

NIL

output..

no

load

tap

attached.

short.

needed.

amprobe.

or

repair

or

repair

of

from

each

stator

windings.

they

hertz.

governor

the

governor

the

electrical

leg

are

as

using

clean

and

tight.

needed. as

needed.

connections.

amprobe.

Engines & Generators

47

DUAL

EXCITER

These generators ment

connectors

available

selection, and

When

proceed

1.

2.

for

60

#9,

are

making Hertz change or no-load

as

Shut

the

Select

the appropriate Hertz connection

capacitor

1500

RPM.

#7,

#8, produced group

can

will

increase between achieve

NO-LOAD

have

dual Hertz

at

each capacitor.

each capacitor. 1\vo

Hertz

or

50 Hertz, and

for

no-load voltage adjustment.

follows:

generator down.

#60,

60

Hertz, 1800

The

three other connectors

and #9,

----

will

have

by

the

generator. One connector

be

plugged into each

or

decrease approximately 4 - 6

connectors used in

tbe-prescribed no-load

DUAL

5.0KW

VOLTAGE

and

There

connectors

RPM

an

effect

capacitor.

any

voltage

EXCITER

CIRCUIT

Be

GENERATOR

ADJUSTMENT

no-load

three

on

pair

voltage

are

five

connectors

are

for

connectors,

voltage

adjustments

to

plug

or

50,

#50

at

each

the

no-load

from

No-load

AC

combination

as

illustrated

Hertz

into Hertz, capacitor,

voltage

each

volts

to

adjust-

#7,

#8,

each

voltage

below.

SINGLE

NOTE:

When changing

engine speed adjustment

The

made. must

be selected

The Hertz plug connection

for

50

Hertz (#5)

must

be nwved when

230 volts,

A

WARNING:

handling

tia//y

lethal

power

source.

NOTE:

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

PHASE

AC

output

for

or

50

Hertz.

as

they charge

Hertz

produced

at

the

connections

the

voltage

at

the

60

Hertz

(#6). Thejrame ground wire

changing

Capacitors store

electricity

even

when

by the generator,

throttle arm linkage

on

the terminal blocks

and

Hertz to be produced

capacitor must be changed

from

115 volts, 50 Hertz to

must

be

discharged

and

can

disconnected

terminaLs

must

before

pack a poten-

from

their

with an

an

be

GENERATOR

BACK

END

. Engines & Generators

48

5.0KW

BC

GENERATOR

SINGLE

PHASE

SINGLE

1. Remove the louvered metal plate, at the back

2.

3.

EXCITER

generator, covering the AC terminal connections and the capacitor(s).

Start the generator and allow it to run for approximately

five minutes generator is operating without any equipment drawing AC current from the generator (that is, shut electrical appliances). (Hertz) is correct. Adjust the fuel throttle/speed linkage as needed to obtain the correct engine speed before proceeding.

Referring to the AC load connections diagram below, check the generator's no-load voltage by measuring the voltage across the neutral lead and the hot lead with a volt meter. Make sure you record this reading. ator's no-load voltage is 115 - 124 volts Hertz.

If

proceed.

NO-LOAD

so

the engine

the voltage output is higher or lower than specified,

VOLTAGE

can

warm up.

Make

sure the engine's speed

ADJUSTMENT

of

Make

sure the

off

all .

The

at

60.5 - 61.5

the

gener-

·A

WARNING:

voltage The Touching

shock.

voltage could generator's

5. There

minal, is low, then disconnect the nect the plug with the next tor's no-load voltage is high, then disconnect the higher numbered plug and connect the plug with the next lower number. terminal

If

6. because numbered or bered speed

adjustment

capacitor

any

In

addition,

adjustment

cause

are

three plugs grouped

#7,

:f#l"

Note may

the generator's no-load voltage cannot be adjusted

the

plug

the voltage needs to be

plug

is already connected, then adjust the no-load

and

check the capacitor ratings.

00

not

attempt

while

can

produce a 400-500

wiring

can

produce a severe

attempting

while

your

fingers

to

the

generator

the

generator

be

to

make a no-load

is

volt

to

make a no-load

is

caught

in

the

operating. charge. electrical

operating

rotor.

for

the right capacitor ter-

and

#9.

If

the generator's no-load voltage

lower

numbered plug and con-

higher

number.

that the plug presently connected to this

be

anyone

voltage needs to

is already connected to the right terminal,

of

the

three plugs available.

be

increased and the highest

lowered

and the lowest num-

If

the genera-

115V/5DHz

4.

Shut

(60 Hertz #6,

capacitor(s).

A

before pack nected

CIRCUIT

CD

N

off

the generator.

WARNING:

handling

BREAKER

•

L1

23DV/5DHz

or

50

Hertz

Capacitors

as

L1

they

a potentially lethal

from

their

power

12DV/6DHz

Ih'-+-:oM1

L1

N

Make

sure the correct Hertz lead

#5)

is plugged into

must

store

electricity

charge

!l;;g~

CIRCUIT BREAKER

be

discharged

even

when

source.

the

and

L1

CIRCUIT BREAKER

L1

can

discon-

A

WARNING:

covers

on

are

NOT

in

with

the

generator's

5

BCD

Make

the

unused

contact

with

housing.

GENERATOR

120V/60Hz

certain

leads

each

BACK

the

insulating

are

in

place

and

other

or

in

contact

NOTE:

THEn

WIRE

SHOWN

CONNECTED DEMONSnMnONOFHOW THESE

CONNECTIONS

BE

MADE.

END

SHOWN

IS

AS

A

CAN

NOTE:

Simply

cross

the

capacitor's insulated (plastic handle) any

excess

electricity.

screwdriver.

two

This

terminals

will

with

an

discharge

See the ENGINE ADJUSTMENT section in this manual for

ADJUSTING THE

Engines & Generators

49

ENGINE

SPEED.

5.0KW

Be

GENERATOR

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 Charging

A separate group bridge rectifier which converts the AC current to supply the I.C. unit.

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

NOTE:

produce a low the

generator

The Integral Controller is mounted inside the generator housing

in ment on the controller that will allow a DC voltage output adjustment

NOTE:

circuit since internally. the

newer four

CONTROLLER

Voltage: 13.0 - 14.0 volts Amperage:

of

stator windings supplies AC voltage to a

The

I.C. unit senses the needs

DC

charge when one is needed.

When

the

generator isfirst

charging

is

operated.

the 12:00 position. There is a voltage output adjust-

of

± 2 volts.

New

four

wire

the

ballast resistor's junction

Whenever

wire

replacing

model,

(I.C.)

0 - 10-

amps

of

if

the battery's charge is

started,

rate.

This

charging

controllers eliminate

an early style controller

remove

the

ballast resistor

DC

the starting battery

If

you suspect

the I.e. unit will

rate

will

the

ballast resistor

is

now handled

wiring.

DC

~~~""'----""'I~

RECTIFIER

VOLTAGE ADJUSTMENT (ON

+ -

GND

o

BLACK

w

CI

:J!

II:

Q

GENERATOR

NOTE:

Earlier model controllers had white/green

and whitelblack ground connections that

YELLOW

GROUND

TO

CASE

CDNTROLLER

OUTPUT

BACK)

INTERNAL

BRIDGE RECTIFIER

AC

CONTROLLER

(-)

are

interchangeable.

rise

as

with

and

its

DIAGRAM

negative

Testing

, 1.

2.

3. Testing

BRIDGE

the

Battery

Bridge Normal AC voltage running to the rectifier (while the

engine is operating two AC connections on the bridge rectifier. (As illustrated).

AC voltage running to the bridge rectifier (approximate):

Normal DC) is measured across the two DC connections bridge,r.ectifier; that is

DC (approximate):

AC Lift the two AC wire leads off the bridge rectifier and

measure, the resistance between these two leads with an ohmmeter. It should measure should exist between these two leads and the ground or the main AC stator windings.

a.

b. Connect the

c. Remove the positive

d. Leaving the negative ohmmeter

e.

NOTE:

produce opposite test

Rectifier

No-load Full-load

off

DC

voltage running out

voltage running from the bridge rectifier

off

winding: 0.14

the

Bridge

Set your ohmmeter's scale

needle to zero.

point

#4. Taking the ohmmeter's negative

momentarily touch points #1, meter should register no deflection for any points touched.

connect the negative points #1, deflect when each point is touched.

touch point should take place.

Place the positive (+) lead on point #1 and the negative

(-) register any deflection (no deflection indicated infinite resistance). Reverse these connections and the ohmme-

ter should again register no deflection. fails any fier because it is defective.

#2, and #3.

lead on point #3. The ohmmeter again should not

of

Different types and/or

Charging

at

1800 rpm) is measured across the

the

generator

the

generator

+ and

the

generator

the

generator

Circuit

16.0 volts AC

17.5 volts AC

of

the rectifier (in volts

-.

17.0 volts

18.5 volts

DC DC

ohm

0.14 ohm. No continuity

Rectifier (meter used - Simpson 260)

on

RXI

(+

DC) and set the

(+) positive lead from the ohmmeter to

(-)

#2, #3, and #5.

of

(+) lead from point #4 and

(-)

lead; momentarily touch

The

ohmmeter's needle should

(-)

lead on point #4,

#5

with the positive lead. No deflection

If

the rectifier

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

brarufs

of

test meters

results.

RECTIFIER

POINT

#4

of

lead,

The

the

may

#3

the

ohm-

Engines & Generators

50

5.0KW

BC

GENERATOR

SINGLE

PHASE

Ballast

Early installed bridge tor the battery.

Early cuit of either wire

TESTING

An

Checking determine

RESIDUAL

Single Dual Dual

AC generator 500 exciter windings charge the capacitor(s) and the capacitor(s)

discharge reading connection

is

rating ance beneficial

istics

To

locate

NOTE:

and

Resistor

model

along

rectifier

functions

controller

controllers having

are

of the three lead

three

leads

from

THE

Single

Capacitor

1.9

Ohms

AC

voltage

the

VOLTAGE:

Capacitor

Model:

EIcHer

Model:

voltage

can

is

operating. This voltage

volts

AC.

back

is

taken

plugged into the capacitor(s) while the generator

operating

measure

#9,.

at

AC

in

the exciter windings produces a phase-imbal-

type

of field that effects the auxiliary windings: a result that produces good motor starting character-

for

this

the

#9 and

Three

numbered capacitor connections

and

two

0.5

Ohm

integral controllers

the

DC

positive (+) lead running from the

to

the

integral controller. This coil-type resis-

to

suppress high amperage

when

it

is

trying

BALLAST

this

type.

spade plugs

the controller.

EXCITER

Dual

Capacitor

2.2

Ohms

is

induced

residual

condition

Model:

be

This voltage buildup

into

between

its

type of generator.

resistance value of the exciter windings,

Hertz

in

voltage

of

10 14 7 - 9

measured across the capacitor(s) while the

the exciter windings. This

rated Hertz (61.5 - 62.0). This

the

#50 Hertz capacitor connections.

connections,

have

a ballast resistor

draw

to

charge a discharged starting

RESISTOR

resistor

in

the

These three lead types consist

connections or consist

r-n-------

I I

I

Hz Hz

50

1

I I

I

fC~PACITO~Sf

I..

______

I

.Hi

WINDINGS

Dual

Exciter

1.3

Ohms

these

windings

output

the

winding

-14

Volts

-16

Volts

AC

the

#60 Hertz connector and

by

from

this

when

AC

from

each

AC

from

each

from

each

may

be

is

accomplished

#50

and

coming

DC

from

charging cir-

of

three

1

I

60

7 8

91

I

.;.

___

.J

I

the

rotating

winding

troubleshooting.

winding winding

winding

as

high

AC

flow

exist:

#60.

can

as

400

as

the

voltage

the

of satu-

#7,

#8,

field.

#

to

Unplug their position on the capacitor. Place one lead of the ohmmeter

tion windings. Check ground/generator case check that plug or on exists between

FIELD·

With a capacitor

instructions included with the meter,

with the

meter

1.

2.

. 3. With

4.

s.

any

other connections from

on

plug connection #9 and the other lead

#50

Hertz.

Measure the resistance value

to

make sure there

from

either of

no

continuity exists between either the #50 Hertz

the

#9 plug and

the

AC

terminal

the~e

FIELD CAPACITORS

TESTING

value

shown

is

not available, perform the

Marking them unplug

the

connections from

With

a jumper, short across the

in

the

(+) lead

lead should be read attempts ably

Indications

a. Zero resistance or

b. c.

Capacitor Ratings (Capacitor a. Single Capacitor b.

NOTE:

microfarad

units

replacing model, installed. of

as

it would

an

ohmmeter on

one capacitor connection

on

the

other capacitor connection. A resistance

to

charge

good

capacitor.

of

capacitor). Infinite resistance (open capacitor). No

continuity should be found between the capacitor's

connections

Dual Capacitor

Ratings

The

older

capacitor.

now

have

a capacitor

ensure

The

the

capacitor:

25.0

Microfarad

31.5

Microfarad

any

of the

block.

If

continuity

two

winding

TESTING

THE

CAPACITOR

meter,

test the capacitor following the

on

the

capacitor. When a capacitor

so

they

may be reattached correctly,

step.

This ensures

be

at shutdown.

~et

on

and

should rise

the

capacitor.

a defective capacitor:

no

rise

and

the

capacitor's case or base.

Units:

31.5 microfarads (uF)

are

found on

single

capacitor

All

new

a 31.5 microfarad

in

either

that

the

correct

capacitor

rating

capacitor capacitor

the

capacitor(s) noting

on

of

is

no

continuity

the

two

main

stator windings leads

is

found here, a fault

groups.

and

compare the results

following

the

capacitor.

two

the high R scale, place

slowly

This

in

resistance value (shorted

meter)

25.0 microfarads (uF)

the

capacitor

models

model

an

rated

is

marked

PN

simple

connections exposed

the

capacitor

and

the negative

as

the meter

indicates a presum-

case. used a 25.0

single capacitor capacitor. early

model or a later

capacitor

on

035985

035978.

plug connec-

the

exciter

leads. Also

test:

is

5°

When

is

the

housing

to

dis-

its

the

plus

(-)

Engines & Generators

51

6.

12

volt generator the

engine's starting across ings

capacitors(s).

will

DC

the

with

help

excitation

may

be

excited using

#50

and

#9 leads

any

other numbered

The

generator's

determine

(low

battery.

its

fault.

5.0KW

or

no

AC

output voltage)

12

volts

This

voltage

of

the

exciter circuit

leads

unplugged

reaction

during

Be

GENERATOR

the

DC

taken

from

is

applied

wind-

from

the

flashing

SINGLE

7.

During

"follows:

a. A slight rise

b.

c.

12

volt excitation, output voltage

Single

Capacitor

22

- 26VAC

the

engine and/or a growling noise

end

will

indicate a fault

No

rise or

very

indicate a fault Normal output voltage

exciter circuit capacitor(s).

,',

PHASE

Dual

Capacitor

24 - 28

in

the

output voltage

slight rise in the output

in

the

exciter windings.

VAC

in

the main stator

as

specified

12

with

from

above,

ranges

Dual

Exciter

-14

VAC

the

loading

the

generator

windings.

voltage

check

are

will

as

of

Engines & Generators

52

5.0KW

Be

GENERATOR

SINGLE

PHASE

Testing

Rotating

Two sets of windings are found in the rotor assembly. An AC voltage turns at rated rpm. The AC voltage passes through each the two diodes mounted rotor carrier bearing. The AC sine wave and this DC voltage is passed through the two groups of.

. rotating field windings producing a DC field around these

windings. This field affects the AC winding stator groups inducing is available at the AC terminal block connections.

1.

Field/Auxiliary

is

produced

Rotating Field! Auxiliary Windings

5.0 KW

To

check the resistance values, rotate the engine's crankshaft to position the diode(s) on the generator's shaft at 12

o'clock. presume the diode is ter's leads the other lead at the connection at the base Compare readings with the value above. ference is noted in the ohm value, carefully unsolder the lead on the top its isolated heat sink using a thin walled, deep well in

(11

mm) socket.

NOTE:

The aluminum heat sink that the diode threads into can be bent carefully outboard to the diode.

With the diode removed, both leads for the first group rotating field!auxiliary windings will be isolated with no interference from a possibly faulty diode. Check the resistance value placing the ohmmeter's leads across the two exposed leads. Also, verify that no continuity exists between these windings and the rotor shaft by leaving one ohmmeter lead attached to the winding lead and the other ohmmeter lead touching the shaft: no continuity should exist. ity is found, a short exists Repeat this same check on the second group Rotate the engine's crankshaft ond diode and connections at 12 o'clock. . No continuity should be found between these two groups of

windings.

in

BCG

To

make a quick check

on

the connection at the top

of

Windings

two groups

on

an

AC voltage in these windings that

3.8

OK

the diode and remove the diode from

of

windings as the rotor

the isolated fixture

Ohm

and place one

make

of

the rotating windings by

..

1800 to

Component

and

Diodes

just

before the

is

changed to a

of

the two main

of

these windings,

of

the ohmme-

of

the diode and

of

the diode.

If

a distinct dif-

easier access to

If

continu-

of

windings.

position the sec-

of

DC

7116

of

Resistance

2. Diodes 8 - 9.5 ohms (approximate) using a Analog Meter To

check the diode, unsolder the connection from the top

of

the diode. Place one ohmmeter lead on the connection at the top diode's base. Then reverse the position leads.

Values

of

the diode and the other ohmmeter lead

of

LOW

RESISTANCE

260 Simpson

the ohmmeter

H.\(-*B~f

DIODE

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

NOTE:

Different meter models

values, but should read the same

Diode Rating: 1600 amps 26 Amps The diode's rating is far in excess ments. Most likely a diode failure will result from an overspeed

Main

Single

Capacitor

0.6 Ohms

Residual voltage measured between #1-#3 and #4-#6 will be 2-3 volts AC between each pair block. This would be an indication that the stator windings are okay. Check exciter windings and artificially excite the generator.

r-

------------1-;

I I

b

I

: 2

Stator

or

load surge.

Windings

Dual

Capacitor

0.4 Ohms

of

NOTE:

terminal block are numerical order. They are shown below.

!b~

I 5

: 6

'--

---

----------

Group

#1

- Measure resistance value between terminal with lead #1 and terminal with lead #3. (Check that there continuity

Group lead continuity

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

of

Group #1 windings to the case ground.)

#2 - Measure resistance value between terminal with

#4

and terminal with lead #6. (Check that there

of

Group #2 windings to the case ground.)

of

stator windings.

INFINITE

RESISTANCE

in

may

show different ohm

jor

both diodes.

of

the circuit's require-

BC

Model

0.3 Ohms

leads at the terminal

The numbered leads on the

not

in any

~----..,

1 4 3

000

5 2 6

000

TERMINAL

the ohmmeter on the termi-

BLOCK

no

is

no

is

no

of

stator

continu-

to

the

one

Engines & Generators

53

SPECIFICATIONS

-

5.0KW

BCDBR

GENERATOR

Engine

Type

Aspiration

Governor Combustion Bore & Stroke

Piston Firing

Direction Compression Dimensions

Weight Fuel

Inclination

Compression

(Limit Between

Valve

Engine Valve

(engine Injector Emission

General Oil Sump

(not Operating

(engine Oil

Chamber

Displacement

Order

of

Rotation

Consumption

of

Difference Cylinders)

liming

Seat

Angle

Speed

Clearance

cold) Pressure

Control

Filter

Capacity

including

Oil

hot)

Grade

ENGINE

Diesel,

water-cooled,

mechanism Naturally Centrifugal Swirl

2.76 x 2.76

49.31 1-3-2 Clockwise,

Ratio

23: Height:

Width: Length:

3751bs

1.0

Continuous

Temporary

TUNE-UP

Pressure

Syatems

398 (33.5

Intake Intake Exhaust Exhaust

Intake Exhaust

1800 1500

Intake 1988 ± 142

Smoke

LUBRICATION

Pressure Full

filter)

Pressure

3.2 35 -55 API

SAE

SPECIFICATIONS

four-cycle,

type

cubic

1

24

18

gph

vertical

(9.2

aspirated

type

inches

when

inches

34

inches

(170

kgs)

(4.2Iph)

14°

25°

(not

three-cylinder,

in-line

at

1800

(70 x 70

(0.808

mm)

(863

mm)

1800

to

exceed

overhead rpm

mm)

liters)

from

rpm

Hp

viewed

(612

(460

at

fresh

maximum).

the

30

SPECIFICATIONS

psi

(28

kg/cm2)

at

280

rpm

limit

psi

(2.5

kg/cm2})

Opens

19°

Opens Closes

45°

60 50

Exhaust

psi

puffer

BTDC

51 ° ABDC

51 ° BBDC

19°

ATDC

Hertz Hertz

0.098

(140 ± 10

limiter

inches

(0.25

kg/cm2)

Closes

45°

rpm rpm

and

SYSTEM

fed

system

by

geared

pump.

flow,

paper

element,

spin~on

U.S.

qts

(3.03

liters).

psi

(2.5 -3.8

kg/cm2).

Specification

30,

CF

or

10W-30, 15W-40.

CG-4,

front

min.)

type.

valve

mm)

General Fuel Fuel

Injection

Pump

Fuel

Injection

timing)

Filter

combustion)

Battery

Capacity

Aid No-Load Cranking Charging

Regulator

Temperature

Water

Capacity

water)

Air

liming

Current Current

Pump

Row

(spill Nozzle Fuel Air

cleaner

Air

Flow

(engine

Starting

Battery Starter Starting DC DC DC Voltage

General Operating

Fresh System

(fresh Radiator

AC

General -Single

Voltage -Single Voltage

Regulation Frequency Rating

Electromagnetic interference

Cooling Air

NOTE:

Generator Temperature

Regulation

(Volts

AC)

level

Requirements

Increase

Compartment

FUEL

SYSTEM

Open

flow,

No.2

diesel

In-line

plunger,

11 ± 5°

BTDC

Throttle

type

Canister

type

Paper

or

26.0

cfm

ELECTRICAL

12-Volt,

(-) 600 -900 12-Volt,

reduction Glow

plugs,

90

Amps 175 -200 17

Amp Capacitor

COOLING

Fresh

water-cooled

controlled 170

-190° F (77 -88°

Centrifugal

6

qts

(5.6

695

cfm

GENERATOR

Phase

Brushless, Self-exciting, excitation.

design.

120

Volts -60

220

Volts -50

±5%

no

3.0

Hertz

60

Hertz

50

Hertz

Exceeds telephones (Certified

GENERATOR

Cast

Centrifugal

175 -200

(60

Hertz@

air

supply

15%

for

50

120° F (50° Ambient

self

bleeding -self

oil

(cetane Bosch

(Before

filter

(0.73

cmm)

SYSTEM

negative

ground

Cold

Cranking

sheathed

type

(max)

at

11.5

Amps

(engine

IC

13 -14

volts

SYSTEM

block,

type,

metal

liters)

(20

cmm)

(SINGLE

four-pole,

Pre-lubricated,

120

load

(5%) (1800 (1500

requirements

Europe)

capacitor

volts,

single

Hertz

to

full

no

load rpm) rpm)

and

standard

requirements.

revolving

load

120 230

COOLING

blower,

cfm

(4.95 -5.66

1800

rpm)

Hertz

operation @ 1500

C)

maximum

Temperature

priming

rating

of

45

or type Top

Dead

Center)

Amps

(CCA)

Volts

cold)

DC

(in

generator)

thermostatically-

C) impeller,

belt-driven

PHASE)

field.

saturated

field

single-bearing

phase.

to

full

load

Volts

41.6

Volts

18

Amps

for

most

marine

televisions.

direct

connected.

cmm)

rpm.

higher)

Amps

radio

Meets

CE

Eng/nes & Generators

54

GenRemote

CALIBRATION

NOTE:

THE

OPTIONAL

THIS

DATA

APPLIES

GenRemote

ONLY

TO

CONTROLS

. The unit consists

Cable. display panels can cable outputs allowing for a total

module, including The logic module

than

12

three

The shielded cable links the display to the module

70 milli amps (7011000

or

24

volts. The AC generator output can

(3

0)

Generator and Engine

1.

2.

3.

4.

5.

6.

7.

DC Oil Water AC

AC AC Line

of a Power

be

daisy chained to one

both

Logic

display cable outputs,

is powered directly from the generator's cranking battery and consumes less

of

phase.

Monitoring

Voltage

Pressure

Voltage Current

Current

Frequency

-

Temperature

L-l L-2

Module,

of

four

an amp) when the generator

Hz

Display

(1)

module output. The module supports two display

(4)

displays

is

be

Panel

per

six-hundred

115V, 240V, 50/60 Hz, single phase

and

six conductor shielded Display

and

can be up to 300 feet long. Two

module. Total allowed cable length per

(600')

is

idle.

feet.

DC

operating voltage can

(10)

be

or

8.

9.

GenRemote digital

mechanical The

assures package. mote

Electrical

Electrical hookup includes interconnecting with both the generators AC and DC systems. TheACwires Required: The

Line to the GenRemote.

The

Color] The DC Wire Harness

Switch], White/Black Temperature, Yellow

is the Start Button.

,

IMPORTANT!

Engine Exhaust

display

GenRemote

that

be

accidentally

Hours

Over

is

designed

is

easily

gauge

circuitry

GenRemote

Electrical

Temperature

to

calibrated

package.

is

will

isolation

disconnected

Up

to

safely

isolated

not

interfere

also

10,000 Alarm

interface

to

match

from

allows

from

the

Hours

with

the

generators

with

normal

generator.

the

existing

readings

the

manufacturers

generator

engine

of

the

OEM

operation

sensors.

manufacturer

electrical

supplied

system.

should

gauge

Hook;'Up

115

volt Line One

-2 [L-2 ] is BlackwithaRed Stripe. The 220 VACNeutral connection

220 VAC Generator Neutral is the same as Green Ground wire. The 115/220 VAC Neutral [White

is

connected

to

the generator frame.

Supplied Color Code as follows: Green

is

the Stop Switch, Black is Preheat, Orange is Oil Pressure, Red is Water

is

the Exhaust High TemperatureAiarm [marine applications only] andBlack/Red

The Exhaust High Temp terminal is connected to the ESS terminal when

[L-l]

is

Black

Line Two

is

Ground, White is ESS [Emergency Stop

[L-2]

is White. The 220 volt

is

White and is Not connected

it

The

supplied

This

the

GenRe-

is not used.

..

Engines & Generators

55

GenRemote

CONTROL

STATION

IMPORTANT!

calibration mode

. Enter the Calibration Mode: Press and holding the Mode Button

indicated when the

The

generator must be running

can

be

accessed .

hundreds

place decimal

and

the system

of

the 3-digit, 7-segment

Calibration Button Functions

Mode Button: Preheat Button:

Stop Buttqn: Start Button: Mode Button: Press the

Firmware I.D.

Press

and

hold.

the

mode

button to enter the calibration

Use

the Preheat Button

Scroll functions until the desired Use

the

Stop

Button

Use

the Start Button

mode

button

any

button

for

30

The

finnware identification number will appear in the display when the

calibration mode

. "AI 5".

to

manually advance through the AutoGauge

to

deprement or reduce

to

increment or increase

to

exit the calibration

seconds

is

exited.

will also exit

A typical

gauge

Calibration Method

Calibrate the AutoGaugeScroll the

mechanical

Calibrate the

and

Voltmeter normally carried

No

'calibration

calibrated to ±

gauge

package supplied with

AC

Volt

and

of

the Frequency Meter

one

(1)

Hz.

by

using

the

values

derived

the

generator.

Current Meter with a standard

by

most service technicians.

is

required or allowed.

fully

operational before the

for

10

seconds. Entry

display

is

reached.

the

mode.

the

calibration

firmware

from

Amp

1I:iiji;l~""'"

The

Frequency

turns

on.

mode.

gauge

value.

the

gauge

value.

Not pressing

mode.

identification number

lnd'atesOiJPteuure

9gelaln

888

Meter is

Caiblation

factolY

is

Mode

NOTE:

(30)

The

unit will automatically exit the Calibration Mode ifno

seconds. .

Firmware Identification

When

calling

identification hardware can be identified

numberis also placed asseJ:!lbly. mode

is exited.

The

fail-safe

settings. occurs.

Failures

temperature alarm will appear at The

alarm

stopped. The

alarm

The

Fail-Safe Protocols include:

for

service or warranty repair it

number.

The

firmware

system

This

allows

are

displayed by turning on the appropriate' warning

LED

will remain,lit after the

LED

can be cleared

The utnt's age, software revision level

on

is setup

time for

from

this

the

28

pin microprocessor

number

appears in the display when

FAIL

to

display potential failures approximately

the

operator

195

by

pressing

is

useful

to

have

number.

SAFE

to

0 F and

generator

Oil

1 2 - Coolant Temperature 3 - Exhaust

The finnware identification I

locate~

in

the

PROCEDURES

manually shut down the generator before

the

OEM

safety switch will stop the generator at

shuts

down

the

stop

button or

Pressure,'

Over

temperature

buttons

the

and

control

the

LED.

to provide indication

by

restarting the

are

pressed

fumware

the

systems

.

module

calibration

For

KLIXON

IBI8181

10%

lower than the

Example, the high coolant

unit.

for

Flfmware

~o

as

thirty

ID

0 0

serioUs

to

why

OEM

damage

210 0 F.

the

unit

Engine~

& Generators

56

GenRemote

WIRING

DIAGRAM

000

BlACK

WHIl'E/RED

ORANGE

VELLOW/RED

\Nesferbeke

GROUND

STOP

OIL

START

Black

W'hIte/Red

PI

REDMOLET

WHIlJ:

YELLOW

ESS

PREHEAT

H2O

GenRemoIe

Teomlna18lock

feJmlnals I

Ground

.

•

ESS

..........

STOP

START

PreHeat

. . . . . . . .

•

Exhaust

OIL

Water

thru

e

Press

Temp

for

/UMP

•

Figure -2a

Westerbeke

LAND

BASED

ESSTOEXH

To

Westerbeke Wire

Hamess

Westerbeke

Hamess

UNIlS

and

Plug

J

Wiring

Plug

~.

Notes: Follow

The

Required Federal Requirements

and

Local

for

State,

Electrical

Proper

Important I

Neutral Connection Not Required for 220

For

115

Volt

systems

Is

usually the white

this

L2

OUfPUT

Dls1rIbu1Ion

Code

Wire

Sizing.

to

GenRemote

Volt

Applications

l2

Is

Neutral,

wire.

TO

LOAD

PcneI

or

Is

II

o

1

...

=:::

C

e

l2

INPUT

--.

INPUT

FROM

00000000

RELAY

I-I

Accessory

Jack

DISPLAY

JACK

1

DISPLAY

JACK

2

FROM

GENERATOR

dlS

SS]

A.,.'

o

Ll

OUTPUT

TO

Distribution

LOAD

Panel

or

Engines & Generators

57

GenRemote

Westerbeke 8 Wire

INSTALLATION

Harness & Plug

GenRemote

Electrical

Box

J;;

'li

~

J;;

DIAGRAM

Note: GenRemote

and

AC engine Without and

GenRemote Battery, No

AC

Run

Indicator

uses

voltage

is

running.

AC

input

Water

Temp

readings

will

engine

to

recognize

the

generator

will

only

and

will

be

not

tum

oil

pressure

the

will

monitor

Oil

Pressure.

displayed

on.

run

the

and

the

rr-----~~==~~--Jlll~~~~C~k--------~

D

The functions

Sta

the generator

. Stop

Trou

problem and

IOO@]

i

~~~~~i

~

i i

~~~~~~~~~

ffil

Westerbeke

Neutral for

220

STOP/START

One

llluminated Button Start /

are

required

and

no

space

rt

the

generator

the

generator

ble

Indicator:

is

High Exhaust Temperature

by

is

starting.

by

developing.

pressing

The

indicator lamp

pressing The

indicator lamp will flicker

Possible problems include, High Coolant Water

~

E

U)

~

11

'-12':"O-uf-Wh-H-e--+

L...--""-----+AC

12

In

Whffear

115

vee

~utral

AC

Output

L 1 &

L2

Not

Required

Volt

Applications

ROCKER

Stop

Rocker

Switch

is

available

and

releasing the upperrocker

will

and

releasing the

Safety

Switch. .

START

for

the

remain

lower

slowly

is

standard display

on

rocker

SWITCH

provided

for

once.

The

and

steady

once.

while the generatoris

Press

L\lh1

Generotcr

Light While

Operotng

Out

Black

areas

where

panel.

lamp

will

flicker

while

the

generator

operating

Temperature,

Once

To

Fleshes I10pidlyWliJe

Js

Starting.

Remains

On

Generator

Is

To

AC

Load directly the

L 1

will

not

The

AC

to

GenRemote.

remote

rapidly

is

if a service

Low

Oil

Start

Load

can

to

generator,

and

L2

be

available.

signal

start stop

while

running

Pressure

be

connected

current

MUST

be

.

however,

readings

wired

STOP

6 Conductor Data

Maximum Length 150 •

Engines & Generators

Coble

Accessory Display

2

Display

1

58

Press

Once to

S10w

SUnIl.,.

1he

Generator

Inc:llcates

~----~

light

Is

SeTVlce

WhIJe

Rmnlng

Problem

Stop

GenRemote

SPECIFICATIONS'

DC OPERATING VOLTAGES

CURRENT RECUIREMENT--MoDULE

DC

. DC CURRENT REQUIREMENT--DISPLAY

DC CURRENT

EACH

ADDITIONAL

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

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

DiSPLAy

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

12

OR

24 VDC

50 20

15

MA MA

MA

AC VOLTAGES ••••••••••••••••••••••••••••.•••••••••••••••••••••••.•.•••••••••••••••••••••••••• 120 I 240 VAC

PHASE

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

STAN PARD CURRENT

REMOTE

START

STOP RELAY ••••••••••••••••••• ~ •••••••••••••••••••••••••••••••••••••••••••••••••••••••.•••.•••••••.••••••••.• 7 AMPS

PREHEAT

MAXIMUM # MAXIMUM #

MAXIMUM DISPLAY

TOTAL ALLOWED DISPLAY CABLE LENGTH

TEMPERATURE

NOTE:

should

output lines.

CURRENT

RELAY

Each

be

••••••••••••••••••••••••

RELAY

OF OF

module will support a maximum

daisy chained to one module output. The module supports two (2) separate display

METER

MeTER

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

DISPLAYS

DISPLAYS DAISY CHAINED

CABLE

RANGE

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

••••••••••••••••••••••••.••••••.•••••••••••••••••••••••••••••••••.••••••••• 200 AMPS

~

•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7 AMPS

PER

MODULE

LENGTH (ONE

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

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

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

DIRECTION)

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

of

four displays. No more than two (2) displays

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

.-;

••••••••• 1 0 OR 3 0

.-

•••••••••••••••••• 7 AMPS

0 0 F

THROUGH

60 AMPS

300 FT. 600 FT.

180 0 F

4

2

Engines & Generators

59

POWER

TAKE

OFF

SYSTEMS

POWER

A power

backend.

~~

Contact your

SUPPUER

.

XRT

The XRr power system combined

generator provides electrical firelemezgency power for operation of

TAKE

OFF

take

off adapter

This

adapter

for

a variety of

WESTERBEKE

for

additional

POWER

SYSTEM

apparatus

auxiliary lighting

up

to

ADAPTER

can

be

allows

access

hydraulic

COMMERCIAL

information

and

The

system

and

three

extrication

SPECIFICATIONS

Components

System

AVailability

Dimensions

Dual

stage

high

pressure

with

filter,

block

assemblies.

5,000

psi

fluid

systems

COMBI

pump

L:10"

x

W:15"

Reservoir:

Open

Center

L:

3.75" x W:

attached

and

hydraulic

provides

continuous

pump

phosphate

H:

to

the

to

the

full power of the

electrical

.

with a Westerbeke

power for

generates

continuous

tools

at

the

duty

fHtings,

three

enclosure

up

in

shroud.

x

H:14"

12" x W:

Valves:

2.75"

with

ester

fluid

to

10,5OOpsi.

x421bs

12" x D:

x

H"

4.0."

generator

accessories.

GENERATOR

electrical

same time.

pump,

stainless

gallon

reservoir

integral

control

and

mineral

6.5"

POWER

TAKE

OFF

ADAPTER

For

additional

SYSTEMS XRT

321ioga

at

POWER

Way

Marblehead,

information,

contact

www.xrtcombi.com

SYSTEMS

MA

01945

XRT

or call

POWER

(800)

343-0480.

*MODEL

SHOWN: WESTERBEKE SIZE:

L 44.0" X W

TOTAL

WEIGHT:

XRT

COMBI

XRT 3 TOOL

7.6kW.

18.4"

492

X H 24.1"

LBS.

POWER

SYSTEM

WITH

,.~I_JERBEKE

.,

EingltJeJI & Generators

I'

'50

.

~~~

,

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

1

Minute

of

Latitude

Latitude = 60

VOLUME

Cubic

Inches

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

Pints

(IMP Quarts Gallons Quarts Gallons

OUDces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds

Per

Sq

In

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

Nm = 111.120

= 1

Nm = 1.852

pt) x .568 = Liters

(IMP

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

(IMP

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

gal) x 3.785 = Liters

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kilopascals

(Hg) x .4912 = psi x 2.036 = Hg (Hg) x 3.377 = Kilopascals

(H20) x .07355 = Inches

(H20) x .03613 = psi x 27.684 = H20

(H20) x .248 = Kilopascals

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts

(US

qt) x .833 = IMP

Gallons

(US

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kPa) x .145

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20 (kPa) x 4.026 = H20

3

=in

pt

qt

gal

qt

gal) x .833 = IMP

;"

psi

gal

TORQUE

Pounds-Force Pounds-Force

Inches

Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(OC) = (OF -32) x .56

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

gallon = 6.1

US

(in-Ib) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers (Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L)

x

2.352 = US

(OF) = (OC X 1.8) + 32

gallon

'77.13Ibs

gallon = 8.33

gallon = 8.56

Ibs

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

,,,,.,,WESTERBEKE

I

Engines,

& Generators

61

CONTACT

YOUR

WESTERBEKE

SUGGESTED

--

DEALER

SPARE

FOR

SUGGESTIONS

PARTS

AND

ADDITIONAL

INFORMATION

THERMOSTAT

FUEL

SYSTEM

KIT

HARDWARE

FILTER

CARTRIDGE

KIT

Engines & Generators

62

Engines & Generators

WMDW107301106

Westerbeke 5.0Kw BCDR, 5.0Kw BCDBR, 7.0Kw BTDR, 7.6Kw BTDR Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual