Westerbeke 5.5 kw EDC, 5.0kw EDC Operator's Manual

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WESTERBEKE

MYLES

WEBSITE:

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...,,.,,.

REVISION

DECEMBER

CORPORATION'

STANDISH

INDUSTRIAL

WWW.WESTERBEKE.COM

Member

National

MarineManufllcturers

.'

3

2011

150

PARK.

.

JOHN

HANCOCK

TAUNTON

---.-

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

ROAD

MA

02780

Association

.

·

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

cause

and

Exhaust colorless unconsciousness exposure

-

-Nausea

-Headache

-

gasses

gas. can

Dizziness

Weakness

and

contain

Carbon

and

include:

Sleepiness

diesel

and

some

to

the

cancer,

other

reproductive

A

Carbon

Monoxide

death.

and

gasoline

of

its

constituents

State

of

California

birth

defects,

harm.

WARNING

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

engine

an

odorless

and

of

Carbon

in

Temples

Twitching

to

Think

and

can

cause

Monoxide

Coherently

IF

YOU

OR

GET

OUT

seek

medical

until

it

has

·:WARNING

GenelalolB

Produce

CARBON

Regular

Maintenance

~~::'~;.,!

MONOXIDE

Required

A

WARNING

should

be

generator.

WESTERBEKE MONOXIDE are

inexpensive

hardware

DECAL

fixed

DETECTORS

store.

ANYONE

INTO

been

to a bulkhead

also

and

ELSE

THE

FRESH

attention.

inspected

is

provided

recommends

near

easily

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

repaired.

by

WESTERBEKE

near

your

installing

the

engine

room.

obtainable

at

ANY

OF

the

unit

and

engine

or

CARBON

They

your

local

THESE

If

symptoms

and

dl!

not

SYMPTOMS,

pelSist,

restart

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

to

follow

precautions.

take

the

personne~

The

following

the

American

PREVENT

A

while

power.

•

Do enclosures

•

Shut equipment.

•

Use equipment.

•

Make (particularly

•

Remove electrical

•

Do circuits, transfer result if

• Electrical shock capacitor. together.

PREVENT

A

exhaust

very

•

Always

recovery

A

• In case of

before

Know

when

necessary

and

precautions

your

machinery.

safety

instructions

Boat and

ELECTRIC

WARNING:

engine

Lethal

not

operate

off

insulated

sure

not

connect

00

is

running,

voltage

thls

and

covers

electrical

mats

your

clothing

shoes)

wristwatch

equipment.

utilily

except

through a ship-to-shore

switch.

Damage

thls

procedure

results

Discharge

BURNS -HOT

WARNING:

system

hot!

WARNING:

touching

00

components. A running

check

the

tank.

Steam

an

engine

the

power

carefully.

fundamental

dangerous

Yacht

Council

SHOCK

not

touch

or

when

is

present

machinery

in

place.

before

whenever

and

when

handling

and

all jewelry when

shore

to

vessels

is

not

from

capacitor

ENGINE

not

touch

engine

coolant

can

overheat,

engine

Most

accidents rules

and

conditions

to

protect

yourself,

are

in

complwnce

(ABYC)

AC

electrical connected

at

these

without

accessing

working

skin

are

power

followed. handling a charged

by

shorting tenuinals

hot

engine

connections

to

connections!

electrical

on

electrical

dry,

not

electrical

working

to

vessels

double

AC

generator

.

parts

engine

level

at

the

cause

injury

or

death!

allow

the engine

or

checking

the

are

exist

and

your

with

standards.

shore

damp

equipment.

on

AC

throw

may

or

gets

coolant

to

cool

coolant.

PREVENT

A

•

Prevent sparks pump, vapors. removing

•

Do arrester.

•

Do Backfire

•

Do

the engine/generator chances

•

Be

PREVENT

A

injury

•

Follow

hatches

after running before

•

All

equipment

•

BURNS -FIRE

WARNING:

flash

to

occur

or

other

Use a suitable

not

operate

Backfire

not

operate

can

not

smoke

fuel

system.

of

aware

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling

closed

fueling.

the

starling

fuel

vapors

when

handling

well-ventilated

Do

not

fill

Shut

off

the

fuel

system.

spill.

DO

sources

of servicing. the

fuel

system.

Do

not

alter Be

sure

all fuel

Be

certain

free of

leaks.

Make

sure a fire properly Extinguishers for

all

applications

Fire

can

fires.

Do

near

the

potential

the

fuel

line,

without a Coast

can

cause

with

the

cause

severe

or

pennit

Keep

clean

fire.

Wipe

up

- diesel fuel

Explosions

safely

when

fueling.

Check

below

blower.

and

the

NOT

fire

Ensure proper

fuel

maintained.

your

are

and area out

fuel

service

Take

allow

near

or

modify

supplies

line

extinguisher

rated

Run

engine.

highly

storing

away

of the tank(s)

the

fittings

ABC

encountered

cause

injury

not

smoke

carburetor,

sources

container

carburetor,

air

flames

the

and

will

valve care any

fuel

the

Be

of

to

Guard

severe

cleaner/silencer

injnry

or

compartment

free

of

all

spilled

bum.

from

fuel

instructions.

Open

for

fumes/vapor

the

blower

explosive.

fuels.

from

spark-producing

reach

of

while

at

in

catching

smoking,

system

ventilation

fuel

system.

have a positive

are

adequately

is

familiar

by

the

or

pennit fuel spilled

catch

or

fuel

Approved

injnry

or

death.

sparks

debris

fuel

vapors

Keep

and

for

Use

Store

fuel

children.

the

engine

the

engine

any

open

or

engine

exists

installed

with

its

NFPA

in

thls

death!

flames

or

line,

filter,

fuel

fuel or

fuel

all

fuel

when

filters.

flame

or

death.

removed.

to occur

and

to

and

ventilate cabin four

extreme

flames,

shutoff

nearby

proper

are

environment.

near the minimize engine

can

cause

the

vessels

before

minutes

care

in

a

is

running.

when

servicing

fuel

that

or

when

servicing

valve.

tightened

and use.

appropriate

oil.

might

other

the

and

is

~

WESTERBEKE

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

Disconnect generator.

it

last.

•

Make starting.

•

Make re-installed

BAnERY

A

WARNING:

or

death!

•

Do

not being highly arcing equipment duriog

•

Never positive Do

not together. Ventilate

accumulation disturb is

being

•

Avoid burns wristwatch, the

battery.

•

Always the

battery

and

BATTERY

A

WARNING:

severe

STARTING

Accidental

the

Remove

certain

all

certain

all

before

EXPLOSION

Battery

smoke

or

serviced.

explosive

or

by

lit

in

the

servicing.

connect

contacting

or

reconnect

the

(+) connection

test the battery

Sparks any

comparttnent

of explosive

the

battery

charged.

sparks

rings,

tum

the

connections.

it last

ACID

injnry

or

death!

battery

cables

the

negative

personnel

Covers,

starting

explosion

allow

an

Lead

acid

gas,

which

tobacco

products.

vicinity

negative

condition

could

ignite

charger

the

terminals

that could

and

any

battery

when

Sulfuric

startIng

before servicing

lead

are

clear

gnards,

and

the

engine.

open

flame

batteries

can

be

Shut off

to

prevent

(-) battery

termioal

charger Remove

acid

of the starter by

battery

containing

gases.

To

connections

with

cause

an

other

jewelry before

off before

the

disconnecting

in

batteries

can

cause

first

and

of

the

hatches

can

cause

near

emit

hydrogen,

ignited

electrical

cable

shorting the

gases

batteries

avoid

while

tools,

explosion.

negative

the

injury

the

engine/

reconnect

engine

before

are

injury

the

battery

a

by

electrical

all

electrical arcing

to

the

solenoid.

termioals

or

fuel

vapors.

to

prevent

sparks,

do

the

battery

etc.,

to

prevent

Remove

handling

disconnecting

lead

first

battery.

can

cause

not

TOXIC

•

EXHAUST

A

WARNING:

Ensure discharged regularly manifolds/water-injected

•

Be

sure

Run

blowers

•

Do

not equipped detector that boat

builder or

detectors.

•

For

additional

(educational

A

WARNING:

odorless

nausea

•

• Although

AVOID

gas.

or

Do

not

frnnes

can

systems.

copper

Do

not install through exhaust enter

the

flow

of exhaust.

exhaust

gas

is present in symptoms poisoning

Vomiting Dizziness Headache

Nausea

MOVING

Carbon

that

the

exhaust

from

for

leaks

the

unit

when

run

the

generator

with a functioning

complies

dealer

information

Carbon

Inhalation

death!

use

copper

rapidly

Exhaust sulfur

tnbing

resulting

exhaust portholes, discharge

exhaust

diesel

fumes

from

or

signs

are:

Inability Throbbing Muscular

Weakness

GASES

monoxide

system

the

engine.

and

make

elbow

and

its

surroundings

running

set

with

for installation of approved

on

monoxide

produces

tnbing

destroy

causes

in

outlet

vents,

outlet

is

discharge

Avoid

overloeding

engine

exhaust

gasoline

diesel

exhaust

of carbon

to

(CO]

is

adequate

Check

the

sure

the

is

securely

the

generator

or

engine

marine

carbon

ABYCA-24.

refer

to

ABYC

Carbon

(CO]

flu·like

in

diesel

exhaust

copper

tnbing

rapid

exhaust/water

where

exhaust

or air

conditioners.

near

the

waterline,

outlet

and

the

gases

engines,

fumes.

monoxide

think

coherently

in

temples

twitching

and

sleepiness

PARTS

is a deadly

exhaust system

exhaust

are

well ventilated.

set or engine.

unless

Consult your

Monoxide).

is

an

to

expel

attached.

the boat

monoxide

T-22

invisible

gas!

symptoms,

systems.

in

exhaust

deterioration of

lealcage.

can

be

If

the

water

close

or

restrict

craft.

are

not

as

toxic

carbon

monoxide

Some

of

the

inhalation or

gases

is

Diesel

drawn engine

could

the

as

•

When

servicing

level,

wear protection. destructive.

at

once

off into

the

eyes

caps.

the

battery

rubber

gloves, a rubber

Batteries

If

it

comes

with

water.

inadvertently

contain

in

contact

Acid

or

checking

sulfuric

may

when

apron,

acid

with

splash

removing

the

and

which

your

on

electrolyte

eye

is

skin,

wash

the

skin

or

-.y:

A

WARNING:

or

death!

it

•

Do

not service sitnation make touching components.

operating

WESTERBEKE

Engines & Generators

ii

arises

moving

Rotating

the

in

adjustruents,

engine

which

parts

it

and hot

can

while

is

absolutely use

exhaust

cause

it

is

running.

extreme

injury

If

necessary

care

to

system

a

to

avoid

-----

----------

-

•

Do

not

wear

loose equipment; jackets, could

•

Make Keep places

•

Do

not

the

engine

•

Stay when be

caught

HAZARDDUS

A

WARNING:

tie back

shirts,

be

caught in

sure

all

protective

at

all

times.

check

is

clear

of

the

engine

in these

NOISE

sleeves,

attaching

fluid

operating.

the

loss!

•

Never

•

Do

not

removed.

•

Do

not

open.

A

WARNING:

mentally

operate

an

run

an

engine

run

engines

or

physically

clothing

long

hair

rings,

moving

hardware

shields

and

levels

dtive

shaft

is

running;

rotating

High

noise

engine

without its

with

for

long

Do

not

work

incapacitated

or

jewelry

and

necklaces

parts.

guards

or

the

and

heir

parts.

levels

the

periods

on

SAFETY

when

avoid

wearing

or

is

properly

in

their

dtive belts

the

transmission

and

clothing

can

cause

muffler

air intake

machinery

with

by

fatigue!

(silencer)

servicing

bracelets

tightened.

respective

tension

can

hearing

installed.

their

enclosures

when

INSTRUCTIONS

loose

that

while

coupling

easily

you

are

ABVC,

INSTALLING

Read for recommendations

ABYC

"Safety

Order

NFPA

''Fire

Order

USCG

"USCG Order

NFPA

the

following

safety

codes

(American

Standards

from:

ABYC 3069

Solomon's Island

Edgewater,

(National

Protection

from:

NFPA

11

Tracy

Avon

Industrial Park

Avon,

MA

(United

33CFR183"

from:

U.S.

Government

Washington,

AND

DIESEL

ABYC,

and

when

Boat

for

MD

21037

Fire

Standard

Drive

02322

States

D.C.

USCG

PUBLICATIONS

ENGINES

NFPA

standards.

installing and

Yacht

Small

Craft"

Rd.

Protection

for

Motor

Coast

Guard)

Printing

20404

Office

and

USCG

Follow

their

your

engine.

Council)

Association)

Craft"

FOR

publications

OPERATORS

Many

of

in

your

notes

to carefully, procedures.

GASOLINE

Preparations thorough Council's combination

Sections

H-2 P-l Exhaust P-4 E-9

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintain

Manual critical

ENGINE

to install

examination of

(ABYC)

of

sources

of

the

ABYC

Ventilation

Inboard Engines

DC

Electrical

must

(FCR).

safety

along

information.

your

equipment,

AND

an

engine

the

standards.

including

standards

Systems

comply

tips

and

wamings

with

other

cautions

Read

your

and

follow

GENERATOR

should begin

American

These

the

of particular interest

with

INSTALLATIONS

with

Boat

and

standards

USCG

the Federal

are

and

are

manual

all

s;,rety

Yacht

a

the

Code

repeated

and

a

NFPA.

are:

of

~

WESTERBEKE

Engines & Generators

iii

When

installing

attention

WESTERBEKE

be paid

to

the

following

INSTALLATION

engines information:

and

generators

it

is

important

t)1at

strict

CODES

Strict when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For installations or

will be break in the minimum

the

exhaust manifold

raw

water

If

you

have

to

the vessel's

Siphon-break.

NOTE:

A

siphon-break

operation.

engine

damage.

EXHAUST

The exhaust

prevent of the

water

vessels

A detailed diesel engines and generators copies

where

the

below

the

vessel's

raw

water

supply

of

20"

above

injection

damage

any

doubt

waterline

to

the

about

requires

Failure

to

properly

Consult

SYSTEM

hose

must

be

from

entering

hull.

40

page Marine Installation Manual covering gasoline and

can

be obtain off our website in pdf

ABYC

guidelines,

and

generators

exhaust

the

vessel's

engine

under

waterline,

hose

the

periodic

in a

manifold/water

provisions

to

the

waterline.

port

is

at or

and

possible

position

of the

vessel's

inspection

maintain a siphon-break

the

siphon-break

certified

the

for

marine

exhaust

under

is

provided with each unit

and

safety

marine

environment.

injected

must

exhaust

elbow.

Failure

below

the

flooding

water-injected

various

operating

and

manufacturer

use.

The

any

sea conditions

form.

codes mnst

exhaust

be

made

This

to

use a siphon-break

load

of

the

cleaning

can

for

system

www.westerbeke.com

be

complied

elbow

to

install a

hose

must be looped a

waterline

will

boat.

exhaust

conditions,

result

proper

elbow

install a

to

ensure

in

catastrophic

maintenance.

must be designed

and

at

sold.

Additional

any

with

is

close

siphon-

when

result in

relative

proper

angle

to

AVAILABLE YOUR DEALER

FROM

WESTERBEKE

....v:

WESTERBEKE

Engines & Generators

iv

~--------

..

-------

..

----,,------_

..

_-----------

-

--

-----------

TABLE

Parts

Identification Introduction Fuel,

Engine Preparations Digital LCD

Sequence ...................................................

Digital Generator

Daily

Routine

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

Oil

for

Control Control

Break-In

Maintenance

Fuel

System

Cooling

Fresh Water Cooling CircuiL. ..................... 14

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

Air Intake ..................................................... 14

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

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

Raw Water Cooling Circuit ......................... 16 Circuit Breaker

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

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

Engine

Engine Remote

Starter

Troubleshooting ........................................... 20

Generator Wiring Wiring Wiring

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

System

Lubricating

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

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

Motor

Specifications Diagram Diagram Diagram

............................................. 2 Engine

and

Engine

Initial

Panel..

Box

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

Procedure

Coolant...

Start-Up

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

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

........ ; ................................

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

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

Schedule

(Chart)

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

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

~

........... 14 Battery Care ................................................ .33

Oil

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

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

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

#52414

#52793 #53477

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

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

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

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

OF

CONTENTS

Adjustments

.3

Drive Belt Adjustment ................................. 23

5 Torquing the Cylinder Head Bolts .............. 23

6 Generator Frequency Adjustment.. .............. 24

7 Electronic Governor .................................... 24

7 A Valve Clearance Adjustment ....................... 25

8 Engine Compression .................................... 25

9 Spill Timing ................................................. 26

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

10

12 Fuel Injectors ............................................... 28

13

Testing Oil Pressure ..................................... 27

Engine

Troubleshooting

Alternator Shore

Power

15

16 16

17

17 18

.

19

21

22

22A

22B

Generator

Generator Single Phase ...............................

Internal Wiring Diagram .............................

No Load Voltage Adjustment .......... , ........... 37

AC

Terminal Block Connections ............... .38

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

EDC Generator Troubleshooting ................ .40

Lay-up Power Metric

and

Take-Off

Conversion

Suggested

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

'"

(Chart)

Testing

Information

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

Transfer

Switch

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

'"

........................................ .36

Recommissioning

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

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

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

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

Data

Spares

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

(Chart)

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

23

............... 27

29

.31

34

.35

36

.A(

A3

44

..46

.

"""

WESTERBEKE

Engines & Generators

1

5~5KWGENERATOR

20A

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PARTS

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FILTER

DRAIN

FILTER

OIL

FILTER

WATER

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PUMP

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Engines & Generators

4

DIESEL

FUEL,

ENGINE

OIL

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COOLANT

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WESTERBEKE

Engines & Generators

5 .

PREPARATIONS

FOR

INITIAL

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PRESTART

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6

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7

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0

Generalor.s

l'Ieating ......

cycles

np

to

and

The

functions

1800

.'

....

_.

inspection

illuminate

text:

....

thru

1800

rpms-60Hz

engine

RPM

250J,

S¢J~PLl

completed,

sequence

green

. Waiting for operator

the

engine

coolanJ

will

cycle

.Co"lant Temperature

81C

press

will

begin.

and

the

.

Press start to

engage generator

Cr.nking ......

functions,

(1500

rpms-50Hz)

will

rise

in

the

following

32',

0

the

START

The

six

panel

will

-

the

speed

and

to

their

nonnal

sequemce:

17~f.

!

1~tr·

SCROLL

.

-._-

STOP

SEQUENCE

To

stop

the

generator,

will

cycle

thru

the

following

Shutting'

110w,;'

Waiting

Press'

engag.e

FAILURE

If

a

problem

FAILURE

indicator where

the

message Examples:

Failure

Light

CPQl.aill;Temperature

"is

orange,"

..

for

operator

start

generator

LIGHT/SHUTDOWN

occurs,

light

will

lights

will

ttouble

what

has

is

red.

.

press

to

the

generator

illwninate

change

has

occured

happened.

Light

the

STOP

button.

text

messages

Engine Shutdown

will

shutdown

red.

In

addition,

from

green

and

the

display

High Engine Temp.

Reset

ECU

The display

and shutdown.

and

one

to

orange

to will text .

to

Restart'

the

of

the

reveal

.

•

Batt\ry

0 30

SCROLL

To

stop

button.

for

any COfl)!lr. functions.

button

Voltage

13.5voo

Engine Hours

3,8

HOURS

LOCK

the

continuing

This

ellllbies

length of

Use

the

To

resume

again.

,._I:l.CROLL

."

time.

up

and

!

SCROLL

sequence,

the

operator

The

down

scrolling,

.

3.1

·B:A.R'

"

0

120V

word

arrows

press

Oil

Pressure." ' ..

.0

0

.

AC

Frequency

60,1Hz

AC

Line Voltage

o

press

the

to

monitor a single

LOCK

will

to

find

the

SCROLL

40

PSI'.

1Q.Q

.6~9

.

SCROLL

100

!

SCROLL

~i

~~i<;

TTl

function

appear

in

and

observe

LOCK

.

the

other

Failure Oil

Pressure

When

a failure

wiring

assist

in

There

are

displayed

can

easily

Before breaker'

generator

A

NOTE:

\l

output configuration

Light

is

Light

diagram,

solving

many but

they

isolate

re-starting

must

be

started,

Three

phase voltages

red.

is

or~nge.

occurs,

refer

and

general

the

trouble.

combinations

are

all

self

and

correct

the

generator,

reset.

With

the

sequences

of

the

Oil

ECO

20

begin

vary

Pressure

to

text

in

that can and should

amp

corrected

cycling

depending

Low

Reset

to

thetroubleshooting

operating

of

messages

explanatory

the

problem

tlie

the

problem

will

generator.

Restart

this

manual

the

one

DC

circuit

on

chari;

be

operator

occur.

and

the

again.

the

AC

to

"'loY'

WESTERBEKE

Engines & Generators

7A

Conlrol

and

Frequency

are

on

Box

Components

Ihe

following

pag

t

•.

Adjustments.

'.

DIGITAL

CONTROL

BOX

FREQUENCY

Frequency engine

The

ECD

signal

from

over

the

signal

as

Should

a

frequency

The

red

frequency

display

NOTE:

If

same

fault

frequency

.

WHEN

.

FREQUENCY ON BOARD

.ON

is

displayed

is

running

is

receiving a

the

flywheel

both

this

signal

fault

failure

LED

screen

the

unit shuts

"overspeed"

LED

CHANGING

THE

CONTROL

MUST

FOR

50

FAULT

MPD

RPM

LED

will

will BUNK.

(50160

BE

HZ

on

in

·RPMand low

which

ring

gear

and

hertz.

vary

approximately

shut

down

on

the

turn

from

show

the

down

will

THE

GENERATORS

HZ)

SWITCH

PANEL

SWITCHED:

AND

OFF

FOR

the

LCD

frequency

AC

is

positioned

teeth.

will

display

green

fault

for

show

ECU

60

display

voltage

The

ECD

2%

occur,

panel

to

text

"overspeed".

an

underspeed

on

the

#1

HZ.

screen

(hertz).

signal

on

the

interprets

eit\ler

initiated

will

amber

screen

while

and

hertz

bellhousing

this

up

or

down,

by

the

illuminate,

and

the

LCD

condition,

but

the

ECD.

the

GENERATOR

CAUTION:

the.

ECU,

box.

Tum it back

NOTE:

If

same

fault "overspeed"

frequency

1.

Turn

FREQUENCY.

When

changing

tum

off

on

the unit

LED

the

DC

shuts

will

breaker

.position.

2.

Open

the

cover

(Elec.tronic

3.

Locate

position See control

4.

Replace the

and

Control

th"·#1

that

corresponds

the illustration

box.

control

start

the

unit.

engine/generator

frequency.

the

20

amp

after

down

will

BUNK.

on

of

the

Unit).

dipswitch

below

box

Monitor

is

operating

ADJUSTMENT

the

generator frequency setting

DC

circuit

the

setting

has

for

an

underspeed condition,

show

on

the

lhe

control

box

and

on

the

ECD

to

the

Hertz

showing

cov.er,

tum

the

frequency

is

operating

(HERTZ)

breaker on

been changed

screen but

panel

to lh.-OFF

view the

and

move

operation

the

ECU in

the

DC breaker

that the

at ihe

.

the

control

th.e

ECD

it

to

the

desired).

the

ON

COlTect

on

the

CONTROL

INTERNAL

CAUTION

generator's This normal

to

NOTE:

BOX

COMiPONIENTS

(WESTERLINK

starling

can

be

as

tleasollal

the

generator

Keep

ilJ

much

use.

with

mind

or

NMEA-200D):

battery

when

as

72

amp-hours However, a

NMEt\.200q

that

the

Westerbeke

rhe.,unir

if

the

The

electronic

is

in

in a monrhs

generator

,Iystem

or

gellerator

Q.

static

time

set

is

shllt off

maybe

components

Slate.

This

with

no

not

to

be

the

DC

the

DC

~

in

rhe

Digital

as

much

use.

number

the

generator's

Diesels

as

It

js

not

ofmomhs,

50

the

maybe

generator

used

for a

breaker

~n

power supplyJor

WESTERBEKE

Engines &

Generators

draw

a very

milli·amps for

necessary

vessel)'

such

control

N1v1EA·2000

to'

as

box

small

the

system

be

concerned

willter

for

a

WESTERL/NK

amount

storage,

network.

of

EeU

with

it

DISPLAY

NOTE:

DURING

OF

THE

LCD

CAUSED

BY

AND

NO

CAUSE

amperage

and

50

milli·ampsfor

this

slight

is

best

to

system.

PANEL

OPERATION

DISPLAY

MAY

HEAT.

THIS

IS

FOR

CONCERN.

(milli·amps)frQm

amperage

disconnect

each

draw

the

DC

THE

COLOR

VARY.

NORMAL

the displ.ay.

during

power

.

8

-~~-'

---

------

DESCRIPTION

A

remote

panel

is

availa1:>le

and

started

stopped

connecting of

these

NOTE:

WESTERBEKE

harnesses

can

For

additional

REMOTE

from

be

combined

dealer.

3-1/4"

(B2.ij5Mn~1

PANEL/PIG

that

allows

any

location

come

in

three

for a maximum

information,

TA

Il

REMOTE

AND

EXTENSION

the

generator

on

the

boat The

different

contact

run

your

lengths

at

75'

local

STOP/START

HARNESSES

to

be

and

two

(22.17M).

6"

PANEL

(152.4MM)

CONNECTING

CABLES'

15'

(4.75M)

3~'

(9.1M)

60'

(1B.2M)

EXTENSION

PN

052959

PN

052789

PN

052960

PN052560

~

....

l""~

These

two

dimensions

are

the

measurement

of

the

cut-out

opening

.

Engines ,i."q",".rators

8A

DESCRIPTION

Although hour of assembly operated life operated and

Breaking-in a piston and glazed engine

Your conditioning to Perform following:

Start section. water

AFTER

Once tion between

your

test

operations

procedures

properly, a break-in

of

your

engine

serviced

new

rings

to

smoky

operation

or

scored,

during

new

engine

operation

maximize

this

the

engine

Run

pump,

the conditioning

the oil

START·UP

the

generator

and

then

encourage a fast

20%

engine

is

engine

the

cylinder

which

the

break-in

requires

performance

according

engine

pressure,

has

and

60%

has

experienced a

at

the

factory

were

followed

time

dependent

during

its

basically

walls.

indicate that

is

caused

period.

approximately

to

break in

and

carefully,

to

the

while

checking

battery

been

started,

warm-up.

of

full-load

GENERATOR

minimum

to

make

sure

and'

that

the engine

is

required.

upon

how

initial

involves

Excessive

the

cylinder

by

overloading

each

service

keeping

STARTING

charging)

check

for

the

hours

of

seating

oil

50

hours of

moving

life of the

in mind

PROCEDURE

that

all

are

for proper

Run

the

first

The

engine

use.

consumption

walls

systems functioning.

10

BREAK-IN

of

one

accurate

service

is

the

are

the

initial.

part in

order

engine.

the

(raw

opera-

generator

hours.

PROCEDURE

After

the

first

10

hours of

can

be

increased

cally

vary

Avoid

overload

exhaust

the

the rpm Hertz), current

NOTE:

draw

with

current

generator's rating.

to

produce

control drawn

Be

requiredfor starting

can

GENERATOR

Once

the governor the

engine's break-in period

period

see

ENGINE

may

also

adjustment

to

the

full-load

the

load

at

all

times.

reduced output

being

drawn

Since

60 hertz

of the generator's break-in is governed

from the

aware

of

motor

be 3 to 5 times

INFORMATION

ADJUSTMENTS

generator has been

adjustments

ENGINE

ADJUSTMENTS

be

required in

see

required

SPEED

GENERATOR

the

generator's

rated

An

overload

voltage

from

the

generator

(or

at

1500

generator.

starting

motors.

normal

placed

for

(first

(HERTZ)

..

A

no-load

conjunction

INFORMATION.

operation,

output,

is

signaled

and

frequency.

generator

and

operates

rpm

to

produce

loads

and

This

starting amperage

running

in

this

manual.

in

operation,

amperage.

engine speed

50

hours)

the

or

then

keep

high

after

the load

periodi-

by smoky

Monitor

at

50

there

(hertz)

this

ADJUSTMENT) under

voltage

adjustment

with the engine's speed

it within

1800

by

the

current

See

may

during

be

CHECK

Follow

•

CHECK

•

LIST

this

Check in

the

off

Record

relate

to

Any

deficiency

be

corrected Visually Check

Check Check

WITH

Check blow-back

•

Confirm

When When

When

check

that

position

the

inspect

the the

your the drive

for

exhaust

the the

the

engine engine engine

all

hourmeter

oil coolant

starting

abnonnal

sounds.

list

each

generator

before

reading

maintenance

or

problems

before

start

the

engine

level

(dipstick).

level

fuel

supply.

batteries

belts

for

wear and

THE

ENGINE

noise

smoke:

is

cold - White

is

warm

is

overloaded -

day

before

circuit

starting.

in

schedule.)

in

up.

for

i~

the

(weekly).

RUNNING.

such

- almost

starting

breakers

your

the

followil1g

fuel,

oil,

coolant

proper

as

knocking,

Smoke.

Smokeless.

some

THE

your

(power

log

(engine

or water

recovery

tension

Black

DAILY

generator. panel)

hours

items

must

leaks.

tank.

(weekly).

vibrating

Smoke.

are

and

ROUTINE

NOTE:

Some

unstable

This

condition

is

reached

A

periods

and

CAUTION:

of

time

generator.

STOPPING

Remove the

generator temperature, generator safety

CAUTION

Digital Diesels draw a very

the

generator',SlStatting

maybe

. for

each

I: with

amperage draw during nonnal seasonal set

is

best

to

."

system or

:

WESTERLINK

. .

NOTE:

supply for

THE

the

AC

to

then

is

shutdown,

precaution.

(WESTERLINK

as

much

display.

no

generator

not

to

be used for a

disconnect the

shut

off the

system.

Keep

in

mind that

the

vessel:S-

running

should

abate

loads

are

applied.

Do

not

operate

without a load

GENERATOR

loads

from

run

for

3-5

tum

the

close

or

NMEA-20DO):

small

battery

as 50

milU-amps

This

can

be as

use.

It

is

not necessary to be concerned with this slight

number

DC

power

DC

breaker

the

Westerbeke

NMEA-2000

may

as

normal

the

generator

minutes

key

to

down

amount

when

the

for

the

much

as 72 amp-hours

of

months,

to

the

on

the generator's

network.

occur

in a cold

operating

the

generator

being

placed

one

to

stabilize

the off

position

all

circuit

breakers

The

electronic components

of

amperage (milli-amps)

unit

is

in

system ECU

use.

generator

a static state. This

and

However, such

as

winter storage,

with a NMEA-2000

control

maybe

engine.

temperature

for

long

on

the

at

a time.Allow

the

operating

..

Once the

as

50

milli-amps

in

a months

if

the

generator

box for a

the

DC

a

in

the

from

time

it

power

. .

is

Engines & Generators

9

A

WARNING:

running. use

the

servicing

NOTE:

Many

difficult

and

Wear

the

correct

any

of

the

may

MAINTENANCE

Never

attempt

proper

tools

for

the

engine's

following maintenance jobs

require

the expert

safety

each

DC

to

perform

equipment

job.

Disconnect

electrical

knowledge

SCHEDULE

any

service

such

as

the

battery

equipment.

are

simple

of

a service

while

goggles

terminals

but others

mechanic.

the

and

engine

gloves,

when

are

more

is

and

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Separator

Oil

Level

Belts

Inspection

.

Fuel

Filter

SiartingBatieries,

'(a~d

House,Batteries)

Engine.oil

.

,

Generator

Heat

Fuel

(and

Exchanger

Filter/Water

of

Engine

filter)

Zinc

Anode

Separator

CHECK

EACH

DAY

D

weekly

D

weekly

HOURS

OF

OPERATION

100

250

500

750

50

NOTE:

and

oil

remain

Please

will

inhibit

cool.

keep

the

engine

engine's

1000

surface

ability

clean.

to

D D D D D D

, '

D

D D

D D D D

D

D D

D

D D D

1250

Dirt

D

EXPLANATION

Diesel

No.2

Check

for

water

if

necessary).

Oil

level

should

dipstick. Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Initial

change

Every

50

operating

and

make

excessive

Initial

engine

change

both

Check

that

with

no

chafing.

for

additional

Inspect

zinc

exchanger Inspect

daily.

hours

of

use

drain

separator

MAINTENANCE

rating

of

and

dirt

indicate

tank;

if

needed.

proper

tension

if

needed.

fuel,

oil

and

connections.

loose

belt

tension

at

50

hrs, hours

sure

connections

corrosion

.

oil & filter

every

100

AC

connections

See

information.

anode,

replace

end

of

zinc

Replace

or

as

found

bowl

OF

SCHEDULED

45

cetane

or

higher.

in

fuel

(drain/replace

between

if

Check

water

hours.

GENERATOR

anode

filter

as

empty,

(3/B"

belt

leaks.

Keep

.

then

change

check

are

change

are

clean

if

needed,

debris.

element

to

be

needed.

MAX.

check

to

1/2"

edges

Inspect

bolts

electrolyte

very

at

50

SECTION

needed.

and

LOW

at

manifold.

deflection)

for

wear.

wiring

,&

nuts

every

250

levels

tight.

Clean

hrs.,

then

and

secure

clear

the

every

250

Clean

filter

on

tight.

hrs.

off

heat

and

Text

Removed

Exhaust

System

Engine

Hoses

Inlet

Fuel

Filter

D D

D

D D D

D

D D

Engines & Generators

D D

D

D D

10

D

Initial

check

the

system

manifold.

and

other

dition.

No

Hose

should

spongy.

Check

Replace

initially

or

as

needed.

at

50

hrs.,

is

securely

System

is

properly

components

leaks.

,be

hard & tight.

and

tighten

at

50

hours

then

every

fastened

supported

are

in

good

Replace

all

hose

and

250

hrs.

to

the

exhaust

and

serviceable

if

soft

clamps.

then

once a year

Ensure

muffler

con-

or

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

hour

meter

gauge

to

by

running

time.

SCHEDULE

log

your

engine

hours

or

record

your

SCHEDULED

MAINTENANCE

Raw

Water

Pump

At

80Q

.

operating

disassemble

for

overhauL

Raw

Water

Pump

Air

Inlet

Filter

Coolant

System

Electric

Fuel

DC

Alternator

'Fuel

Injectors

'Starler

'Preheat

'Engine

'Torque

•

'Heat

Motor

Circuit

Cylinder

Compression

Cylinder

Hold-down

Adjust

bolts

the

Valve

Exchanger

and

Lift

hours,

inspect

Drive

Pump

Head

Clearances

CHECK

EACH

DAY

50

0

HOURS

100

0

OF

OPERATION

500

250

0 0

0

0 0

0

0 0

0

750

0

1000

0

1250

Remove

0

imp~lIer,

Inspect

seal

should

Remove slot

Inspect

0

Replace

Drain,

appropriate

various

Periodically

0

inspect Check

0

bracket; Check

spray Check

0

and

pinion

Check

0

clean Reinstall

Check

0

(see

At

(see

Adjust

(see

Remove,

pressure

EXPLANATION

the

pump

cam,

cover

housing

or

oil

leaks.

turn,

not

pump

for

wear.

every

100

as

needed.

flush,

and

antifreeze

cooling

check

the

fuel

DC

charge

tighten

and

adjust

condition

solenoid

lubricate.

first

ENGINE

Clean

drive. operation

glow

plugs;

with

anti

compression

Engine

Adjustments).

50hours,

ADJUSTMENTS).

Valve

Clearances

ENGINE

ADJUSTMENTS).

have tested.

OF

SCHEDULED

MAINTENANCE

cover

and

impeller.

and

inner

wear

weep

holes

for

Check

shaft

bearings

wObble).

and

inspect

pump

hours.

Remove

refill

cooling

system

mixture

compatible

system

metals.

the

wiring

connections

line

connections.

from

alternator.

electrical

(see

and

professionally

injection

ENGINE

motor

and

of

preheat

check

seize

pressure

then

every

connections.

opening

ADJUSTMENTS).

for

corrosion.

lubricate

solenoid.

resistance

compound

and

500

cleaned

plate

signs

shaft

and

Check

pressure

the

(0.4-0.6 on

timing

hours

Inspect

the

for

wear.

of

shaft

water

(the

shaft

and

drive

clean.

with

and

mounting

and

Remove

starter

motor

Remove

ohms).

threads.

and

'WESTERBEKE

,

-,

c"',

A

DC

components,

I .

tuined

battery

recommends

_

"'7-:_

CAUTION:

When

the

off

using

either

switch.

this

service

be

performed

" •

ser~icingJchanging

DC

power

must

be.

the

DC

breaker

. .

or

".

the

by

an

authorized

Engines &

11

mechanic.

Gene.ralors

FUEL

SYSTEM

DIESEL

USE A DIESEL

(No.

FUEL

Th~

manufactured from must separator

clean,

schedule

FUEL

A

installed

water be

The fuel impurities.

maintaining fuel a

FUEL

The of The and the owner/operator is cautioned not it. authorized attempt

FUEL

2·0

(SAE

J313)

FILTERS

fuel

injection

water

aiJ.d

pass

through at least

and

the engine's spin·on

and

change

in

this

WATER

primary

10

fuel

between

and

other

carried

to

the fuel

owner/operator reaching

tank

micron

the engine's

This

a proper

and

the

filter

INJECTION

fuel

injection

the

diesel

engine,

fuel

injection

If

it

requires

fuel injection

to

disassembly

WITH A CETANE

diesel

fuel

according

pump

and

1he

and they

dirt.

To

these

manual.

must

ensure

two

filters

receive'

this

fuel

according

SEPARATOR

filter

of the

water

the

fuel

tank

and

contaminants

system

is

process

fuel

generator/engine.

be

used.

from

on

the engine.

responsible

injection

is

accomplished

filter/water

PUMP

pump

is

the

most

requiring

pump

servicing,

the

has

been thoroughly bench-tested

remove

pump

service

and

repair

RATING

fuelinjectors

flow

filters, a fuel

fuel

separating

the engine

the

for

equipment

Westerbeke

utmost

it and

it.

OF

#45

OR

HIGHER.

to

ASTM

0975}.

are

precisely

clean

diesel

fuel,

free

of

clean

fuel,

the fuel

water

filter.

Visually

to

the

type

fuel before

making

separator

important component

certain

by installing and

caution

to

attempt

take

it

facility.

inspect,

maintenance

must be

to

remove

they

can

the

is

free of

between the

recommends

in handling.

to

service

to

an

Do

not

ENGINE

Periodically leakage. then

Changing/cleaning

1 .. Shut off

2.

3.

4. Replace

FUEL

Replace

follbw

Unscrew housing housing,

Remove

to the

housing.

as

not

so

"0"

ring,

supply

FILTER

check

the fuel

the

filter

the

MAINTENANCE

the

fuel

supply.

the

retainer ring that

and

allow

the bowl

and

replace the

the

sealing

Thread the retainer ring

to

cross

thread.

tighten 1/4 -

and

run

the engine

the

"0"

connections

element

after

SCHEDULE.

filter

element

holds

to

come

filter

element

ring

and

When

1/2

turns

to

inspect

and

the bowl

the first

the filter

away

and

reassemble

on

retainer contacts the

by.

hand.

for

leaks.

50

hours

bowl

from

the

clean

the

carefully

Open

for

to

the

bowl.

bowl

the fuel

the

FUEL

LIFT

PUMP

Periodically and

make

~etight

pulnp's rriouniiligbolts the

mOunting

When purge

qffuel

INLET'

,!,o,ens.ureclean in-line

check the

sure'that

and

energized

air

frOm·theiuel

as

the

FUEL

fuetfillJ:l:,c,onnected

no

s~ure.

The

bolt

to

ensure

thru

engine

is

FILTER

fpel into

fuel

connections

leakage

DC

should

the

preheat

system rurriJiug:

the

to

is

present

ground

connection

be clean and

proper

pump

circuit,

and

provide a

fpelliftpump,

to

the

fuel

lift

and

out

and

that

at

well

secured

operation.

the

fuiol1iftpump

continuous

'.

there

pump

elbow.

of

the

fitiings

one of the

"

flow

' ,

is a

small

,

~

pump

THE

O·RING

ONLY

by

will

'

REPLACES SIGNS

WESTERBEKE

Engines & Generators

GASKET

NEEDS

TO

IF

IT

OF

AGING.

FUEL FILTER

FUEL

PN#052853

BE

SHOWS'

LIFT

PUMP

12

DESCRIPTION

Westerbeke for

fresh bustion which water parts, from exchanger,

water

marine

water

and

friction

circulates

coolant

and

the

fresh

similar in

flows

through

cooling.

throughout the cools engine

water

diesel

Heat

is

transferred

the

engine

oil.

The

co01ant

function

the

tubes

engines

are

produced mille

to

fresh

engine.

block,

heat

is

transferred

to

raw

water

to

an

automotive

of

the

heat

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

designed

water

This

its

internal

by

exchanger

----

COOLING

and

equipped

engine

by

com-

coolant

circulating

externally

means

radiator.

fresh

moving

of a

heat

Raw

while

.

-----.:...

--.

SYSTEM

fresh

water

coo

ferred

to

the

tube

walls

to

exhaust

other coolant transferred heat

fresh

each allows harmful

system

words,

is

water

other.

the

deposits.

cooled

coolant

Using

cooling

hint

fresh

the

raw

where

the

engine

by

overboard

only

flows

water

raw

and

water

around

coolant

finally

is

cooled

water,

through

raw

fresh

passages

the

tubes;

engine

is

conducted through the

which

is

then

pumped into the

it

is

discharged overboard. In

by

fresh

water coolant, this

and

the

raw

water

the

exhaust system. The

water

circuits

water

to

are independent of

coolant

within

stay

clean

heat

carries the

the

engine

and

free from

trat]s-

INCOMING

COOLING DIAGRAM

FRESH

CIRCUIT

WATER

RAW

WATER

RAW

(TYPICAL)

¢

..

NOTE: VALVE

FRESH DRAIN

AN

ANTI-SIPHON

MAY

HEAT EXCHANGER

WATER

BE

REQUIRED

.....

WESTERBEKE

Engines & Generators

13

WATER

DRAIN

···CootINGSYS-TEM

FRESH

NOTE:

WATER

Refer

ommended

fresh

water

Fresh

water circulating coolant to enginl'

When prevented flow manifold thermostat coolant cooling

RECOVERY

Ihen

the

heat

exchanger

block

the

engine

by

is

bypassed

from

to

flow

system.

TO

COOLANT

TANK

FROM

COOLANT

RECOVERY

TANK

COOLING

to

the

ENGINE

antifreeze

coolant.

coolant

pump,

absorbing

passes

via

the

is

the

closed around

overheating).

gradually

umestricted

and

water

is

pumped

through

where

suction

started

thermostat

the

opens,

CIRCUIT

COOlANT

mixture

through

heat

from

the

thermostat

it

is

cooled,

side of

the

cold,

external

(allhough

thermostat

As

the

engine

allowing

to

the

external

KEEP

THE

COOLANT

section to

be

used as

the

engine

Ihe

engine.

into

and

returned

circulating

coolant

some

to

prevent

warms

full

flow

of

portion

PASSAGE

PRESSURE

yCAP

for

by

The

the

manifold,

pump.

flow

coolant

the

up,

the

of

the

rec-

the

a

to

the

is

exhaust

the

engine's

the

CHANGING

The engine's

MAINTENANCE

become

A

COOLANT

coolant

SCHEDUlE.

contaminated,

CAUTION:

Proper

critical; a SUbstantial

.

traced

bilCk

to

cooling

Drain

the

engine

coolant

engine

block

and

opening

the

system

with

fresh

the

refill

process.

NOTE:

Tlte

drain

petcock

be

used

to

drain

must

be

it

can

cooling

number

system

by

the

water,

on

engine

changed

If

Ihe

lead

to

overheating

system

of

engine

corrosion

removing

manifold

then

reinstall

the

heat

coolant.

according

coolant

is

maintenance

failures

•.

the

drain

pressure

the

draio

exchanger

COil

.'

/"LLI'"

to

the

allowed

problems.

can

plug·on

cap.

Flush

and

should

also

LAliT

DRAIN

HD

PLUG

to

is

be

the

start

6MM

NOTE:

Periodically

pressure good

the

closes cap. coolant

coolant

able

to

Coolant

The

traction out provided

water

operating

NOTE:

located

cap.

condition.

vacuum,

valve opens and

tightly.

Check

also

passage

within.

to

expand

andfron'/.

the

Recovery

coolant

recovery tank

of

the engines

introducing

with

coolant conversion kit

the

Tltis

tank,

at or

above

check

the

Ensure

the

upper

Check

to

ensure

Cony a

spare

to

ensure

the

is

clear

so

the,

system

is

and

contract

coolant reCaVel)1

Tank

coolant

air

into

the

fresh

water

cooled

engine.

with

its

slWI1

the

level

COOLANT

RETRACTION

condition

and

lower rubber seals are

tank.

allows

for

dnring

system.

This

models

and

must

run

of

the

engine ~ manifold.

of

the

manifold

the

expansion

engine

operation

recovery tank is

and

with

be

installed before

plastic

hose,

and

Witll-

the

fresh

is best

con-

in

Refilling

. After

exchanger's slowly

Monitor the the manifold to the filler pressure

Remove coolant Inix the

flow

After

Coolant engine needed and spilled

AIR

Clean top functions: provides

The be

clear periodically obstruction.

the

Coolant

replacing

pour

cap.

into

checking

cools coolant.

coolant

clean, coolant

cap. the

cap

to

Run

the

should

check

the

engine

premixed

on

the

halfway

the

engine

ricovery

for

leaks,

draw

down.

Add

the

petcock.

in

INTAKE/COOLING

air

is

drawn

into

side

of the

generators

it

cools

the

clean

fresh

generators

from

be

air

intake

obstruction

inspected

c\

block

coolant

the

manifold

neck

coolant between

and

observe

tarik.

stop

back

into

coolant

the

engine

backend.

electronics

air

for

engine

must

and

to

be

drain

Then

and

install the

recovery

LOW

the

engine

the

to

in

the

Ihrn

in

have

the

air intake

sure

run

the

engine

into

the

manifold.

and

add

as manifold

tank

and

MAXand replace

the

coolant

and

allow cooling the

combustion.

system

recovery

manifold.

the

air intake at the

The

air

the

control

"breathing

it is

also

serves

hose

free

heat

at

idle

needed.

fill

with

expansion

it

to

as

the

tank

if

Clean

up

two

box

and

space"

should

from

and

Fill

cool.

any

and

Engines &

14

A

CAUTION:

with

the

Generators

Never

generator

running.

perform

air

intake

maintenance

THERMOSTAT

A

thermostat,

engine,

continuously

the

engine coolant hole

in overheating). gradually checked,

and

gasket

Replacing

Remove housing gasket, gasket cap

screws.

Run

the

there

are

controls

is

from

Ihe

Ihermostat

opens.

cleaned,

the

cap

as

shown.

apply

before

engine

no

leaks

located

the

coolant

flows

through

first

started,

flowing

As

the

(some

Ihe

engine

The

Ihermostat

or

replaced

Thermostat

screws

When

a thin

coat

pressing

and

check

at

the

near

the

temperature

the

closed

coolant

to

prevent

wanns

and

disassemble

installing

of

sealant

it into

for

thermostat

manifold

closed

thermostat

is

1he

up,

is

accessible

easily.

the

on

place.

DO'

nornrnl

housing.

at

the

front

as

the

coolant

cooling

circuit

prevents

by-passed

exhaust

manifold

Ihe

Ihermostat

and

Cany a

the

new

thermosta1

both

sides

not

over-tighten

spare

thermosta1

ternperatores

of

tlie

When

1j:rrough

from

can

be

Ihermostat

and

of

the

1he

and

that

RAW

WATER

NOTE:

Alw~s

the

strainer

A

clean

a

engine's strainer in

Ihe

glass

Perform

INTAKE

install

will

always

raw

water

cooling

when

making

should

the

fOllowingmamtenance

STRAINER

the

strainer

be

intake

system.

Include a visual

your

be

clear.

strainer

at

or

below

self-pliming.

is a vital

periodic

engine

after

the

waterline

component

inspection

check.

every

100

of

The

hours

of

Ihe this water

of

so

,

operation: L

Close

the

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open

7.

Run

NOTE:

Also

Ihe

the

and

the

engine

follow

raw water

clean

glass.

washer

and

seacock

install

and

the

seacock.

Ihe

strainer

if

necessary.

the

..

check

above

'

filter.

strainer.

for

leaks.

procedure

after

haviJ'g

TUn

hard

aground.

If

the

engine normal may

have

raw

water

temperature

reading,

been

through

Ihe

caught

cause

the

gauge

may

up

in

the

cooling

ever

shows a bigher

be that

strainer,

system.

silt,

leaves

slowing

or

the

than

grass

flow

of

I-~''!'-''=.~~:~

FOR COOLING

GASKET

USEHI-TACKSEAf.ANT

PETCDCK

PUSHING

AIR

FROM

SYSTEM

PN#036956

THERMOSTAT ASSEMBLY

THE

STI)A,INER

~I~TER

_-"'"liS'

INCOMING RAW

WA1'tR-

SEACOCK

TYPICAL

(OWIIER

.......

I',!

---'7>""_

INSPECTAND

CLEAN

EVERY

100

HOURS

RAW

WATE;R~~;

INSTALLED)

~

WESTERBEKE

EngInes & Generators

15

RAW

WATER

The

raw impeller ocean,

lake,

the

water

to through exchanger water

coolant. water-injecte4 exhaust exhaust driven

thruugh

HEAT

EXCHANGER

Cool

raw exchanger. the heat of the internal which

is

charged. through

NOTE:

Operating

that a

heat

every

1000

CODLING

water

flow

pump.

TIns or river from a strainer.

the

pump

tubes)

The

gasses.

T1:rls

the

water

flows

As

the

then

pumped

The

engine

the

engine

exchanger

hours.

is

pump The

to

where

raw

nrlxture

stem

engine

coolant

and

in

silty

CIRCUIT

created

draws

thru-hull

raw

the heat

it

cools

water

elbow,

tube

through

coolant

engine

into

the

(now

the

circuit

arullor

cleaning

by

a positive displacement

water

directly

opening

water

passes

exchanger

the

engine's

is

then

discharged

mixing

of

exhaust

and

overboard.

the

inuer tubes of

passes

is

conducted

exhaust

cooled)

repeats

tropical

be

peifol7ned

Witll,

from

(through

circulating

and

gas

and

around

to

system

flows

itself.

waters

through

the

and

more

COOLING

SYSTEM

RAW

The

from

the

strainer

the

heat

into

the

cooling

raw

water

the

heat

these

raw

dis-

back

may

require

often

a hose

fresh the

is

tubes,

water

then

non-ferrous

has

within

On

always

(an wheo operation.

are start-up. periodically

MAINTENANCE

NOTE:

(seals purchase a new

a

Changing

Close

and,

carefully

inlpeller

curved

ing.

the

WATER

raw

fle«ible

the

no

acconn! should this pump be run

be a spare

inlpeller

lubricant

cautioned

water

housing blades

inlpeller

kit).

Such

The

raw

for

PUMP

pump

and a Neoprene

which

housing,

inlpeller

Raw

(raw

water)

failures

to

make

water

broken

is

a

self-priming, wipe

and

water

is

are

not

sure

raw

pump

or

tom

producing

pump

not

should

SCHEDULE.

Should a failure

ami

bearings),

pump

occur

it

may

alld

with

be

rebuild

spare.

the

Raw

Water

fue

raw

using

pry

and

carn

When

inlpeller

water intake

an

impelle,

the

inlpeller

gasket.

plate

and

assembling,

and

gasket.

valve.

puller,

out

Move

fue

push

the

apply a thin

Opeo

screw

of

rotary

inlpeller_

against

a curved

the

inlpeller

warrantable, water

impeller

nwre

Pump

blades inlpeller

the

inlpeller

present

flow

be inspected

the

pumps

cost

the

original

Impeller

Remove

drivers,

the

pump.

to

coating

raw

water

cover

blades.

COnfOffil

into

pump with a

The

inlpeller

caro pumping dry_

There

gasket

failures occur

during

engine

and operators

is

present at

See

.

internal parts

efficient

to

pump

the

pump

or

pliers,

Install

the

to

fue

pumps

of

lubricant

intake

valve.

plate

action.

should

aboard

as

cover

new

the

hous-

to

HEAT

EXCHANGER

CLEAN

OUT

ZINC

ANODE.

A zinc

anode,

circuit

witl:rln

anode

is

to

in the

raw

water cooling

of

electrolysis condition of the

anode

cleaned

should be

NOTE:

and

NOTE:

not insulate 1wusing

carried

ELectrolysis

vesseL

The

threads

require

the preventing

BOTH

ENDS

or

pencil,

the

heat

sacrifice

on

other

the

zinc

or replaced

on

is

Location;

of

sealant.

zinc

from

~"1l'i~=::.--

-/"'''AN

is

located

in

the

exchanger.

itself

circuit,

componeots

anode

board.

the

result

1Wt

thot

the

zinc

Sealant

the

electrolysis

to

electrolysis

thereby

should

as

of

the

atwdes,are

should

metal

of

action

The pwpose

of the

be checked

required.

each

engule.

not

tIle

'HAW

WATER

OUT

DEBRIS

CLEAN

REUSE

raw

water cooling

of

the

action

taking

reducing the effects

system.

Spare

pa/ticular

pipe

be

used

The

monthly

anodes

instalLation

threads

as

it

may

heatexc/wnger

on

the

zinc.

DRAIN

AND

zinc

place

and

WU}

do

.

A

CAUTION:

impeller,

cooling

they

circuit.

exchanger.

INSPECTIDN:

EACH REPLACE

ANY

CHECK

BLADE

BY

THE

CRACKS.

If

any

must

They

THE

BASE

BENDING

IMPELLER

IF

THE

SLOT LIGHTLY

PUMP

AND IMPELLER

GLYCERIN.

INSPECT

AND

IMPELLER.

IF

THEY

OF

WEAR.

of

the

vanes

be

found

to

often

can

be

OF

VIGOROUSLY.

THERE

ARE

FITS

INTO

IN

THE

GREASE

CHAMBER,

THE

SHOW

THE

SHAFT.

THE

O-RING,

WITH

Q-RING

REPLACE

SIGNS

have

prevent

blockage

found

broken

in

the

heat

off

in

the

Engines & Generators

16

- -

---

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

ENGINE

1.

OIL

Drainulg

the

sump

while

the

replace

the

CHANGE

the

Oil

drain

hose

engine

hose

securely.

NOTE:

Thread

size

is

114NPT.

Always yellow/gray the prompt qualified Raw the siphoning circuit is poor

2. Replacing the Oil

filter, in the helps should

NOTE:

filter

Place

filter (Oil cooling oil sealing rubber

bracke~

oil.

Although

water

exhaust

into

often

location

you

the

upper

oil

from

to

be

Do

to

some

when

or

any

filter

sealing

observe

emulsion

attention

mechanic

present

system

of

raw

the

exhaus~

caused

by

or lack of

may

find

and

it

into a container

lessen

spillage. A small

helpful

IIOt

punch

nui.ke

certain it

paper unscrewing other

abiJi1y.

Keep

as

it is

removed

gaSket

comes gasket

gently

remove it.

the

Sump.

Discharge

(attached

is

warm.

in

its

bracke~

for

the

used

indicates

this

condition

to

prevent should

in

the

attached

water

the

absence

Drain

lube

oil

as

serious

water

oil

can

to

through

filling

to

the

and

oil

it is

the is

the

of

maintenance.

Filter.

When

it

helpful

and

lower portion of

before

in

removing

this

towels

fiuid

your

off remains

on

the

lrole

witlrout

can

be

renroved.

and a plastic

it

to

catch

the

engine

to

make

with

the

sealed

ENGINE

the

used

oil

through

the

front

of the

engine)

used

oil

completely,

replace

drain

rare,

be

be the

engine

the

engine.

an

removing

cleaner the

automotive

old

any clean.)

sure that the rubber

old

the

hose

removed.

presence

it

does

damage.

present

result

andlor

raw

water

This

anti-siphon

the

to

old

filter

removing

oil

filter.

first

loosening

bag

around

oil

left in

reduces

Inspect

oil

filter.

against

end

capped

A

of

water

require

Call

in

the

of a fault

cooling

problem

valve,

used

punch-a

to

it.

filter

the

the engine's

If

the

filter

LUBRICATING

When gasket's apply on

cap

end

in

a

oil.

a

oil

hole

drain

This

wrench

the

filter.

the

old

this

in

its

filter filter

NOTE:

through

A

contaminants. and discard used

NOTE:

matedal generic parts.

run

and that

3.

Filling

-cap After checking around stop lube the

OIL

installlng

sealing

a

thin

coat

the

new

oil

nipple

on

finnly

by

TI,e

engine

passages

WARNING:

Avoid

nails

thoroughly

clothing

oil

properly.

Genedc

standards

parts

might

Irmnediotely

the

engine

there

the

Oil

on

the

top

refilllng,

the

oil

the

new

the

engine.

oil

dipstick.

dipstick,

should

the

surface

of

clean

filter.

the

oil

hanel.

oil

in

Used

prolonged

using

or-

rags

filters

or after an

to

make

are

110

Sump.

of

the

run

the

pressure.

oil

filter

Then

Fill

new

oil

on

the

engine

Screw

the

filter

bracket,

is

cooled

the

oil

filter

engine

soap

containing

are

not

diameters

be

entirely

sure

oil

leaks

Add

engine

Make

or

check

to,

but

the

engine

filter

element,

bracket

oil

filter

free

to

the

onto

and

by

engine

bracket

oil

contains

skin

contact.

and

water.

used

recommended,

of

important

different

oil

filter

change

the

oil

pressure

around

the

new

oil

through

or

through

for a few

sure

there

from

the

oil

the

quantity

not

over

the

require

additional

.as;;;=::::",

wipe

of

oil

rubber

the

threaded

then

tighten

coolant

housing

harmful

Clean

Launder

oil.

Discard

as

the

items

from

genuine

and

is

nonnal

new

oil

the

oil

the

side

moments

is

no

drain

system,

of

oil

with

high

mark

PN#036918

SPIN·ON

TURN

ON

the filter

and

gasket

oil

the

flowing

assembly.

skin

or

oj,

oil fill,

filter.

filler

oil

fill.

while

leakage

and

the

on

oil.

DlL

FILTER

HAND

TIGHT

LUBRICATION

OIL

OIL.~~~;SSljRE-~rnll~..,.

SWITCH

OIL

FlLTIER--~

OIL

PRESSURE

RELIEF

OIL

DIAGRAM

PRESSURE

VALVE

PUMP

OIL

DRAIIN

--->

SEALING

.APPLY

Engines & Generators

·1~,~;t;~~~~mi1l1~11(

';,

17

TO OIL

DRAIN

UP

THRU

USING

THE

OIL

THE

AN

BMM

OR

HOSE.

(11/16')

PUMP

SOCKET

THE

WARMED

FOR

EXTENSION

114"NPT

REMOTE

OIL

FILTER

(OPTIONAL)

INSTALLATION

This

popular

filter

from

an

engine

NOTE:

instructions

APPLY A THIN INSTALLING TIGHTEN CONTACTS

the

roorri

Refer

THIS

AN

ADDITIONAL

THE

accessory

engine

bulkhead.

to

ENGINE

on

removing

COAT

OF

CLEAN

KIT:'I!lREAO

BASE.

is

to a more

DlL THE

3/4

TURN

used

to

relocate

conveniept location

OIL

CHANGE

the

oil

filter.

TO

THE

O-RING

KIT

ON,

THEN

AFTER

THE

O'RING

PN:040078REMOTEOiL

To

install,

the

engine's

such

oil

as

WESTERBEKE's install

Contact

in

this

manual

for

NOTE:

incorrect

A

rectly. pass

from failure.

immediately

WHEN

HAND

.

F1LTERSET

simply

.

remove

remote

this

kit with

your

Westerbeke

installation

CAUTION:

If

the valve reaching

If

the

oil

WESTERBEKE

is

not

of

.It

is

Oii'f,ows

in

the

filter

the

engine

there

is

no

and

check

the

engine

oil

filter

facing

dealer

responsible

the

Remote

vital

to

install

in

the

reverse

assembly

causing

011

pressure

the

hose

oil

filter

and'

kit

as

shown.

down

as

illustrated.

for

more

information

for

engine

failure

Oil

Filter.

the

oil

lines

directiDn,

will

prevent

an

intemal

reading,

shutdown

connections.

FASTEN

SECURELY

(SCREWS

ARE

thread

on

Always

due

to

cor·

the

by·

the

Dil

engine

TO A BULKHEAD

OWNER

SUP~LlEO)

NOTE

THE

ON_THE

ADAPTER

REMOVED

FOR

WILL

BE

RECONNECTED

'

MARKINGS

WHEN

THE

INSTAllATION

HOSES

C.0RRECTLY

SO

ARE

THEY

'THE

IN

CONNECTION

:

MUST

ATTACH

CONNECTION

/ne",u',e

Oil

CONNECTION REMOTE

DlL

TO

THE

AT

THE

FILTER.

TO

THE

ATTHE

FILTER.

HOSE

OUT

IN

APPLY A THIN

G~SKET

CONTACTS

:y~.rURN.

COAT

WHEN

INSTALLING.

THE

BASE,

OF·

TIGHTEN

DlL

AFTER

IT

AN

.

TOTHE

FILTER

THE

FILTER

ADDITIONAL

"IIY'

WESTERBEKE

Engines &

18

Generators

DESCRIPTION

STARTER

MOTOR

The starter high-speed internal-reduction separate from the motor shaft; pinion shaft A reduction gear shaft exposed outside the starter smoothly without becoming fouled with dust and motor shaft lever mechanism, switch and overrunning clutch inner circuit

. are identical

is a new

and

a pinion

is

TERMINALS --......

MOTOR

type,

shaft.

supported at both

to

conventional

small,

The

so

"""IIiV'

light-weight and

starter.

The

pinion shaft

the

pinion slides only

is

installed between the motor

pinion

sliding part is not

that

the

pinion may slide

ends

on

ball bearings. The

ones.

....

is

grease.

SOLENOID

called a

is

on

the

The

TYPICAL STARTER

REFER

DIAGRAM

MOTOR

TO

THE

IN

THIS

.

WIRING

MANUAL

TROUBLESHOOTING

A

WARNING:

procedures

Sparks

could

must

cause

The

not

be

an

following

used

with

explosion

emergency

gasoline

and

fire.

starting

engines.

~~---I(M)

'IG~ITION

TERMINAL

To

test the ignition circuit, locate

is

one of the circuit). Use a from that ignition terminal to the positive battery terminal on

If

the starter cranks,

circuit.

If

the solenoid clicks

motor

small

tenninal

screwdriver,

the

solenoid.

is probably faulty.

SOLENOID

the

bnt

the

ignition(s)

studs

and

is

wired

don't

touch

the blade,

fault

lies

with

the

ignition

nothing bappens, the starter

TERMI~AL

terminal

to

(it

the

ignition

to

jump

connection

Prior to testing, make cbarge and that (terminals) are clean and tight. the ground wire connections on

To check the

seconds, never more than 10 hand along the

that indicate resistance. Repair

Using a multirneter, test the terminal stud on (ground).

If

you

read

wiring,

12

the

starting

try cranking

wires

and

the

start solenoid

volts,

certain

terminals

the

starter

the

system

seconds

voltage

ships

batteries are at full

wiring connections

Pay

particular attention to

the

engine block.

the

starter for a at a time, then run yonr

looking for warm spots

or

replace any trouble spots.

between the positive

and

the engine block

is

faulty.

few

IGNITION

If

nothing bappens at cnrrent.. Check wiring

connections.

defective.

A

WARNING:

fly

when

jumping

space

is

free gasoline, materials

and

stored

~";;::-----/;Ml

aIJ,

the

solenoid is

the

battery isolation switch

it is also possible that the

There

will

be

'arching

terminals.

of

potentially

that

there

Be

explosive

are

1m

certain

flammable

nearby.

~

not

getting

and

solenoid

and

sparks

the

engine

fumes,

solvents

POSITIVE

TERMINAL

inspect

the

is

will

especially

or

Engines &

19

Gen~rators

STARTER

MOTOR

A

WARHING:

position

the other

Test screwdriver blade screwdriver blade wonld cause a

yourself

engine

crew

again

by jumping the

in

case

members

short.

When safely

the

firmly

to

touch

pedonning

away

engine

of

the

danger.

lJ'YV-+...::----\IVI)

two

between the

the solenoid or

these

from

the

starts·up.

large tenninal

studs.

procedures,

moving

Also

studs.

Do

starter

parts

warn

POSITIVE

TERMINAL

Hold the

not

allow

casing,

of

the

this

EMERGENCY

Corrosion to can

cause

time

hnt

will

need.

It

is

however,

starter

lightly

With

the

starter/solenoid

CAREFULLY FITTINGS

OR

START

the

starter

the

sporadic

not

another.

to

be

rebuilt.

sometimes

with a small

battery

switch

casing

NOTTO

HIT

WIRE

CONNECTIONS

I

brushes

problem

If

corrosion

possible

bannner.

off

as

shown,

".-:

andlor

the

of

the

engine starting

is

the

problem, the starter

to

get started by

and

no

ignition,. tap lightly

then

try

~',j

solenoid

to

start the

TAP

\

.

INDICATED

contacts

one

taping

on

engine.

LIGHTLY

the

WHERE

A

WARNING:

starting

the

Iftbe

If

the

If

no

solenoid.

NOTE:

In

the that uoing will starler switch it

will

tTwugh

current

screwdriver.

starter

arching occurred,

Stalter nwtors

pre-engaged

engages

a screwdriver

run

the

create

the

contacts

There

should

spins,

the

fails to spin,

are

nwdel,

the

starler motor

to

nwtor

witTrout

on

to

provide power

enough

magnetic field for

inside

will

be

"owing

solenoid

the

motor

there

is

either inertia

the

solelwid

to

bypass

the

engaging

the

solenoid

arching

no

the

soleJwid

as

thru

the

is

faulty.

is

probably fanlty.

juice reaching

type

also

flywheel the

flywheel.

to

the

soleJwid. the are

the

full

blade

or

pre·engaged.

nwves

an

of

the

on

such

Turn

Hopefully

ann

to

nwve

bad.

of

the

am!

engine.

a starler

the

even

If

that

fails,

turn the

member

with the contaCt the starter

turn

the

hammer.,

to start

wili

SERVICE

WESTERBEKE

serviced

center,

If

certified USCG

dealer.

TO

1.

2.

3.

4.

5.

or

rebuilt

replacing

the starter

for

marine

standards.

REMOVE

Disconnect

If

necessary,

to the

starter

Label

and

disconnect

allow

wires Remove Remove

starter

obstluctions,

the starter

the

wili

battery

ignition

the need

uses a standard

FOR

the

remove

motor.

to

starter

have

on

This

may

engine.

to be

at

any

starter

motor,

use.

Automotive

If

in

doub~

SERVICE

negative

any

the

touch,

tape mounting from

to be turned

switch

on and off rapidly loosen the

When

you

reparred.

starter

motor

make

certain

starters

contact

battery

cable. components

wiring

from

over

the tencinals).

bolts.

the

engine.

to a different

and

have a

as

you

brushes

reach a reparr

automotive

your

and

motor

which

the

new

do

not

WESTERBEKE

to

gain

full

the

starter.

In

some

cases

angle

crew

tap

allow

facility,

can

service

motor

meet

access

(Do

the

to

clear

again

be

is

not

EngInes & Generators

20

SPECIFICATIONS·

5.5 KW"EDC

GENERATOR

Engine

Type

Aspiration Governor

Combustion Bore & Stroke

Piston

Firing

Direction

Compression Dimensions

Weight Fuel

Inclination

Generator

Compression

(Limit

Between

Valve

Spill Valve

Engine

Valve

(engine

Injection

General

Fuel Fuel Fuel

(spill Nozzle Fuel

Air

(engine

Chamber

Displacement

Order

01

Rotation

Ratio

Consumption

Power

Pressure

of

Difference Cylinders)

Timing

(Static)

Seat

Angle

Speed

Clearance

cold)

Pressure

Injection

Pump

Injection

Timing

timing)

Riter

cleaner

Flow

combustion)

ENGINE

Take"Off

SPECIFICATIONS

Diesel,

water-cooled,

mechanism, Naturally Electronic Swirl

2.99 x 2.76

59.09

1 - 3 -2

Clockwise,

23:1 Height:

Width:

Length:

3951bs

0.53 Continuous

Temporary 11/9

TUNE-UP

396

47.2 Intake

Intake Exhaust

Exhaust 15'

Intake

Exhaust

1600 1500

Intake

1920 + 71

FUEL

Open No.2

In-line 15'

Throttle Spin-On

Plastic

30.2

four-cycle,

type

cubic

20.4

19.0

US

three-cylinder,

vertical

in-line

(llhp@1600rpml9hp@1500rpm)

aspirated.

inches

(76 x 70

inches

(0.952

when

viewed

inches

(516.6

inches

kgs)

(205

Iph)

(462.6

(516.6

27.6 (1797

gph

from

at

full

mm)

liters)

mm)

Iresh

overhead

the

front

load

15'

25'

(not

to

exceed

30

min.)

Hp

(maXimum)

SPECIFICATIONS

psi

(26

kg/cm')

at

260

rpm

limit

psi

(3.0

kg/cm')

Opens

no

471'

Opens Closes

BTDC

0

45

60

Hertz

50

Hertz

Exhaust

-0

51' 13'

psi

BTDC

ABDC

BBDC ATDC

0.010

(135

inches

+ 5 -0

(0.25

kg/cm'

Closes

±.5

45

rpm rpm

and

SYSTEM

flow,

sell

diesel

plunger

±.5

type

intake

cfm

all

BTDC

type

silencer

(0.65

bleeding _ self (cetane

type

cmm)

priming

rating

0145

(Bo'3ChtyIllL

valve

mm)

or

higher)

____

ELECTRICAL

Starting Battery DC

Charging Starter Starting DC

No-Load

DC

Cranking

Battery

Capacity

Altemator

Aid

Current

12-Volt, 600

50 12 Glow

±

2%

190 -200

COOLING

General

Operating Fresh

Water

Raw

Water

Raw

Water

at

1600

rpm

System

Capacity

(Iresh

water)

Temperature

Pump

Flow,

Fresh controlled

170 Centrilugal

Positive gear-driven.

6.5 before

4.0

LUBRICATION

General

Oil

Filter

Sump

Capacity

(not

including

Iilter)

Operating (engine

Oil

Pressure

hot)

Grade

AC

General -Single

Voltage -Single

Voltage

regulation:

Frequency Rating

regulation:

(Volts

AC)

GENERATOR

Phase

-+-------~2~311l.0'!:VO~lt~s

Pressure

Full

3.2 plus

35 -55

API

SAE

Brushless, lubricated

120 220

±

5.5 120

5.0

GENERATOR

supply

200

15%

30.2 120°F

100

Air

Requirements

(60

Hertz

at

1600

NOTE:

increase

Engine

Combustion

Generator

Temperature

Compartment

rpm)

air

COOling

SYSTEM

(-)

negative

ground

-1000

Cold

CranWng

Amps

(CCA)

Amp

rated,

belt

driven

Volt,

reduction

gear,

1.2

KW

plugs,

sheathed

twe

of

rated

amps

Amps

(engine

cold)

SYSTEM

water-cooled

-190' F

displacement,

US

gpm

discharging

qts

(3.97

with

heat

(77 -66'

type,

metal

(25.6Ipm)

liters).

block,

thermostatically-

exchanger.

C). impeller,

rubber

(measured

into

exhaust

belt-driven.

impeller,

elbow).

SYSTEM

fed

system

with

external

relief

Ilow,

paper

element,

spin-on

type

U.S.

qts

(3.03

filter/cooler

SpecITication

30,

Volts -60 Volts -50

5%

no

0.05

Hertz

KW·

Volts -45.6

KW -50

liters)

assembly

psi

(2.5 -3.6

kg/cm')

CF

or

CG-4,

CH-4

10W-30,

15W-40

(SINGLE

four-pole,

single

load

no

60

Hertz

.::2!112.7~~

bearing

Hertz

Hertz.

to

lull load

Amps

PHASE)

revolving

design

load.

to

luilioad.

(1600

(1500

_______

or

lield

rpm)

GODLING

cfm

(5.66

cmm)

for

50

Hertz

operation

(1500

rpm)

cfm

(0.65

cmm)

(5

.O°C)

maximum

cfm

(2.6

cmm)

valve

CI-4

sealed

1-----'---

Engines

21

& Generators

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Engines & Genera'tors

22B

NOTE:

ments

be

below

is provivedto

ENGINE

WESTERBEKE

peiformed

by a competent

assist

ADJUSTMENTS

recommends

the

that

engine

mechanic.

the

following

mechanic.

The

engine

information

adjust-

DRIVE

For

equipped

front

guard

advis~d

required. Excessive

and

A

slipping,

The

deflected

inch

midpoint

belt.

Adjusting

1.

2.

3.

4.

5.

6.

7.

8.

BELT

your

safety,

with belt

of

the

engine.

is

NOTinstalled

that proper

drive belt

reduce

the service

slack

belt

resulting

drive

belt

no

(12mm)

between the

A spare belt or

A

WARNING:

drive

belt's

Remove

Loosen

loosen With

edges. Pivot the idler

loosen

Replace the minutes

Remove

the

the belt

or

Tighten

and

Replace the

or

less

Belt

the belt

tighten.

the pivot

the

ADJUSTMENT

WES1ERBEKE

gnards

that

cover

("Out of sight -

for

that

purpose.)

inspection,

the

presence

in

is

properly than

as

the belt

belts

Never

tension

life

high

3/8

two

while

can

of

the

of

oil

operating

adjusted

inch

(lOmm)

is

depressed pulleys

should

attempt

the

service,

cause

engine

Tension

guard.

pivot

belt that

adjusting

loose,

sheave

gnard.

then

shut

gnard

guard.

holds

bolt.

inspect for

to

the left

bolt

and

the

Operate

and

the

generator

recheck the belt tension.

generator

over

out

of

and

rapid

fresh

water

on

the

temperatures.

if

the

and

with

on

the

always

be

to

check

is

the

idler

wear,

cracks

or

right

adjusting

generator

down.

models

the

belles)

mind."

Operators

maintenance

wear of

pump's

belt

can

belt

can

no

more

the

thumb

longest

span

carried

or

adjust

in

operation.

sheave

and

as

required,

bolt.

for about 5

come

on

The

are

the

bearing.

cause

be

than

at

on

and

frayed

the

belt

is

belt

1/2

the

of

the

board.

the

to

TORQUING

After

every re-torqued.

Tighten

shown.

Before

1/4

to procedure illustration

Bolts #1, 2 and 3, (l2mm socket) Bolts #4, RocketshaftHold Down Bolts Rocker

FUEL

In

case injectors injection loss

of

in

injector clean injector

Before base of falling

out

easily

the injector side-to-side free

it,

The injector

washer.

replaced

installed.

NOTE:

additiolUll

THE

CYLINDER

the

initial

break-in

500

hours

thereafter,

the

cylinder

Make

applying

1/2

of a turn and

according

to

5,

6, 7,

Cover

head

sure

the

specified

to

the

right.

8,

9,10

Hold Down

CYLINDER

INJECTORS

of

severe

vibrations

checked

service

positive

room

as

removing

the

down

and

TIris

with a new

Refer

and

center.

fuel pressure

faults.

Since

enviromnent,

a spare

should a problem

the

injector

and

then

START 1988 ± 142PSI

to

into the injector

is

held

lift it

seats

in

washer

TO

INJECTION

to

the

~l

infol7nation

HEAD

period

(approximately

the

cylinder

bolts

according

engine

is

cold

torque

then

apply

the

numbered

and

11

Cap

HEAD

BOLT

and

overnauled

Poor

fuel

to

the

fuel

injectors

it

is

best

old

injector,

help

prevent

hole.

in by

carbon

with

the

out

the

cylinder

should

be

removed

washer

when

.

PRESSURE

(140 ± 10KG/CM')

injector

.

page

BOLTS

50

hours) and

head bolts should be

to

the sequence

when

this

is

done.

to

the bolt,

the

torque

sequence

14

- 22 ft-lb

(14mm

12mm

Nuts

- (lOmm socket) (snug)

PATTERN

detonation

by

an

authorized

quality,

injection

must be

to

carry

occur.

clean

the

any

rust or

If

the injector

build-up or

aid

of the

head

on a copper

the

new

in

this

loosen

..

Follow

shown

socket) (54 -

socket

(11 -16

noise,

have the

fuel

contaminant's

pump

can

serviced

at

least

One

area

around

debris

will

the

like,

socket

wrench

with

the

injector

nwnual

it

this

in the

61

and

result

in a

extra

the

from

not lift

work

sealing

is

for

ft-Ib) .

ft-lb)

to

and

....

WESTERBEKE

Engines & Generators

23

ENGINE

ADJUSTMENTS

GENERATOR

Once

the

there

may during this

period. A no-load

required

These

are

mal

break-in

Frequency indicated

When

the

ontput frequency

FREQUENCY

diesel

generator

be

adjustments

the

engine's

in

conjunction

not

warrantable

and

maintenance.

is

a direct

by

the

following:

generator is

is

break-in

result

60

When the generator is

outpnt freqnency Therefore

speed perform

1.

must

With the

to

the

AC connections change These

connections

tion

of

this

A

WARNING:

cettain

away

from

is

change

be

changed.

following:

engine

terminal

diagram

the

Hertz manual.

that

everyone

pulleys

50

the

stopped, block

circuit

ADJUSTMENT

set

has

required

period

voltage

adjustment

with

the

adjustments

of

engineigenerat<;>r

rnn

at

1800

Herlz. rnn

at

1500

Hem. generator's

To

accomplish

.

connect

in

accordance

specified

connection

are

shown

.

Before

statting

is

clear

and

belts

(HERTZ)

been

placed in

for

engine speed

(first 50 hours) or after

engine's speed

as

rpm, the

frequency,

the

AC

with

for

your generator

to

in

the

GENERATOR

the

of

moving

during

may

also

adjustment.

they

relate

speed,

AC

the

frequency

output

the

capacitor.

engine

parts!

test

procedures.

operation,

AC

make

(Hertz)

be

to

nor-

as

voltage

engine

change,

leads

voltage

set,

sec-

Keep

to

and

ELECTRONIC

The

Electronic

sensing

flywheel. the

engiries

controller

engine

to

GOVERNOR

Governor

the engine's

The

governor's

speed

and

signals

the

desired

Actuator

The

following instructions

the actuator.

1.

Shut-off

2.

Disconnect

3.

Measure

mounting

the

DC

the

acI\I'lIOr

the distance between the actuator and

smface as

regclates

RPM

with a magnetic

controller

if there is actuator speed

electronically.

are

power

to

wires

shown.

the

engirie

continuously

any

discrepancy,

and

the

actuator

for adjusting

the

generator.

fuim

the

sPeed

pick-up

wiring

at

monitors

the

adjusts

ENGINE SURFACE

or

replacing

harness.

the

by

the

MOUNTING

engine

2.

In

Electronic Control Unit

engine and OFF for for

3.

Star! and out put as

WHEN

CHANGING

.

FREQUENCY ON

THE

CONTROL

BOARD

MUST

ON

FOR

50

HZ

the

control box on

the

speed/generator

60

Hz.

Select the correct switch position

the

desired operating hertz.

the engine and

no

load

AC

as

needed using

observe

voltage output. Adjust no load

needed to increase or

THE

(50/60

GENERATORS

HZ)

PANEL

BE

SWITCHED:

AND

OFF

SWITCH

ECU

FOR

flO

HZ.

#1

generator is located the

(ECU).

frequency.

Switch # I

ON

for

contoIs

50

generator hertz

the

capacitor taps

decease

no load

SWITCHES

#7,

AC

Hz

AC

#8

or

voltage.

#9

4.

Back-offthe 1

5.

Apply a actuator mounting actuator measured (The

standard

6.

Reconnect

NOTE:

Should

the

proper shut

NOTE:

For

Troubleshooting, refer

diesel

ACTUATOR

REFERENCE

7/16"

small

amount

and

screw

boss.

Maintain

and

the

engine

Secure

distance

the

actuator

the

unit

jam

nut

and

down.

additional

generators.

jam

nut

and

of

teflon

the

actuator into

the

same

mounting surface

the

actuator's position

is

13/16"

wires

and test

fail

to

shut

the

to

down

actuator

the

booklet

thread

information.on

ENGINE

'SURFACE

unscrew

sealant

the

distance

to

7/8").

1+---13/16"

and

only

in

LA

Electronic

on

MOUNTING

theaclllator.

to

the

engine's

between

as

with

the

unit

go

to

Y2

tum

Governing

our

website

replacement

the

previously

the

jam

nut

TO

idle,

to

7/8"

Loosen

obtain

for

STANDARD

Ehglnes & Generators

.

24

VALVE

NOTE:

engine's

BOLTS.

Pull off rocker

Remove

the

cylinder

Valves·are adjusted stroke. order

Valve crankshaft cylinder piston the

look now in

Align

timing the by

and

should

CLEARANCE

Retorque

valves.

A

WARNING:

engine

is

cold.

ing

order

of

the

to

the

specified

off

the

air breather

the

rocker

cover

shaft

and

the

glow

crankshaft

(1-3-2

adjustment beginning with cylinder

cylinder).

for

starting

the

cylinder the

#1

rotating

after

to

for

valve

adjusted with

at

Top

Dead.

Each

cylinder

for

slowly

#1.

Watch

is

on

it's intake stroke

Continue to rotate the crankshaft slowly and

the

intake

it's compression stroke (the

towards

IDC

mark

marker

on

Piston

at

TOC

the crankshaft approximately

this point

not

move.

ADJUSTMENT

the

cylinder

See

TORQUING

Adjust

Valves

engine.

torque

bolts

valve

plugs

be easily rotated

adjustment.

WESTERBEKE three cylinder engines).

and observe the operation of the

for the intake valve to

valve

the front gear case cover

and

head

the

are

adjusted

Tighten

before

pipe

from

and

assembly.

from

each

the

cylinder Center (IDC) is

adjusted

(the

to

close.

IDC)

..

on

the crankshaft front pulley

of

it's compression stroke. Confirm

the

two

bolts

before

adjusting

THE

CYLINDER

valve

clearance

by

the

cylinder

adjusting

the

rocker

the rocker

of

the cylinders to enable

by

hand to position each

in

of

its

following the engine's

piston TIrls

indicates the piston

valves for the

when

cylinder

head

tlie

valves.

cover

to

the

piston

compression

#1.

open

indicating the

is

moving

piston

is

when

20

degrees before

#1

the

HEAD

the

in

the

fir·

bolts

and

take

expose

the

being

firing

Rotate

the

valves

for

down

in

moving

with

the

positioning

this

cylinder

is

up

Re-install threads)

bolts.

manual.

ENGINE

Check the remove shut-off the tester motor this matically of the more

Siandard

If

is for cylinder cylinder comes

Abnormally

carbon

accompanied

NOTE:

cause

TORS.

fuel

the

glow

and

assemble

See

TIGHTENING

COMPRESSION

compression

all

fuel

injectors,

solenoid

injector

a weak either

the

hole

or

on

the

adapter

untl1

the

pressure

process

for

each

(at

least

others.

Compression

than

35.5

psi

compression

cylinder

valve

or

piston

weak

cylinder,

is

still

low,

to

seal

the

up • the

In

may

pressure

rings

high

accumulations, a condition

by

high

crue

of

severe

be

fuel

Poor

fuel

to

tJze

faults.

When

re-inslalling

plugs

(use

the

rocker

TORQUE

pressure.

or

glow

wire,

and

install a compression

glow

plug

and

crank

reaches a maximum

cylinder.

20%)

lower

pressure

(2.5

kglcm')

pressure

is

rings

readings

398

flanked

by

related.

adjust

as

apply a small

and repeat

are

faulty.

on

pressures

vibrations

injector

quality,

the

contaminates

injection

glow

problems,

pump

plugs

anti-seize

hole.

the

Look

compression

at

Ib/ln'

healthy

Check

needed

all

and

compound

cover

and

SCHEDULE

To

do

this

plugs,

disconnect

Connect

engine

for

cylinders

should

280

rpm.

al280

cylinder,

the

and

amount

the

test.

cylinders

that might be

noise.

and

detonation

see

and

will

result

use

anti-seize

on

the

rocker cover

in

this

warm

the

engine,

the

fuel

adapter

a compression

with the starter

value.

Repeat

with

dra-

than

the

average

not differ

rpm

'(28.0

valve clearances

test

of

011

If

indicates

by

kg/em')

the

problem

again.

If

into

the

compression

heavy

noise,

FUEL

INJEC-

loss

of

positive

in

injector

compound.

in

the

Adjust

the

valves

in

#1

cylinder for both intake and exhaust Proceed Rotate

rotation

order. the

Acljust

(0.25mm)

stem.

to

the next cylinder

the

crankshaft 240 degrees in the normal direction of

and

adjust the next cylinder's

Rotate the crankshaft another 240 degrees

valves

of

the

next cylinder in the

each valve's clearance

feeler gauge between the rocker arm

Make

sure

to

adjust all valves while the engine

in

the firing

by

insertIng a

VALVE

valves

firing

CLEARANCE

0.25

mm

COLD

order.

in

the firing

order.

O.OlOin

and

(0.010

In)

ENGiNE

and

adjust

the

valve

is

cold.

Engines

25

COMPRESSION

ADAPTER~

.t~f

~--

& Generators

TESTER

.>.

'~:~n;'

.:,'

___

INJECTOR

GLOW

OR

PLUG

HOLE

NDTE:

WESTERBEKE

ments

be

below

is

ENGINE

performed

provided

by a competent

to

assist

ADJUSTMENTS

recommends

ihe

that

engine

mechanic.

the

following

mechanic.

engine

The

-----,====--=---=--=-=--,,-----------

adjust-

information

Injection

If

your engine's fuel injection timing the engine will uot operate properly, start Have the injection pump delivery rate checked by a well-established fuel injection shop.

-follows:

NDTE:

fuel

do

this, side move

fully

1. Remove the high pressure fuel line

No.1 injector and the No.1 fuel

2. Remove the No.1 fuel delivery

"0"

the

3. Reinstall ouly the delivery valve holder and reattach the

high pressure fuel line to the delivery

that the end that would connect to

pointing away from the engine fuel

line during the timing check.

Rotate the engine's crankshaft in its

rotation'to position piston

,compression stroke.

Move the throttle lever the electric

(as viewed from the front), catching the

fuel line, until the instant the fuel completely stops

(no drips). At this instant, the 15° crankshaft pulley should be directly

indicator

If

the specified injection timing attained, adjust the timing by increasing or decreasing the thickness mounting Changing the shim thickness by 0.004 changes the injection timing To

advance the timing, decrease the required, required; Refer numbers,

Pump

Timing

The

injection

delivery

unscrew

cover

to

the

fuel

to

the

left)

ring and remove the delivery

holder.

lift

on

of

flange

To

pump

fuel

position

expose

the front of the gear

shim material under the injection pump's

retard the timing, increase

when

performing

the

fuel

shut

the

injection

rack

to

the

full fuel

secure

it

in

this

No.1

to

its full

pump.

Slowly rotate the cnmkshafr clockwise

to

change the injection timing point.

to

your Generator's

Adjustment

rack

off

solenoid

pump delivery

position

at

open

BIDC

case ± .5

(15°

by

approximately one degree.

(Spill

is

not

properly adjusted,

and

may

be difficult

Adjust

the injection

needs

to

be

in

this

spill

timing.

and

remOve

fuel

rack.

position

thenproceed.

from

between the

delivery

valve

normal

the

aligned

shim

Parts

valve

holder over

valve

spring beneath

holder.

Attach it

the

fuel

injector

will

flow

from

direction of

beginning

position and operate

fuel

from the

timing mark

with the timing

degrees.

BIDC) cannot be

inch

(O,Olrnm)

thickness, as

the

shim thickness,

List for shim part

Timing)

the

full

the

Manually

(move

holder.

is this

of

its

No,

flowing

on

as

To

to

so

1

the

as

INJECTION

UNION

STOP BRACKET

CONTROL

SLEEVE

CONTROL

IT

MARK

ON

PULLEY

RACk

PUMP"

WIRE--..J

RACK,

DELiVERY

PLUNGER

VALVE

ROLLER

HOLDER

SPRING

.vALVE

Engines & Generators

26

TIMING

POINTER

CRANKSHAFT PULLEY

MARKS

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

ENGINE

NOTE:

WESTERBEKE

ments

be

performed by a competent

below

is

provided

OIL

PRESSURE

The engine's oil pressure, control

pane\.

The red light will shutdown restart the generator without checking problem.

NOTE:

A

reading

pressure

depending placed

LOW

OIL

The

specified

(0.3 -

0.1 engine worn

bearings.

Fe)tdings,

TESTING

To

test oil pressure, remove the oil gallery "T" plug

install a mechanical oil pressure gauge in its place. After

wanning

'Oil

PRE$SU~€··

if

the oil pressure

newly

started, cold

upwards

reading

on

upon

the

generator.

of as

the

PRESSURE

safe minimum oil

kg/em'). An oil pressure of 5

down.

A gniduallossof

For additional iufonnation

see

the

ENGINE

OIL

PRESSURE

up

theeirgine, read

is

constantly monitored

will

illuminate and the generator

falls

engine

60 psi. A warmed low

as 35

psi.

te"1perature

35.0

IbM

9·1.3

!t.\b

of

pressure

oil

TROUBLESHOOTING

.the

oil pressure gauge.

(3.8

kg/em')

(1.2

-1.8

below 5 psi.

the

can

have

engine

These

the

engine

is

psi

pressure usually

or

m·kg)

oil and

an

can

readings

and

4.3 -1.4

Will

shut the

on

low

more

to

assist

by

Do not

finding

oil

pressure

have

will

the

psi

indicates

oil

chart.

at

1800

,the

pressure

and

ADJUSTMENTS

recommends

the

an

oil

vary

load

.'.

rpm

that

the

following engine

engine

mechanic.

~

-GLOW

.

PLUGS

To

inspect the

connections, then unscrew or unc\amp each plug from the

cylinder with a soft

carbon

for

wear

the

plug.

An accurate

Touch other

to

plug

will

used

with

multimeter

A

hot

to

when

plug,

head.

Thoroughly clean each plug's tip and thre""s

brush and cleaning solution to remove all the

and

oil deposits. While cleaning, examine the tip

and'burn

way

one

prod to the glo\" plug's wire connection, and the

the body

have a 0.4 -

the plug in or out of theengine.You can also use a

to test the power drain

WARNING:

the

touch.

testing

adjust-

The

information _

remove the electrical tenninal

er.osion;

to

of

the

if

it has eroded

test

glow

plugs

is

with

the

glow

plug,

as

shown.

0.6

ohm resistance. This method can

(5

- 6

amps

,

These

glow

plugs

will

Be

careful

not

toburD

plug.

.

TESTING A GLOW

, \

WITH

AN

OHMM,ETER

PLUG

too

much, replace

an

ohmmeter.

A good glow

per plug).

become

your

very

fingers

be

TERMiNAL

ENO

MANUAL

Shou\dfue stop button function to stop the engine; the manual shutdown leverloc.led above until

ENGINE

the side

the

engines comes

SHUT-OFF

~n:'the

~ontrol

oil;

fill.

Siffiply hold dowritlie 'lever

toa

colllplete

TESTING

engme on

the engine blockjust

OIL

PRESSURE

p.u:elfail inits

is

equipped

sidp.-

n()rn:,al

with

to

fueleft '

'

,

TIP

a

\TESTING

•

USING

GLOW

PLUG

7 -11

Fr-LB

iA:GhOW

;"LUG

,AlrEST,UIGHl

TIGHTENING

(1.0

,TORQUE

-I.S'M,KG)

+

Re-install·the plugs

plugs

should get very'hot' (at thetenniilal seconds. circuit. When reinstalling the compound

If

the plugs don't heat up quickly, check for a short on

the

in,th_e

threads.

engineand

glow

plugs,

t~st

them end)

use

again.

The

Within 7 to

anti-seize

15

SIDE

Oil

FILL

Engines & Generators

27

FUEL

INJECTORS

REMOVING

NOTE:

1.

Disconnect

loosen

and

bending

2.

Using a 17mm

its lose the

NOTE:

prior any hole. by side

it

and

3. The

jng injector tor

INJECTION

1.

Using tion

limit,

tester,

A

of

skin

enters

a.

If replace

h.

Set dust

c. Mount

tester.

d.

Use

of

e.

Operate bleed lever ing

THE

Injector

must

the

lines at

move

them

the

lines.

entirety

carbon

is

from

the

two

fuel

return

Clean

to

lifting

rust

or

If

the

injector

build

with

the

then

lift it

injector

washer.

and

reinstalled.

debris

This

replaced

TESTING

the

nozzle

starting

pressure

adjust

or

take

the

CAUTION:

snch

velocity

of

fingers

the

bloodstream,

the

diesel

it.

At the

the

nozzle

or

dirt.

the

fuel

68'

F (20'

the hand

the

air

at

intervals of

the

injectipn

INJECTORS

be

serviced

high

out of

long

the

sealing

line

the

area

it

out

from

up

aid

of

out.

seats

in

washer

tester,

replace

following

The

that

and

fuel

of

tester

nozzle

at

the

C)

in

the

starting

in a "clean

pressure

their

attachment

the

way

socket, top

of

the

washers

to

each

injector.

around

of

the

cylinder

falling

will

not

or

the

like,

the

J7mm

the

cylinder

should

with a new

check

of

nozzle

the

nozzle.

precautions:

spray it

may

hands,

it

the

nozzle

same

time,

in a clean

and

nozzle

approximate

lever

of

nozzle

one

stroke per.second

pressure.

lines

from

to

of

the

remove

lift out

injected

destroying may

nozzle

line,

the

injectors.

and

banjo

the

base

head

down

into

easily

work

the

deep

socket

head

be

removed

washer

the

spray

and,

if it

When

from

ppnetrate

cause

tester

clean

or

place

holder

temperature

tester

then

room"

erwironment.

the

il\iectors

the

injection

injectors.

fuel

return

Take

care

bolt

that

of

the

injector

to

help

the

injector

and

is

injector

wrench

on a copper

with

when

pattern

exceeds

using

the

nozzle

deeply

into

tissue.

If

blood

poisoning.

is

discolored,

replace

where

there

on

the

nozzle

several

move

the

while

and

pump

Avoid

line

not

attaches

prevent

held

in

side

to

free

seal·

the

injec-

and injec-

the

nozzle

is

the

it

the

filter.

is

no

times

hand

read-

to

in

Inspecting

1.

Operate one rectly injects strips. defect. ging cleaned expose and

2.

Apply

by nozzle on

repl~ced;

remain indicate a

the.

stroke

in

its

fuel

Also, a spray

These

with

before

ones

cause

the

operating

tip.

the

bottom,

A

on

il

The

injection starting

increasing The

(0.05 With increased replacing the remove the specified

or

shim

has

mm):

each

0.0020in

approxhnately

the

decre!lSing

between

shim,

body

torque:

Spray

Pattern

hand

lever

per

second

axial

direction.

in

an

oblique

defects

dust

and, reassembly.

skin

to

infection.)

CHATTERING

pressure

If

the

defect.

10

of 1635Ib/in'

the

hand

it

drips it

is

considered

very

small

tip

of

pressure

different

0.0049in

(0.05mm)

grip

with a wrench.

of

the

nozzle

to

check

A nozzle

direction

in

the

form

may

sometimes

therefore, this

(Care

spray

all

as

bI

3i

'il

FAULTY

,',

¥~'

,(I

TEST

lever,

and

or

has

a large

amount

the

nozzle;

DRIP

TEST

for

the injectors

the

thickness

thicknesses

(1.25mm).to

increase,

71.1lb/in'

the

retaining

Tighten

tester

at

intervals of

if

the

fuel

is

injected cor-

is

defective

or

in

several

of

particles indicates a

be

caused

parts

should

should'

be

taken

it

may

penetrate

(115

kg/cm')

check

the

drips

accumulation

defective

of

however,

fuel

and

may

this

should

sometimes

D

is

of the

adjusting

for

every

0.0020

0.0669in

injection

(5.0

kg/cm').

nut

in a vi&e

the

ADJUSTING

SHIM

When

retaining

!

SHIM

~

i

if

it

separate

by

clog-

be

carefully

not

the skin

to

nozzle

from

·of

fuel

be

does

not

fi:'

,

..

.

,.

adjusted

shim.

in

(I.7mm)

pressure

and

nut

THICKNESS

to

the

by

is

to

INJECTION 1920

PRESSURE

PSI

Engines & Generators

28

-

--------'

,--=----~--------~c_-~

,

.-

..

START

BUTTON

indications.

START

BUTTON

engagement.

,

START

BUTTON

indications

fuel

solenoid

Generator start,

fuel

Note:

there

:

If

the

engine

will

tenninate

will

display

Battery

runs

Battery

not

Generator

(Fault

display

NOTE:

The

is

protected

reset

circuit

control

Engine

Exhaust

--

-Problem

depressed,

depresssd;

OK;

starter

not

functioning.

engine

cranks,

solenoid

energized.

is

a 8 -

does

not

and a Underspeed

on

the

down.

charging

engine

stops.

under

engines

by a 20

breaker

panel.

starts,

runs

smoking

problems

solenoid

10'

sec.

start.

LCD

speed)

DC

electrical

amp

on

the

and

shuts

no

panel

no

starter

panel

but

does

crank

The

display

rocker

front

down,

_

OK

not

cycle.

cycle

fault

screen.

system

type

of

the

Note:

rocker

·.c

ENGINE

The

engines

type

reset

Probable

Batteryswitch'noion.

1.,

2.

Circuit

breaker

3.

Loose

b~ttery

Connection

1. Faulty

SOlenoid.

2.

loose

Low

K1

relay.

Poor Defective

Faulty

Preheat

2.

1.

High

Low

2.

3.

Poor

DC

alternator

4.

DC

1.

Alternator

2

..

1.

Switches or

disconnected,

2.

Fuel 20

Amp

3. (LCD

4.

Exhaust Water

5.

6.

Air Faulty

1. Water

2.

Blue

1.

2.

White

3.

Black

battery

battery.

connections

fueling

solenoid

resistance

reSistance

battery

charge

starvation.

display

in

intake

oil temperature

smoke,

smoke.

3.

4.

5,

1.

2.

1.

TROUBLESHOOTING

DC

electrical

circuit

breaker

Cause

tripped/Off:

connections.

-to

solenoid

connections.

to

fuel

solenOid.

system.

faulty.

leak

le<;lk.

connections.

not

charging.

circuit

faulty.

drive.

andlor

wiring

circuit

breaker

blank)

system

is

fuel.

obstruction.

pressure

system

mounted

-

'faulty.

fuel

solenoid.

to

ground.

loose

tripping.

restricted.

switch.

l"'fN"IWESTERBEKE

I Engines & Generators

is

protected

on

the

1.

2.

4.

1. 2,

3.

4.

5.

1.

2.

1. 1a. 1b.

'

1c. 1d,

2.

1,

2.

3.

4.

1,

2. are

1.

2,

3.

4.

5,

6.

1.

2.

1.

1a.

by a 20

control

panel,

-,

,--,-. -

Check

switch

Reset

breaker;

circuit

and,

check

(+),connection

engine

ground

Check

connection.

Check

that

12

Check

battery

Check

battery

Check

K1

relay.

Check

connections.

Check

that

fuel Check

Switch Replace Check

Change Check Check

lines. after

Cbeck Check

corrosion.

Check

DC

Penorm

DC

Check for present

Inspect

Check

Check Ensure cause

Check

2. 2a.

3.

3a.

3b.lmproperly 3c.

12

run

solenoid.

thalfuel

to

combine

batteries.

fuel

lift

Inlet solenoid. wiring.

Do

not

short

is

all

wires

table

connections,

ELECTRICAL

D.C.

ELECTRICAL

drive

loose

connections.

at

the

wiring

switches fuel for

high

breaker tripping.

for

blockage

Pump

water

bleed

fuel

Check

air

intake

Check

oil

pressure

Check

water

Incorrect

grade

Crankcase through

the

Engine

Is

running

Faulty

Injector Improper Fuel.burn

insufficient .exhaust

system;

lack

of

air -check

v6lltilation,

amp

Verilicalion}Remedy

--

andlor

if

breaker

circuit

stud.

volts connections.

charge

voltsare

valves

pump.

fuel

filter.

Insert

start

located.

for

connections

voltage

belt

tension.

Exc.

for

supply,

DC

is

from

system.

temperature

is

ovenilled

exhaust).

or grade Incomplete

air

for

timed

_.

battery

connections.

trips

again,

for

to

starter

Check

are

present

state.

pressnt

areopen.

house

sensitive

engine.

temperature

at

check

sho.rts

to

ground.

solenoid

battery

cable

at

the

solenoid

at

the

(+)

and

start

batteries.

(0 -.25

rise

battery

tension.

amp)

connections

to

locate

for

loose

R~m.ove

belt

test

SYSTEM/ALTERNATOR.

check

of

generator

SYSTEM/ALTERNATOR.!n

Check

terminal.

short

circuits

for

proper

fuel

valves,

amperage

not

overly

or

collapsed

fuel

tank(s);

filter

cartridge.

switch.

of

engine

with

cold.

incorrect

of

fuel

or

due

proper

check

air

injectors

air

intake

Alternator

should

output

voltmeter.

and

loose

operation.

fuel

teed

draw

during

sensitive

muffler.

change

switch.

oil.

engine

oil

injector

timing.

possible

generator

to

high

back

combustion

intake).

or

valves

and

air

to

or

filter.

LCD

DISPLAY

preheat

solenoid

and

(-)

connection

connections.

connection,

connection

meter

in

and

the

fault.

connections,

alternator.

charging

circuit.

this

manual.

turn

freely.

Ensure

connections.

strainer.

operation.

heat

which

filters

and

(oil

is

blowing

overload.

pressure

in

(Check

poor

exhaust

for

restrictions

compreSSion.

Check

for

(continued)

to

on

the

battery replace

See

Check

12

volts

would

out

proper

FAULTS

or

in

'"'

1,1

29

ENGINE

TROUBLESHOOTING

LCD

·DlSPLAY

FAULTS

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

PRESSURE

HIGH

COOLANT

HIGH

EXHAUST

BAmRY

GENERATOR Overspeed

Underspeed

LED

TURN

WAITING

VOLTAGE

FREQUENCY

(steady

(flashing

DISPLAY

PINK

FOR

DOES

TEMPERATURE

LED)

EDGES

ECU

PROBABLE

1.

Check

2.

20

amp

3.

Loose

4. 1 amp

1.

Oil

level

2.

Lack

of

3.

Ground

4.

Faulty

5.

Faulty

1.

Check

2.

Sea

water

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

Faulty

3.

Ground

4.

Faulty

5.

Sea

water

6.

Faulty

1.

Check

2.

Check

3.

Check

4.'

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank (underspeed

1.

Compartment

too

high.

1.

ECU

2.

Loose

3.

Panel

4.

Blown 8 amp

5.

Terminating

6.

Battery

CAUSE

battery.

breaker

off.

display

connection.

fuse

blown

(faulty).

low/oil

leak

oil

pressure

connection.

control

module

oil

pressure

system

coolant

pump.

water

pump

temperatiJre

connection.

control

module

sea

water

flow.

exhaust

temperature

Connection.

control

module

pump.

fire

suppression

alternator

charge battery

control

engine fuel

cycle

and

cable

DC

voltage.

connections. module

speed. supply. load.

with

fault)

ambient

LCD

display

connection.

breaker

fuse.

Resistors.

Voltage

drive

no

to

..

(ECU).

sensor.

level.

drive

belt.

sensor.

(ECU).

system.

belt.

(ECU).

start.

temperature

not

OFF.

ECU.

.

switch.

compatible

VERIFICATION/REMEDY

1.

Battery

on.

2.

Turn

breaker

3.

Check

all

cable

4.

Check/replace.

1.

Check

oil

level,

2.

Test

oil

pressure.

oil

filter,

inspect

3.

Check

ground

4.

Inspect

all

the

5.

Check

sensor/replace.

1.

Add

coolant.

2.

Inspect

impeller/pump/replace.

3.

Adjust

belt

tension,

4.

Check

sensor/replace.

'5.

Check

ground

.

6.

Check

plug

1.

Inspect

thru

as

needed.

2.

Test/replace.

3

..

Check

ground

4.

Check

plug

5.

Inspect

impeller/replace.

6.

By·pass

system/check.

1.

Adjust

tension/replace

2.

Check

eXcitation.

3.

Check + and·

4.

Check

plug

1.

Check

speed

2.

Inspect

filters/replace

3.

Check + and -cables

4.

Check

cause

1.

Ventilate Note:

display.

1.

Check

2.

Check

3.

Turn

4.

5.

6.

com~artment.

Heat

This

compatibility all

cable

ON,

check Check/replace Check

all

per Check

unplugged present,

terminating

resister

between

ECU

on.

connections. Determine

add

oil connection. plug

Check

circuit.

connections/replace.

hull

circuit

connections.

cables

connections/replace.

setting.

for

Wit

often

will

connections.

fuse.

measured

from

is

cause

oil

and

repair

leaks.

If

OK,

test

oil

pressure

pump.

conne,tions/replace.

for

leaks.

replace

belt.

fitting,

hose

and

strainer.

if

worn.

Replace/repair

from

filters.

from

no

start.

change

not

effect

with

DC

voltage

Check

resistors

across

pins

P2-24

ECU.

Power

faulty.

alternator

battery

Test

fuel

battery

the

color

the

operation

Westerlink

across

DC

voltage

are

and

P2-25.

turned

sendor,

to

engine.

pump

to

engine.

of

an

or

NMEA.

breaker.

across

in

place.

#4

and

P2

ON.

inspect

Correct

operation.

LCD

of

the

engine.

fuseholder

120

#5.

ECU

plug

If

voltage

ohm

is

"'i'Y'

WESTERBEKE

Eng/ryes

30

& qenerators

ALTERNATORS

50

AMP

MITSUBISHI

TESTING/TROUBLESHOOTING

ALTERNATOR

VOLTAGE

The device the system

The thick-fihn adjusted encapsulated possible

REGULATOR

integral

voltage

regulator

voltage

which

applied

voltage.

assembly

to

the

damage

senSeS

design

proper

to

protect

regulator

the

to

the

utilizes

techniques.

regulating

the

due

to

is

system

field

in order

all-silicon

circuit

handling

an

electronic

voltage

After

the

valve,

and

or

vibration.

level

to

'maintain

seini

conductors

voltage

the

entire

the

components

switching

and

switches

a proper

has

circuit

and

been

is

from

DESCRIPTION

The

following that are Generators.

ELECTRICAL

The

charging

regulator, circuit

breaker

of

the

use regulator back of the

I!

is

desirable

voltage

loads

that provide charging electrical

ALTERNATOR

The

stator rectifier converts

battery Power

alternator paCkage

These

alternators

rated

output

rpm

at

altemators

nmget>f'40°to'2i2"P-(40°1:Q

infonnation

supplied

with

WESmRBEKE'S

CHARGING

system

consists

an

engine

DC

wiring

and

a battery

of

integrated circuits

is

very

compact

alternator.

to

test

regulator)

are a permanent part of

the

system

system.

nsing

technician

as

the

with an

well

and

charging the wiring

as the

DESCRIPTION

is

connected

package

the

AC

charging

to

the

regulator

is

provided

contained

is

an

ambient

are

achieved designed

to a three-phase,

which

contains generated in the stator and

accessories,

and the

by the

in

the

alternator.

produce

at approximately

temperatore

to

applies

CIRCUIT

with

field

a rated

operate in

REFER DIAGRAM MANUAL WIRING

to

the

standard

Engines

of

an

alternator

harness, a mounted

connecting

(1(:'s),

is

mounted

system

harness

the operational major

components

six

diodes.

field

of

diode

output

of

75°P

an

iQO°C).

with a voltage

cables.

the

electronic

internally or

(alternator

and

system

and

test

full-wave

The bridge

to a DC

the

integral regulator

(or

diode

of 50 or

6000

(23.8°C).

ambient

TO

THE

WIRING

IN

THIS

FOR

ALL

CONNECTIONS

alternators and

DC

Because voltage

on

the

and

electrical

will

then

of

the

of

the

bridge

output

for

trio)

51

amps.

alternator

The

temperatore

ALTERNATOR

Use

this

exists

with detennined have a qualified

A

WARNING:

alternator alternator

LOW

BATTERY/FAULTY

If

the

starter

of

spinuing

fanlty

counection problem.

PRELIMINARY

Before

starting

testing

the

1.

Make

2.

Check

if

it

is

3.

Check and

tight. resistance undercharging corroded reaching a fully

4.

Check A

low

readings

NOTE:

An

selector

the

batteries

with

the starting OK

and

TROUBLESHOOTING

troubleShooting

the

charging

that

the

alternator

technician

A

working

can

become

until

if

has

only

moans

the

engine

to

in,

the

INSPECTION

the

actual

following

certain

the

wom

that

battery

the

or

discharged

iIi

isolator

switch

house battery the

problem

checks

your

altemator

drive

belts

or

glazed.

all tenninals,

Loose

or

corrn<;led

and

this

conld

or

damage

cables

charged

condition

the

tests.

with a diode, a solenoid,

is

usually

so

the

starting

balteries.

but

not

is

in

section

to

detennine

circuit

or

with

or

voltage

check

it

alternator

very

hot.

Do

cooled.

CIRCUIT

or

makes a clicking

life it is

starting

for

of battery

if

the

likely a low

circuit

alternator

are

recommended.

is

proper

connectors

coruiections

cause

to

the

could

prevent

condition.

the

battery

may

mounted

battery

the

isolator

house

the

battery

and

securely

tension.

overcharging,

charging

in

is

battery,

the

alternator.

regulator

runs

not

touch

and

not

voltage

mounted,

and

the

and

charge

cause

false

the

circuit

not

discharged

is

charging

the

charging

if

a

problem

If

is

faulty,

hot. A failed

the

sound

iIistead

battery

or a

an

alternator

regulator,

Replace

plugs

or a

are

cause

system. battery

if

or

baltery to

the

clean

high

Badly

from

necessary.

misleading

isolate

along

the

alternator

circuit.

it is

belt

is

Engines &

31

Generators

TESTING

A

certain away

1.

2.

THE

CAUTION:

that

from

~tart

the Engine.

After

the

starting

battery

multimeter a.

If

the

voltage

alternator

b.

If

the

voltage exists continue

ALTERNATORS

ALTERNATOR

Before

starting

everyone

sheaves

engine

set

is

with

is

clear

and

belts

has

run

voltage at the battery tenninals

on

DC

volts.

is

increasing toward

working.

remains

either

the

Steps 3 through 6,

the

of

during

for a

few

around

a1termitor

engine

make

moving

parts!

test

procedures.

minutes,

14

volts,

12

volts, a problem

or the

charging

TESTING/TROUBLESHOOTING

MEASURING

Keep

measure

using

the

circuit;

BATTERY

ENGINE

the

a

VOLTAGE

OFF)

MEASURING BATTERY

(ENGINE

3.

Thm off the engine. lospect all wiring

Ensure connections

4.

If

a

t\1at

5.

Check condition

VOLTAGE

RUNNING)

that

battery

it

is

on

the

battery

the

battery

are

tight

selector

the correct

switch

voltage.

reading

tenninals and the

and

clean

is

in

setting.

If

your hattery

should

be

and

engine

the charging

is

12

to

13

volts

connections.

ground

circuit,ensure

.

in

good

..

TESTING

1.

2. Wiggle

3.

4.

5.

THE

nllTDIIT

Connect the positive probe to the output tenninal B and

to

connect the negative probe

the

engine wiring voltmeter. The battery voltage,

obtained, or outpnt circuit for loose damaged wiring.

Start

the engine.

Repeat ground, the positive probe to B with the The voltage reading should

volts.

If

it

repai):ed

If

the previous test reads ouly battery voltage tenninal tenninill. inspect Jump

12

battery)

is 13-14

rtleter

should indicate the

and

shonld

if

the reading

the

same

measurement,

your alternator

at a reliable service

B,

use

the meter

If

12

volts is not

the

wiring for breaks

volts

from a 12

and

operate the

..

then

ground.

harness

or

dirty connections

is

to

volt source (such

alternator.

the alternatoris

while

not

vary.

varies,

check the

the negative

be

between

over

or under-charging,

shop.

measure

pre&ent

at exciter tenninal R,

aiJd

poor connections.

If

observing

approximate

If

no reading

engine

13.5

the

DC

as

the

voltage

OK

alternator

or

probe

and

at

excitation

the

the is

to

running.

14.5 have

output

TESTING CIRCUIT

Engines & Generators

32

THE

OUTPUT

ENGINE

RUNNING

#100RANGEB

TO

STARTER

OUL,tNUIU

#16

VlliLET

TO

K-3

/TERMINALR

R

RELAY

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

1.

Connect the positive (+) multimeter probe to the excitation terminal R on the alternator (-) lead to ground.

i.

'furn the battery switch to the on position and Mte

ille

multimeter reading. The reading should

2.5

volts (see illustration).

TESTING EXCITATION CIRCUIT

THE

3.

'If

the reading is between

rotor field circuit probably is shorted or grounded.

4.

If

the reading is between 6.0

field circuit probably is open.

5.

If

no reading is obtained, an open exists alternator-excitation lead or in ille regolator. Disconnect the lead Connect ille positive multimeter probe lead and

If

the multimeter voltage, the voltage regulator replaced. excitation circuit for loose or dirty connections or

damaged wiring.

THE

EXCITATION

ille negative multirneter probe to ground.

now

If

no voltage is indicated, check

CIRCUIT

.75

indicates

and

the negative

be

and

1.1

volts, ille

and

7.0 volts, the rotor

in

ille excitation circuit

from

exc terminal R.

to

the excitation

an

approximate battery

is

defective and must be

the

1.3

to

of

CHECKING

Check the have a voltage running. charging circuit isolator, battery

When is

back

'terminal

wiring

ALTERNATOR

If

tests sembled do the job.

NOTE:

instructionsfor standmd

BATTERY

The

minimum

the

engine's

Cranking

Review the manufacturer's recommendations establish'a systematic maintenance schedule engine's starting batteries

• Monitor yonr voltmeter engine

• Check

hydrometer.

Use,

•

leVel.

• Make certain that battery cable connections

tight to

THE

SERVICE

voltage

If

circuit.

by

checking

ille

problem

in

operation,

studs.

hamess.

between

not,

illere

Troubleshoot

switch,

Also

of

ille is a problem

ille

has

been solved

take

clean

REPAIR

indicate a failed

and

repaired.

Any

WESTERBEKE'S

the

disassembly

alternators.

CARE

recommended capacity of ille

12

volt

DC

Amps

(CCA).

operation.

ille

electrolyte level

'

only

dis1illed

ille

battery

water

posts

BATTERY

service battery. this

13

and

14

volts

in

ille

the

service battery charging

wiring

and

connections,

and

ille

battery itself.

and

the

time to tighten

ille

connecting

alternator,

Service

control circuit

and

it

will

good

alternator service

Ml1JlUl11

and

repair

is

house batteries.

for

proper

charging

and

specific

to

briog electrolytes

(and

to yonr

when

service

before

and

terminals

need

has

of

600 -

gravity

engine).

battery

ille

engine is

battery

ille

alternator

clean

to

be

shop

detailed

their

battery

900

and

illen

for

yonr

during

to

are

should

solenoid,

the

from

the

disas-

can

used in

Cold

wiill

a

a proper

clean and

TESTING

THE EXCITATION CIRCUIT

ENGINE

RUNNING

OUTPUT

TERMINAL

EXCITER

TERMINAL

R

Engines

33

& Generators

Shore

Power

If

the

I

installer connects shore power

cuit,

this must be Switch. OFF of

Set the transfer switch

position.

shore

A

CAUTION:

utility

shore

at

the

same covered bility

to

Generator

~

t ~ :

I

L

____

r-----~

I ,

\

L.-+-+---f·I~

···.'

t

~

Shara

Connections

done

TIris

switch

to generator

Damage power time.

This

under

the

warranty;

make

sure

,NOTE:

Diagram

(

for

two~w(re

:

system,

other

hotleo.

/'"--','

-I'll

__

,--~

.-_""1;1)'

.......

-.

_

1---

e ,

__

~

~._

"'","''"'''"'-+----11'· i

f?

Power

and

all

use

~,_

<'!.if

....

~,

...

"J

.....

' ' .

/

SHORE

to

the

by

means

of

the

Shore

shown

in

prevents simultaneous

output.

to

the

generator

type

AC

connections

shows

system.

the

dotted

power

of

generator

it

Is

the

oonneot;ons

For

th(Be

line

for

installer's

wfre

the

--,

I

i

I

....jl-,

I

I I

L-.L2}'

'---.;(1

Neutral

'N-'

.

POWER

vessel's

Power

the

diagrams

connection

TRANSFER

AC

cir-

Transfer

to

the

'.

.

can

result

if

are

connected

damage

are

correct.

Is

not

respons/·

NOTE:

WESTERBEKE

.

,

.

Ship

10

PN

32008

.

PN

32oQ9

PN

32010

PN

32133

,Ship'sLoad

Note:

NO~40.Volt

equipment

:\

.

40

Amps/pole

80

Amps/Pole

125

Amps/pole

200

Amps/Pole

(3

Pole)

SWITCH

A

CAUTlON.Hellv,

before

switching vlce·versa switching

operated

components

Ship

•

because

with

may

iii

to

shore

1

GENERATOR

GROUND

lL1

SHORE

shore

heavy

cause

the

generator.

switches

dealel:

POWER

motor

leads

power

voltage

cQ

w

;;

"

•

surges

AC

loads

damage

,

0

•

N

to

are

5

0

7

Q)

•

L'

~.

U GENERATOR/SHORE·

5

•

~~L1

(NEUTRAL)I

~

N)

should

to

generator

induced

on

the

vessel

the

exciter

available

SWITCH

...-....

~

2 I

, I

~-~

1';,.-

.....

,

~N

• I

, /

--'

SHORE

GROUND

be

at

1 '

shut

power

by

being

circuit.

your

-

SHIP'S

1.

GROUND

off

or

SHIP'S

LOAD

·120

Yolt/60.Hertz

Note

the

repositioning

~al

block

~o

the

generator

Three

wire:Configuration

of

th~.

white

case,

ground

lead

on

the

.

teupi-

,

Engines & Generators

230

Volt/50

Notice

the

.mi~al

repositioning

block

Hertz

to

the

Two

Wire

of

generator

Conlipuralion

the

white

ground

case;

lead

-on

the

ter·

34

USE

OF

ELEGTRIC

The power more Some others. Split-phase under monly

machines,

started,' 7 times avoided, ven motors require to

rUn. load compressor,

motor

In

general,

to

medium

*NDTE:

more

for this

made

Because the

motors

damaged

be seconds.

all

off on

the electric

Required

Run the

generator's indicted should be

the

generating voltmeter and load,

NOTE:

contains tim! vide panel.

required

than

is

motors similar

used

on

or such as

much

whenever

by a small

The

current required

connected

for

to

which

the

slllI1ing

MOTOR

SIZE

(HP)

1/6

1/4

1/3 1/2

3/4

1

In

the

for

some

is

tim!

in

lJ2rger

heavy

is

required

if it

If

difficulty

other

electrical loads

Operating

generator

capacity,

on

the

checked or

ampere

check

When

the

AC

equipment

the

generator's

one

120

This

will

required

require

circumstances,

where

as

generator. from 2 to 4 times

current

above

s111nlll1wtors

the

sizes.

motor.

generator's data

plant and the

volt

generator.

MOTORS

to start

an

to

keep

much

more

(AC)

motors

easy-starting

loads

are

small

power

current

to

start

possible, if

Capacitor

to

it.

An

electric

example,

no

loads

hardest

can

load

is

reqnired

will

(AMPERES)

table

surge of

for

only

bring the

is

experienced

will

connected.

he

AMPS

RUNNING

3.2

4.6

5.2

7.2

10.2 13

the

starting

current

an

and,

Speed

first with

periodically

it with a

vessel

AC tenninalblock

AC hot

ensure

and

finally

meter

pOltable

in

of

good

no

appliances

is

which

120

leg

electric

motor

it

running

current

require

than

other

loads,

such

applied

tools.

to

after

Because

as

to

run,

the

electric motor

and

as

much

start

any

motor

connected

require

more current than a

start

115-Volt

approximately

FOR

maximum

than

for

lJ2rger

types

needed

instant,

the generator will not

motor

up

in

starting

if possible,

load

applied,

loaded

plate.

The output voltage

to

ensure

not

insralled

meter and

the

generator

volts

only,

be

for

the

vessel's

I1wtDr

sta.ting

GENERATOR

INFORMATION

Generator

is

considerably

after

it

is

started.

to

start

them

than

more current

types.

as

washing

the

they

their

repulsion-induction

current

motor

motors as

AMPS

{~TARTIN~l

AMPERES

6.4

9.2

.

10.4

14.4

20.4

Amps

ones.

(split-phase)

for

to

speed

reduce

then

to

its

full.capacity

proper operation

it

supplies.

to

monitor

amp

it

is

configured

to

start,

They

are com-

motor

is

require 5 to

use

should be

is

to

be dri-

to

start

as

varies

with the

to

an

air .

connected

follows:

FOR'

to

22.4'

to

32.2'

to

72.S'

to

29.2'

to

40.S'

26

to

52

for

Starting

The

reason

are

not

starting

in a few

motors,

is

tum

the load

at

half the

If

an

voltage

probe.

installed

as of

AC

recommended

to

pro-

is

distribution

response

from

the

Frequency indicated

•

• Therefore,

generator's dipswitch generator sensing

Generator

•

• For

•

• The drive

• The rear

• Examine

Frequency

is a direct

by

111e

When

the

generator

output

frequency

When

the

generator

output

frequency

to

change

drive

on

the

changed

PC

board

Maintenance

Maintaining

Connections become ducting allowed cause

leum-base

surfaces suggested are

410" and In

inspected of overheated

checked and for should accelerate to

8,

ners

maintenance noisy

of shaft motion

shaft of Repair rub

corroded,

if

salts,

to

excessive

unusually

to

Ashland

addition

for

discs

periodically

any

not

cracking.

the

generator

identified

of

the

armature

or

rough-sounding,

bearing

should

is

detectable,

bearing

Il).ust

and

cause

build

coatings,

reduce

to

be

head.

Adjustment

result of engine/generator

following:

is

run

at

1800

RPM,

is

60

Hertz.

is

run.at

1500

RPM,

is

50

Hertz.

the generator's frequency/voltage,

engine's

ECU.

changed.

reasonable

of tenninal

severe

Daubert

periodic

(a)

terminals

evidence

allowed

by 6 radial

is

required.

be

major

speed

The

AC

output

and

the

connections

cleanliness

boards

and

insulation

dust,

engine

exhaust,

up.

Clogged

heating

on

shaft

socket

made

and

reduced

conditions,

should

be

rusting

and

Chemical

"Tectyle

tightness

single

bearing

at

detected

506"

cleaning,

of

all

and

(c)

bearing

if possible

of incipient cracking

to

become

The

bolts

must

be

marks,

is

lubricated

However,

have

periodic

damage

intervals.

when

bearings

outside

quickly

to

must

be changed using

configuration of

on

is

important

and

rectifiers

surfaces

carbon,

ventilation

life

thin

rust-inhibiting

sprayed

corrosion.

Co.

"Non-RustAC-

or

equivalent.

the generator connections, (b)

loose

or

generators

for

tightness of

rusty

which

fasten

hardened

one

at

each of

if the

it

replaced.

No

force

are

wearing

bearing

or

major

generator.

speed,

theAC

the voltage

may

start

etc. openings of

windings.

or

brushed

'TYpical

should

evidence

damaged

should

screws

failure.

because

steel

and

is has

components

rust

the

drive

SAE

the 6 cor-

sealed;

bearing

side

movement

applied.

or

wear

OCCUlTed.

as

voltage

the

111e

con-

are

may

petro-

over

all

materials

be

wires.

be

Discs

may

disc

grade

no

becomes

if

side

on

will

...-N"

WESTERBEKE

Engines &

35

Generators

DESCRIPTION

The

Be

generator

requires output. windings started, residual voltage in larger voltage quickly regulated same the

AC

The A the The ratings inside of v.Ji.ous as

only the

The

voltage

in reaches

time,

stator

tenninalsto operate

generator

liS

volt

SPECIFICATIONS

generator

of

the

AC

in

this

manual.

drive

stator

and

the exciter

magnetism

the

stator

in

the

four rotating

the

energy

field

this

regulated

windings

is a single

AC

two

data plate

the

generator. An

louvered cover

voltage

---

NOTE:

and

is a brushless;

force

houses

windings

exciter

saturation point of

is

which

wire

section

connections

of

the

two

sets

windings.

in

the

which

windings.

poles

then

maintained

field

produces

can

then

AC

equipment.

phase,

or

230

volt

of

gives

the

AC

at

the

....

self~exciting

and

120

wiring

are

---=--~,~~--=------.----.-~---

Be

GENERATOR

WESTERBEKE

adjustments

generator

engine

to

produce

of windings;

When

four

rotating

then

This

in

the

be

drawn off

volt

two

this

manual

voltage,

decal

generator

provided on

the

the generator

poles

generates an

mutual

the

exciter

capacitor(s)

in

the

stator.

a steady

the

AC

two

wire

at

50

for

current and

is

affixed

end.

recommends

be

performed

which

an

main

is

induces

even buildup of windings

and

At

AC

voltage

generator's

wire

at

Hertz.

generator

frequency

to

Diagrams

this

decal

AC stator

a

the

60

Hertz.

Refer

ratings.

the

of

as

a

in

the

well

SINGLE

that

the

by a qualified

Circuit

A circuit breaker

WESTERBEKE

automatically electrical overload. The circuit breaker can off

when

coming

NOTE:

add-on WESTERBEKE

60

Hz

50

Hz

to

PHASE

following generator

technician.

Breaker

is

installed

generators.

disconnect

servicing the

into

the

This

circuit breaker

kit for earlier

- 5.5 KW

- 5.0 KW Circuit

boat.

dealer.

Circuit

generalDr

model

Breaker

tests

This circuit breaker will

generator

is

generators;

on

all

single

power in case of

to ensure

available

Part

Number

Part

Number 042238

phase

an

be

manually shut

that

no power is

as a WESTERBEKE

contact your

038209

INTERNAL

A

ROTATING WITH

DIDOES.

B

MAIN

STATOR

C

EXCITER

CIRCUIT

BC

GENERATOR,

WIRING

r-------

I

1

I

. I

I

1 . 1

AI

I I

I

l

UIUIJtl~:::

I I

I 1

1 1

L

_____

FIELD/AUXILIARY

WINDINGS.

WINDINGS

AND

....

-"'1

..:

___ J

WINDINGS

CAPAClTOR(S).

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

1 I

I I

~----_(:l2

--.,-----<:I~

------<::>4-=

L~~======~~

____

I

"'"

"'I

9 I

"'I

;;!

I

~IB

~1

. I

I

.1

r--------

I I

: I

1

C

I ,

\ t

________________

AC

TERMINALBLOCK

---

..

----

---'

5~

CAPA!~

t

CAPAI~

l

..1

Engines & Generators

36

DUAL

EXCITER

CIRCUIT

Be

NOTE:

WESTERBEKE

and

adjustments

GENERATOR

re.commerufs

be

peiformed by a

SINGLE

that

the

qualified

PHASE

following

technician.

generator

==--'--

tests

SINGLE

1.

2. Start

3. Refer

4. Shut

EXCITER

Remove generator,

the

five generator

current

~ppliances).

.

correct. correct

configuration by hot reading.

at

lower

plugged

A

handling

tial/y

power

the louvered

covering

capacitor(s).

the

generator

minutes

measuring

lead

60.5 -61.5

so

the

is

operating

from

the

Make

Adjust

the

engine

speed

to

the

AC

then the

with a volt

The generator's

Hertz.

than

specified,

off

the

generator.

into

the

WARNING:

as

they

lethal

charge

source.

NO-LOAD

the

and

engine

generator

sure governor

load

check

voltage

meter.

capacitor.

CapaCitors

stote

even

VOLTAGE

metal

plate,

AC

tenninal connections

allow

can

without

(that

the

engine's speed

as

before

proceeding.

connections

the

across

Make

no-load

If

the

voltage

proceed.

Make

must

electricity

when

ADJUSTMENT

at

the back of

it

to

run

for

wann

up.

Make

any

equipment

is,

shut off

needed

generator's

sure

disconnected

to

diagram for

no-load

the neutral

sure

you

voltage

is

output

the

60Hz

be

discharged

and

can

the

and

approximately

sure

the

drawiug

all

electrical

(Hertz)

is

obtain

the

correct

voltage

lead

and

the

record

this

115 -124

is

higher

Hertz

volts

or

lead

before

pack a poten-

from

their

AC

is

S.

There minal, low,

then

nect

the plug tor's oo,load numbered number. terntinal

6.

If

the

because

numbered

or

the

bered

Generator

A

covers are

NOT

.

with

are

three

plugs

grouped

#7,

#8,

and

#9.

If

disconnect

plug

Note

may

generator's no-load

the

voltage

plug

voltage

plug

is

Troubleshooting

WARNING:

on

the

in

the

generator's

the lower

with

the

is high,

and

connect

that

the plug

be

anyone

needs

is

already connected

needs

to

be lowered

connected,

Make

unused

contact

with

housing.

for

the

right capacitor

the generator's no-load

numbered

higher

then

the

plug with the next

presently

of

the

three

voltage

to

be

increased and the

refer

to

the

Guide).

cerlain

leads

are

each

other

NOTE:

SHOWN DEMONSTRATION THESE BEMADE.

plug and number. disconnect the

cannot be adjusted

and

th';

in

If

the

connected

plugs

available.

to

the right

the

lowest

WESTERBEKE

ins~/ating

place

and

Dr

In

contact

THE

#7

WIRE

CONNECTED

CONNECTIONS

OF

voltage

coogenerahigher

lower

to

this

highest

terntinal,

num-

IS

AS

A

HOW

CAN

ter-

is

BC

NOTE:

Simply insulated any

excess

A

WARNING:

voltage The

capacitor Touching shock.

voltage could rolllr.

cross

(plastic

handle)

electricity.

adjustment

can

any

wiring

In

addition,

adjustment

cause

your

the

capacitor's

Do

not

while

screwdriver.

attempt

the

generator

two

to

produce a 400-500

can

produce a severe

attempting

while

fingers

the

generator

to

be

to

make a no-load

caught

terminals

This

will

with

discharge

make a no·load

is

operating.

volt

charge.

electrical

is

operating

in

the

generator's

an

BC'

GENERATOR

//

BACK

120V/6DHz

/

/.

/

,

END

SHOWN

SINGLE

-

.

AC

TERMINAL

BOARD

\

EXCITER

CIRCUIT

.

See

the

ENGINE ADJUSTMENT

ADJUSTING

THE

ENGINE

section

SPEED.

REFER

AC

in

this

manual

TO

THE

FOLLOWING

TERMINAL

BLOCK

for

PAGE

FOR

CONNECTIONS

lit..

.,

Engines & Generators

37

120

I

VOLTS

60

120v

BC.GENERATQRSINGLE

AC

TERMINAL

HERTZ.CONNECTIONS

60

Hz

BLOCK

AND

VOLTAGE

SENSE

VOLTAGE

TO

CIRCUIT

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115

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3

6

120V/60Hz, REQUIRED

230

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50

HERTZ

230v

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WESTERBEKE·

'Engines & Generator.

38

VOLTAGE

RESISTOR

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SENSE

BOARD

DUAL

EXCITER

These

generators

ment

connectors

available selection, and

#9,

When

making

proceed

1.

Shut

2.

Select capacitor RPM. and

#9, duced can

be

increase

between

achieve

CIRCUIT

have

at

each

for

each

capacitor.

60

Hertz

or

are

for

no-load

Hertz change or

as

follows:

the

generator

the

appropriate Hertz connection

#60,

60

The

three

other

will

have

by

the

generator.

plugged

into

or

decrease

connectors

the

prescribed

MODEL

dual

Hertz

capacitor.

TWo

50

Hertz,

voltage

down.

Hertz,

1800

connectors

an

effect

One

each

capacitor.

approximately 8 -

used

in

no-load

5.0KW

and

There

connectors

and

adjustment.

no-load

RPM

on

the

connector

any

pair

voltage

Be

no-load

are

three connectors, #7,

voltage

to

or

50,

at each

no-load voltage

from

No-load voltage

10

combination

as

GENERATOR

voltage

five

are

plug #50

capacitor,

AC

illustrated

adjust-

connectors

for

Hertz

adjustments

into

each

Hertz,

#7, #8,

pro-

each

group

will

volts

to

below.

#8,

NOTE:

insulated (plastic handle) screwdriver. This will discharge

any

1500

SINGLE

A

WARNING:

handling tially power

as

lethal

source.

Simply cross the capacitor's two terminals with

excess

PHASE

Capacitors

they

stol'l1electrlclty

charge,liVen

electricity.

must

and

when

disconnected

be

discharged

can

before

pack a poten-

from

their

an

50HZ

r.nNNFr.Tlnl'~~

NOTE:

When changing Hertz produced by the generator, an

be

engine speed change must The AC output connections on the terminal block

selectedfor connection (s) on the capacitor(s) changed

from

wire

correct neutral

the voltage

the neutral

terminal.

of

made. This is done

and

Hertz to be produced. the Hertz

and

the AC terminal block moved to the

at

the

ECu.

must

be

the ground

,

,,/60

Hz

120

DDAL

EXCITERCIRCDIT

VOLT

CON.FIGURATION

,

A

WARNING:

the

unused

with

each

leads

other

Make

or

ILLUSTRATION.J

::;:;".",A!;

are

in

contact

certain

place

the

and

with

IEFIMINAL

insulating

are

NOT

the

generator's

BOARD

covers

in

contact

on

...

REFER

TO

THE

AC

TERMINAL

PAGE

BLOCK

CONNECTIONS

FOR

'

-..v'

WESTERBEKE

Engines &

39

Generators

~------'-------~~~-----===-~~~------

I

~

The

following

insight

into

problems

single

ahd

dual

the

simplicity

is

relatively

effect

Keep

electricity

easy,

is

·understood.

in

mind

is remember that therefore, a

generator.

Only These meter

extreme

Ii

few

are

hand

capable

basic

sion required

No

AC

Output.

Residual

voltage

at

NO·Load.

High

AC

Output

Low

AC

Output

Voltage

Orop

No

Battery

Charge/Low

Unstable

voltage

5.5/5.0KW

troubleshooting

which

capacitor

of

the

equipment

once

the

that a basic

required

Problem

Under

lethal

caution

tools

tools:

of

reading

in

reading

4 -6

VAC

at

No-Load.

60·106V.

Load

output.

for

voltages

are

an

component

(Hot

or

Battery

chart

may

be

Be

brushless

and

relationshlp

fundamental

this

troubleshooting,

are

present

is

essential when

necessary

amp

probe

less

than

to

N)

-

at

No-Load.

Charge

EDe

is

designed

encountered

generators.

controls,

between

knowledge

in

the troubleshooting

for

diagnosis

and a quality

one

ohm

due

winding

1.

Shorted

2.

Open

3.

Shorted

1.

Faulty

2.

Open

3.

Shorted

4.

Electrical

1.

Faulty

2.

Incorrect

3.,

Incorrect

1.

Faulty

2.

Faulty

3.

Faulty

1.

Faulty

2.

Faulty

1.

Faulty

2.

Faulty

3.

Blown

4.

Faulty

1.

Electrical

GENERATOR

to

give

with

the

Owing

to

troubleshooting

cause

and

of

and

always

circuitry;

and

repuir.

volt-ohm-

to

the

preci-

resistances.

Probable

stator.

capaCitor.

Exciter.

rotor

diode. capacito, diode capacitor. bridge

Cause

stator.

diodes

(two).

exciter.

connections

winding.

capacitor.

hertz

tap

winding.

..

rectifier.

integral

controiler

fuse.

winding.

connections

faulty.

on

capacitor.

are

Before the witnessing light a problem rather

Bring problem that if replaceable

efficiently.

..

faulty/loose.

TROUBLESHOOTING

attempting

problem

than

basic

equipment,

the

problem

1.

2.

3.

1.

2.

3.

4.

1.

2.

3.

1.

2.

3.

1.

2.

1.

2.

3.

4.

1.

any

repairs,

as

possible,

the

problem.

which

equipment

repair

parts,

tools

such

should

the

problem

preferably

In

is

with

as:

be

VerilicationJRemedy

Check

stator

windings.

Check

stator

windings.

Check

diodes

on

rotor.

Check

capacitor.

Check

exciter

windings.

Check

exciter

windings.

Inspect/clean

Correct

Verify

Connect Check Check Verify Check/replace Verify

Check

Troubleshoot

Inspect/replace

Check

Check/clear/tighten

and

tighten

connections.

capaCitor

rating.

correct

hertz

rotor

winding.

diodes.

capaCitor

rating.

diode.

capacitor

ratings/replace.

rectifier

diodes.

controiler.

30

charge

circuit

gel a clear

some

cases,

to

you

on diodes found

can

connections.

tap.

amp

fuse.

windings.

electrical

an

explanation of

from

an

individual

this

may

the

method

the

initial

and

bridge

in

one

of these easily

be

remedied

connections.

bring

of

trip

rectifier, early

to

operation

to

the

so

and

Noisy

Operation.

112

AC

Voltage

Output

1.

Faulty

2.

Generator

to

1.

Faulty

2.

Faulty

support

engine

Exciter Rotor.

rotor

is

loose.

Circuit.

bearing.

connection

Engines.

~.

& Generators

40

1.

Inspect

2.

Inspect

1.

Check

2.

Check

rear

rotor

securify

exciter

rotor,

carrier

of

circuit

diodes

bearing:

rotor

to

flywheel.

components.

and

windings.

LAY-UP & RECOMMISSIONING

,

I'·

GENERAL

Many

owners

rely

on

their

boatyards including engines off-season to

accomplish

The

procedures

own

lay-up

list

procedures

you

have

local

if others

lay-up

assistance.

check These

during a maintenance

If your provide

Propeller

The

transmission

be

opened

'out

of

the

water

storage

in

severe

strain

the

boat

is

shaft

has

actually

apply

to

small

not

in

use,

period

oftime

Fresh

Water

A

50-50

solution of

recommended

This

solution antifreeze, solution

Should amount

mixture.

and

cooling

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine

sump.

Remove

with

new

ENGINE LUBRICATING OIL

oil

changing

oil

pressure

A

CAUTION:

in

the

sump combustion chemicals internal

and

or

for

long

lay-up

which

and

recommissioning,

do

should

and

also

needs

of

any

questions

servicing

Shaft

up

the

taken out

unless

and

or

cradle.

on

the

boats

..

and

the

been they

dealer;

Coupling

moved

propeller

Cooling

antifreeze

for

use

may

require

depending

make

sure

antifreeze

the

engine

the

of

the

antifreeze

Now

System

warm,

and

replace

oil.

Use

the

procedure.

and

make

00

over

the

deposits

Which

parts.

generalnrs,

periods

preparation

follow

the

procedures.

afford

help

your

engine.

regarding

propeller bolts

from

The

flexibility

or

put

bent

that

are

have

Circuit

in

the

a

on

the

antifreeze

be

needed,

block

engine

recheck

drain

correct

Run

sure

not

leave

lay-up

combine

can

reduce

to

prepare their

for

lay-up

during

of

inactivity.

themselves.

will

allow

or

your

familiarize

he

will

be

you

engine

you

lay-up

more

Others

to

may

protection

with

procedures,

than

[Propulsion

half

couplings

removed

in

by

hauled

been

coolant

higherco~centration

to

the

there

when

the

land

to

water,

of

the

boat

shaft

or

coupling

the

water.

In

some

these

strains.

out

of

the

dry

for

a considerable

and

distilled water

system

area's

winter

climate.

protection

drain

an

appropriate

and add a more

ensure a complete

concentration

the

antifreeze

all

the

oil

grade

pages

the

engine

are

the

period.

to

the

throughout

engine

filter

and

of

oil.

Refer In

in

this

and

no

leaks.

engine's

Lubricating

produce

life

of

your

This

at

solution's

oil

fill

manual

check

craft,

the

prefer

perform

use

them

the

call

willing

Engine]

should

always

boat

is

hauled

and

during

often

puts

or

both,

while

cases,

the

does

not

water

when

is

all

times.

of

Check

is

adequate.

concentrated

circulation

the

strength.

from

the

sump

the

for

proper

old

engine

all

and

harmful

engine's

your

as

a

to

a

the

oil

the

oil

Fuel

System

Top

off

or

higher. A fuel stabilizer should be gasoline/water and

make

fuel.

Fuel

System

Top

off additives mix

with Additives should

be condition used

are

separator

primary

sediment Change

fuel

system,

for

5 system. the

fuel

needed.

allow

movement

equipment

Raw

Water.Cooling

Close

the

hose

from

gallon

bucket

check

the

engine

any

zinc

anode

Start

the

fresh

water

stop

the solution protection

Start

the

through

the

engine.

water

circuit from freezing

as

providing

Remove antifreeze Examine

a

cover

until recommissioning, but

Cylinder

Spray

arrester

oil

will

spark

[GaSOline]

your

fuel

tanks

conditioner

added.

separator

certain there

are

[Diesel]

your

fuel

tanks

should be added prior

the

fuel

being

such

as

Bio-bor

added

at

this

the

fuel.. Care

compatible

used

fuel

bowl.

the

fuel

10

minutes to

Check

system during Operating the

on

through-hull

the

zinc anode

and

debris from

is

engine and

through

engine and

slightly

in

engine

the

This antifreeze

the

mixture

the

gasket

with

in tbe

system.

filter/water

filter

elements

as

needed.

make

for

any

this

engine

of the treated

the

engine.

seacock. Place

of clean

found

clean

or inside

located.

your area ..

raw

cOlTosion

impeller

impeller.

Clean

allow

the

refill

stronger

and

allow

water system

from

will

Do

not

Lubrication[Gasoline]

fogging

plugs

oil

removed.,

stall

out the engine

for

winter

into

while

with

unleaded

such

Change

and

clean

no

with

No.

added

and

time

to

should

the

primary Change

separator

Start

the

sure

leaks

that

servicing,

leaks.

as

Sta-Bil gasoline

the

Clean

2D

diesel

to

topping

and

fuel

Diesel

Kleen

control

be

taken

fuel

the

and

on

the engine no

air

may

correcting

for

5 -

10

fuel

through

gasoline

element

metal

bowl.

up

fuel.

off

still

in

+ Celane Boost

bacteria growth

that the

filter/water

element

clean

the

engine and

and

is

left

have been

minutes

the

Circuit

seacock.

fresh

replace

protection.

accompany

Acquire a replacement,

replace

the

protection.

the

water.

in the

the

system.

the

bucket

than

all

mixture

during

your

replace

open

the

engine

and

Remove

end

Before

the

primary

it

as

heat

raw

water

When

needed

of

this

Once

should

the

raw

the

impeller

air intake,

coat

the

of this hose

starting

heat

required,

exchanger

water

strainer.

pump

the

bucket

with

an

for

winter

mixture to

the

bucket

protect

winter

water

pump

it,

so

catch

the

cover

with

is

running.

the

valves,

of

89.

in

your

Re-install

any

spilled

Fuel

to

ensure

the

tank.

additives

in

separator

bleed

allow

it

in

the

fuel

created

themas

will

injection

raw

water

into a five

the

exchanger

and

also

where

to

draw

is

antifreeze

freeze

be

drawn

is

empty,

the

lay-up,

(some

it

in

if

needed,

(into

the

and

gasket.

the

The

cylinders

octane

they

and

your

the

to

run

in

help

intake

engine,

on

clean

the

empty,

stop

raw

as

well

a bucket).

and

pump)

flame

fogging

and

Engines & Generators

41

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication if battery connections the connections removed

Cylinder

If

WESTERBEKE access the revolutions

If

to be the

Intake

Clean cloth block through-hull exhaust to

Cylinder

After engine small crankshaft manually spark

NOTE:

the crankshaft two full tighten properly and connect

each spark plug.

Motor

and

cleaning of

access

to

the

starter

starter.

Take

care

Lubrication

you

anticipate a

recommends

to

the

cylinders.

cylinder

your engine does

injectors

walls.

and

removed.

and

re-install

Be

return

Manifold

the

filter

screen in

lightly

soaked

any

opening.

start-up!

Lubrication

shutdown,

amount plugs

of

loosely

At spring

fogging

commissioning,

perntits

are

shut

in

properly

from

[Diesel]

long

lay-up

Squirt

Rotate

the

not

have

sure

to

have

fuel

[Gasoline]

the

in

lube

Also

place

port,

Make a note

[Gasoline]

remove

oil

two

complete

for

winter

revolutions.

Batteries

If

batteries make to prevent them batteries will

subjected

batteries

environment.

A

highly-explosive arcing smoke serviced. to

Transmission

Check off the coupling coating. additional information, refer

are

to

be

sure that

to

and

they

from

not

remain

severe

store

WARNING:

or a lighted or

allow

Shut

off

prevent

grime

or

change

and

Check

electrical

[Propulsion

the

grease

and

the

that

left

on

are

fully

freezing.

fully

environmental

them

in a warmer,

Lead

acid

gas,

Which

cigarette,

an

open

all

electrical

arcing

fluid

in

and

touch

output

the

transntission vent

the

starter

drive

pinion

its

easy

removal.

off

before

attempting

replacing

the

starter.

period

(12

removal

some

engine

glow

line

flame

oil

around

an

into

lay-up

the

board

charged,

If

charged,

of

Marvel

crankshaft

plugs. plugs,

replacement

as

needed.

arrester,

the

oil-soaked

to

the

spark

each

cylinder.

revolutions.

remove

Re-install

high tension leads fully onto

during

and

there

is

or

conditions,

more

batteries

can

be

ignited

cigar,

or

flame

near

the

equipment

during

servicing.

Make

any

electrical

months

the

glow

Mystery

the

injectors

sealing

and

flame

cloth

remove

plugs

Rotate Re-install

the

plugs and

the

lay-up

will remain

any

doubt that

that

they

remove

compatible

emit

hydrogen,

by

pipe.

battery

in

by

place a clean

and

Do

Engine]

the transntission

up

any

flange

with

to

the TRANSMISSION

as

unpainted

an

anti-corrosion

is

open.

is

advisable,

sure

to

remove

or

!Dare)

plugs

for

Oill

into

hand

two

will

washers

arrester

to

in

the

cloths

prior

spray

the

rotate

spark plugs,

period,

that

the

will

be

the

a

electrical

not

being

the

vicinity

required

areas.

Protect

For

SECTION.

the

have

for

a

way,

Wipe

Spare

Parts

Lay-up Westerbeke

kit

or

coolant

and

during

SPARE

time

provides a

engine

hoses

order items

the

lay-up,

PARTS

section

to

see

need

replacement.

not

such

good

on

as

of

Recommissioning

The

recomntissioning seasonal those section However, counteracted

1.

2.

3.

4.

5.

6.

lay-up

described

regarding preparation for

some

before Remove Remove

discard removed Install

Reinstall lay-up, terminals

Check

A

and batteries

can cigarette, flame electrical arcing

Remove

proper Check

circuit that it solution engine short period of

advisable,

service, heat

area.

Start in

manual.

the the

the

during

the

raw

the

and

are

to

make

CAUTION:

eye

protection

emit

be

ignited

cigar,

near

the

equipment

during

the

tightness the condition of the zinc

and

is

not from

is

put into

to inspect

exchanger

the

engine in accordance

the

PREPARATIONS

of

your

generally

in

the

PREPARATIONS

of

the

lay-up

starting oil-soaked raw

water

old

gasket.

lay-up

water

pump

batteries

reconnect

clean

and

sure

that

Wear

rubber

when

hydrogen, a highly

by

electrical

or

pipe.

battery

in

servicing.

spark

plugs,

[gasoline}.

clean

or

replace

necessary

the

raw

operation,

time

with

as

either

an

the

and

clear

opportunity

if

external

hand, filters

this

follows

the

cloths

pump

Install

(or a replacement,

that were the

that the

items

Check

or

replace

and

zinc

manual.

Westerbeke

the

same

starting

procedures

engine.

from

cover

the

raw

cover

with a new

removed

battery

cables,

connections

the batteries

FOR

the intake manifold. and

gloves, a rubber

servicing

batteries.

explosive

arcing

or a lighted

Do

not

smoke

being

serviced.

the

vicinity

wipe

to

flush

water coolant

no

end

area

any and

FOR

to

clean,

anode

the

anode

the

antifreeze/fresh water

the

system

adverse

of

season

where

the all

with

STARTING

to

inspect your

such

as

drive belts

your

basic spares

those

items used

anodes.

and

will

water

are

Refer

engine after a

procedures

STARTING

normal

gasket and

if required).

during the

making

fully

starts.

need to

pump impeller

cover

sure

are

tight.

charged.

apron,

Lead

gas,

which

or

allow

an

Shut

off

all

prevent

re-gap,

as

system.

affects.

or

zinc

procedures

electrical

and

in

the

raw

needed.

will

recommissioning

When

self-flush

It

is

located

debris

section

Note

from

described

to

as

be

gasket.

the

acid

open

install

water

the

in

of

this

the

to

in

the

that

a

Engines & Generators

42

POWER

TAKE

OFF

SYSTEMS

POWER

A

backend.

engine

The horsepower can Or

Contact

power

for

EDC

be

utIlized

to

operate

TAKE

take

This

a variety of

generator's.

your

GENERATOR BACKENO

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off

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when running at

either

the power

Westerbeke Distributor

can

be

allows

accyss

hydraulic drive

engine

for

AC

take

attached

and

1800 generator off.

Not

to

the

generator

to

the

full

power of

electrical

is

producing a maximum

rpm.

both for

accessories.

This

horsepower

amperage

additional information.

output

simultaneously.

the

STUDS

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43

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions

an inch

11/64 0.171875

13/64 0.203125

15/64 0.234375

17/64 0.265625

19/64

21/64 0.328125

11/32 0.34375 23/64 0.359375

25/64 0.390625 13/32 0.40625 27/64 0.421875

29/64 0.453125

15/32 0.46875

31/64 0.484375

of

Decimal

1/64 1/32

3/64 0.046875

1/16 0.0625 5/64 3/32 7/64 0.109375

1/8 0.125 9/64 0.140625 5/32 0.15625

3/16 0.1875

7/32 0.21875

1/4 0.250

9/32 0.28125

5/16 0.3125

3/8 0.375

7/16 0.4375

1/2

(in.)

0.015625

0.03125

0.078125

0.09375

0.296875

0.500

Metric (mm)

0.39688 33/64 0.515625

0.79375 17/32 0.53125

1.19062

1.58750 9/16 0.5625

1.98437 37/64 0.578125

2.38125 19/32 0.59375

2.77812 39/64 0.609375

3.175

3.57187 41/64

3.96875

4.36562

4.76250 11/16

5.15937 45/64 0.703125

5.55625 23/32 0.71875

5.95312 47/64 0.734375

6.35000 3/4 0.750

6.74687

7.14375 25/32 0.78125

7.54062 51/64 0.796875

7.93750

.8.33437

8.73125 27/32 0.84375

9.12812 55/64 0.859375

9.52500

9.92187 57/64 0.890625

10.31875

10.71562 59/64 0.921875

11.11250

11.50937

11.90625

12.30312 63/64 0.984375

12.70000 1 1.00

Fractions of

an inch

35/64

5/8

21/32 43/64

49/64

13/16 0.8125 53/64 0.828125

7/8 0.875

29/32 0.90625

15/16 61i64 0.953125 31/32

Decimal (in.)

0.546875

0:625

0.640625

0.65625

0.671875

0.6875

0.765625

0.9375

0.96875

Metric (mm)

13.09687

13.49375

13.89062

14.28750

14.68437

15.08125

15.47812

15.87500

16.27187

16.66875

. 17.06562

17.46250

17.85937

18.25625

18.65312

19.05000

19.44687

19.84375

20.24062

20.63750

21.03437

21.43125

21.82812

22.22500

22.62187

23.01875

23.41562

23.81250

24.20937

24.60625

25.00312

25.40000

.

IgI:Iglnei&

44

Generators

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Miilirneters

Feet

(It) 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

Latitude = 60

1

Minute

of

Latitude

VOLUME

Cubic

Inches

(in') x 16.387 = Cubic

Imperial

Pints

(IMP Imperial Imperial Imperial Imperial Fluid US US US

Quarts

(IMP Gallons Quarts

(IMP

Gallons

Ounces x 29.573 = Milliliters

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(I

b) 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

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt)

x

1.201

(IMP

gal) x 1.201 = US

(g) x .035 = Ounces

(kg)

(psi) x 6.895 = Kilopascals

(Hg) x .4912 = psi

(Hg) x 3.377 = Kilopascals (H20) x .07355 = Inches (H20) x .03613 = psi x 27.684 = H20

(H20) x .248 = Kilopascals

km

Centimeters

(L) x 1.76 = IMP

=

US

Quarts

x

.034

(L) x 1.057 = Quarts

(L) x .264 = Gallons

x

2.205

x

.061

(L)

x.88 = IMP

(L) x .22 = IMP

(US

qt) x .833 = IMP

Gallons

(US

=

Ounces

=

Pounds

(kPa) x .145 = psi

2.036

=

Hg

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

=in'

pt

qt

gal

qt

gal) x .833 = IMP

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

1

US

U~

(in-Ib) x .113 = Newton

(It-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 = 7.131bs

gallon = 8.33

gallon = 6.1

gallon = 8.56

Ibs

.

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = It-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

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CONTACT

THERMOSTAT

YOUR

WESTERBEKE

DEALER

WESTERBEKE ENGINE AND A GALLON

RECOMMENDS

OIL

(YOUR

OF

FOR

SUGGESTIONS

CARRYING

BRAND)

PREMIXED

FOR

AN

COOLANT.

AND

ENOUGH

OIL

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ADDITIONAL

INFORMATION

~

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SYSTEM

HARDWARE

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two

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toolbox.

spares.

off-shore

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cruising.

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Kits,

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INJECTOR

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KITS

KIT

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BELTS

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FILTER

FUEL

FILTER

HEAT

EXCHANGER

IMPELLER

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OVERHAUL

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FUEL FUEL

KIT

GASKET

PLUG

SYSTEM PUMP

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Generators

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WESTERBEKE

Engines & Generators

1165-11-2011

Westerbeke 5.5 kw EDC, 5.0kw EDC Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual