Westerbeke 7.6 KW BTD, 5.7 KW BTD Operator's Manual

OPERATOR'S MANUAL

&

INSTALLATION GUIDE

WESTERBEKE

7.6 KW BTD - 60 Hertz

5.7 KW BTD -

MARINE DIESEL

G

ENE

Publication #040457

RATOR

Edition One

April 1994

50 Hertz

SET

~

WESTERBEKE

WESTER

150 JOHN

BEKE

CORPORATION · MYLES STANDISH INDUSTRIAL PARK

HANCOCK ROAD, TAUNTON,

MA

02780-7319 U.S.

A.

SAFETY PRECAUTIONS

The following symbols appear in this manual to call attention to and emphasize conditions potentially
dangerous to the operator.

I WARNING I

The above symbol is used in the manual

The above symbol is

Read the manual carefully and thoroughly before attempting to operate the equipment. Know when
dangerous conditions can

Fuels, exhaust gases, batteries, electrical equipment, moving and hot
result in serious personal injury or death. Follow recommended procedures carefully.

•

Prevent

Shut off electric power before accessing electrical equipment.

Use insulated mats whenever working on electrical equipment.

Make sure your clothing is dry, not damp (particularly shoes), and keep your skin surfaces dry when
handling electrical equipment.

Remove wristwatch and jewelry when working on electrical equipment.

Electric Shock

used

in the manual

exist and take necessary precautions

to

warn

of

possible serious personal injury or loss

II

CAUTION

to

caution personnel

II

of

possible damage

to

protect personnel and equipment.

partS

to

equipment.

are potential hazards that could

of

life.

Do not connect utility shore power

throw transfer switch. Damage

Be extremely careful when working on electrical components. High voltage can cause injury
death.

• Exhaust Gases

Ensure that exhaust system is adequate to
system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping
exists.

Be sure the unit and its surroundings are well ventilated.

• Use

Extreme

Do not fill fuel tank(

Do

not smoke or use an open flame near the engine or the fuel tank.

Are

Care

Toxic

When

Handling Engine Fuel (A constant

s)

while the engine is running.

to

vessel's

to

vessel's

AC

ex-pel

AC

circuits, except through a ship-ta-shore double

generator

may

result

if

this is not done.

gases discharged from the engine. Check exhaust

danger

of explosion

or

fire

or

exists)

1

WESTERBEKE

GENERATORS

• Do Not

Alter

or

Modifv

the

Fuel SYstem

Be sure all fuel supplies have a positive shut-<>ffvalve.

Be

cenain

fuel line fittings are adequately tightened and free

of

leaks.

Make sure a fire extinguisher is installed
proper use.

Ex1.inguishers rated ABC

neart>y

by

the NFP A are appropriate for all applications encountered in

and is properly maintained.

Be

familiar with its

this environment.

• Use

Extreme

Care

When

Servicing

Batteries

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or
by

a lighted cigarette, cigar, or pipe. Do not smoke or allow

serviced .

• Avoid Moving Parts

Shut off all electrical equipment in the vicinity

Do not service the unit while it is running.

make operating adjustments, use

extreme care

If

a situation arises in which it is absolutely necessary to

to

avoid moving parts and hot exhaust system

an

open flame near the battery being

to

prevent electrical arcing during servicing.

components.

Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets shirts

or

sleeves, rings, necklaces, or bracelets that might be caught in moving parts .

and

Make sure all attaching hardware is properly tightened. Keep protective shields

at

respective place

Do not check fluid levels

all times.

or

the drive belt's tension

While

the unit is operating.

guards in their

Do not work on the equipment when mentally

or

physically incapacitated

by

fatigue.

WESTERBEKE

GENERATORS

2

IMPORTANT

Product software

of

all kinds, such as brochures, drawings, technical data, operator's and workshop

manuals, parIS lists and

from sources other

than Westerbeke, is not within Westerbeke's control and, accordingly, is provided to

PRODUCT

pans

price lists, and other information, instructions and specifications provided

SOFTWARE

DISCLAIMER

Westerbeke customers only as a courtesy and service. WESTERBEKE CANNOT BE RESPONSmLE

FOR TIIE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS

WITH RESPECT TIIERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS
TIIEREOF, AND Wll.L IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY
INCURRED IN

CONNECTION WITH, OR ARISING OUT OF, TIIE FURNISHING

OR

USE OF SUCH

SOFTWARE.

For example, components and subassemblies incorporated in Westerbeke's products and supplied

by

others
(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported
must depend on such software for the design
outdated and no longer accurate. Routine changes made

rarely

bas

notice in advance , are frequently not reflected in the supplier's software until after such changes

by

their manufacturers with their own software, and Westerbeke

of

Westerbeke's own product software. Such software may be

by

Westerbeke's suppliers,

of

which Westerbeke

take place.

Westerbeke customers should also keep in mind the time span between printings
software, and the unavoidable existence

of

earlier, non-current Westerbeke software editions in the field.

of

Westerbeke product

Additionally, most Westerbeke products include customer-requested special features that frequently do not
include complete documentation.

In summation , product software provided with Westerbeke products, whether from Westerbeke or other
suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective
product.
the supplier in question be consulted to determine the accuracy and currentness

It

not only ntakes good sense but is imperative that appropriate representatives

of

Westerbeke or

of

the product software

being consulted by the customer.

3

WESTERBEKE

GENERATORS

FOREWORD

Thank you for selecting a Westerbeke marine product for your use.

We

at

Westerbeke are pleased to have

you as a customer.

Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures , installation checks, system descriptions and minor

so

adjustment procedures are included herein

maintain the equipment at a high level

you can operate your equipment safely and properly,

of

efficiency, and

ex-pecl

dependable performance and long service

life in return.

Should your unit require special attention , contact your Westerbeke dealer for assistance. The Westerbeke
Service Organization is trained

to

provide the support necessary

to

ensure long-term dependable

performance.

WESTERBEKE GENERATORS

4

Engines & Generators

Declaration

of

Conformity

Application

of

Council Directive(s)

Standard(s) to Which Conformity

is

declared

Manufacturers

Name

Manufacturers

Address

Type

of

Equipment

Product

Name

Model(s)

Product

Options

Supplementary Information

EMC

S9/336IEEC

92/31IEEC

& 93/6SlEEC

CISP

12

(1990-01)

EN500S2-1

( 1992)

IEC

SOl

- 2 (1991),

+1-

Skv

AD

IEC

SOl

- 3 (19S4), 3 VIM

Westerbeke

Corporation

41

Ledin Drive

Avon

Industrial

Park

Avon, Ma. 02322, USA

Marine

Diesel

Generator

Westerbeke

Marine

Diesel

Generator

4.0/5.0BCD,5.717.6BTD

6.0/S.0BTD,7.5/10.0BTD
S.3/11.0BTD,9.4/12.5BTDA

12.0/15.0BTDB, 16.0/20.0BEDA

20.0/25.0BED,

25.0/32.0BEDA

All

1.)

The

equipment

listed

is

only for use in

Marine

Applications

aboard

boats.

2.)

The

equipment listed

must

be located below decks on

the

vessel

and

permanently installed in its location.

3.)

The

equipment

listed

must

be wired

to

the grounding system

of

the vessel.

I

the

undersigned, hereby declare

that

the

equipment

specified above conforms to

the above Directive(s)

and

Standard(s).

f1

'1

t;

.

Place Avon, Massachusetts,

U.S.A

C

'c~~

(L

a.,

~

(Signature)

Date January

1.

1996

042021

Carleton

F.

Bryant

(Full Name)

Chief

Operating Officer

(Title)

WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON. MA 02322 U.S.A

.•

TEL. {50B}

588-7700.

FAX: (508)

559-9323.

CABLE:

WESTCORP

TABLE

OF

CONTENTS

Section

Page

GENERAL .................................... . . ...................... 8

GENERAL SPECIFICATIONS ... .

............................ 9

7.6 KW BTD

SYSTEM SPECIFICATIONS ................... . . .... 10

INSTALLATION CHECKS .................. . . .................................

13

DESCRIPTION OF INSTRUMENT PANEL .......................................................................

25

PREPARATION FOR STARTING ........................................................................................ 29

STARTING PROCEDURE ................................................................................................... 30

STOPPING PROCEDURE......

..... . .....

... ... ...

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

...

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

33

FUEL

SySTEM

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

DC ELECTRICAL

SySTEM

................................................................................................. 38

7.6

BID

CONTROL CIRCUIT WIRING DIAGRAM #039284 ............................................. 39

COOLING SYSTEM ......... ... .....

...

...... ....

...

....... . .............................................................. 43

LUBRICATION

SYSTEM ............................... . . .... 49

BT GENERATOR.

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

51

GENERAL INFORMATION AND CARE OF THE GENERATOR............ . ..................... 57

YOUR NOTES ....................................................................................................................... 59

ENGINE

TROUBLESHOOTING ........................................................................................... 60

MAINTENANCE AND ADJUSTMENTS ............................................................................

63

LAY-UP AND RECOMMISSIONING ................................................................................ 70

REMOTE LUBE OIL FILTER KIT - PN#040078 .............................................................

73

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES .................................... 74

SPARE PARTS .................................................................................................................. 76

SOUND GUARD INSTALLATION INSTRUCTIONS ....... .

. ...................... 78

BID

7.6 KW POWER TAKE-OFF (PTO) ADAPTER ........ . . .............. 79

5 WESTERBEKE GENERATORS

~

~

a

Fuel

Run

Solenoid

gJ

z

~

20

Amp

DC

Circuit

Breaker

i}l

Pre

heat

Solenoid

0\

A C

Connections

Outlet

Fuel

Lift

Pum

Air

Intake

Silencer

Lube

Oil

Filter

7.6

KW BTD

RIGHT SIDE

Top

Engine

Oil

Fill

Water

Temperature

Switch

Lube

Oil

Dipstick

Oil

Fill

Oil

Pressure

Sender

Oil

Pressure

Switch

--l

:::!

toO

'JJ

I

~

~

~

~

Water

Temperature

Sender

Water

Temperature

Switch

DC

Charging

Alternator

Belt

Guard

Heat

Exchang

Starter

with

Solenoid

7.6

KW

BTD

LEFT

SIDE

Unit

I.

D,

Plate

450 Exhaust

Elbow

Emergency

Shut~off

Switch

Unit

Data

Tag

DC

Battery

Ground

Connection

GENERAL

Introduction

This manual contains the equipment operating procedures as well

as

additional information needed to

help the operator keep the marine equipment in proper working order.

Study and follow the instructions

carefully. A planned maintenance program

is

included in this manual; adhering to the program will

result

in

better equipment performance and longer equipment life. Proper diagnosis of a problem

is

the

most important step to satisfactory repair; therefore, a troubleshooting table

is

included.

Understanding

the

Diesel Engine-Driven

Generator

The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same. The
cylinders are arranged above a closed crankcase; the crankshaft is

of

the same general type as that

of

a

gasoline engine; and the diesel engine has the same

type

of

valves, camshaft, pistons, connecting rods,

and lubricating system.

Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline

engine. The most important factors are proper ventilation and proper maintenance

of

the fuel, lubricating

and cooling systems. Replacement

of

fuel and lubricating filter elements at the time periods specified is a
must, and frequent checking for contamination (that is, water, sediment, or algae) in the fuel system is
also essential. Another important factor is the use

of

the same brand

of

high detergent diesel lubricating
oil designed specifically for diesel engines. Be careful not to put gasoline in the diesel fuel tank(s).
Gasoline does not have the same lubricating qualities as diesel fuel; consequently, gasoline in the fuel
lines will damage components in the fuel injection pump and fuel injectors.

The diesel engine does differ from the gasoline engine, however, in its handling and firing of

fuel.

The

carburetor and ignition systems are done away with and in their place are

two

components - the fuel

injection pump and the fuel injectors.

Ordering

Parts

Whenever replacement parts are needed, always provide the generator model number designation (i.e. 7.6

KW

BID

), engine serial number, and generator serial number as they appear on the data plates located

on the exhaust manifold and on the generator end. You

must provide us with its information

so

we

may

properly identify your generator set. In addition, include a complete part description and part number for

each part needed (see the separately furnished

Parts List). Also,

be

sure to insist upon Westerbeke factory

packaged parts because

"will fit" or generic parts are frequently not made to the same specifications as

original equipment.

Note that component locations in the manual are referenced from the front

of

the engine which is the
pulley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined by
the engine; imagine straddling the engine and facing in the same direction as the front

of

the engine: the

left side is at your left, the right side at your right.

Westerbeke generator sets are thoronghly checked and given a final run under various load conditions
before leaving the factory. Test running the generator ensures dependable operation, long service life, and
a satisfied owner.

Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel engine­driven generator capable of many thousands

of

hours

of

dependable service. However, what the

manufacturer cannot control is the manner or location the generator

is

installed in the vessel or the

manner in which the unit

is

operated and serviced in the field. That part

is

up

to the buyer/owner-

operator.

WESTERBEKE

GENERATORS

8

Engine Type

Combustion Chamber

Bore

& Stroke

Piston Displacement

Firing

Order

Direction

of

Rotation

7.6

BTD

MARINE

DIESEL

GENERATOR

SET

GENERAL

SPECIFICATIONS

Diesel, four-cycle, three cylinder, fresh water-

cooled. Vertical, in-line, overhead valve
mechanism.

(12.5 hp at 1800 rpm, maximum).

Swirl type.

2.99

x 2.76 inches (75.9 x 70 mm)

58.09 cubic inches (0.952 liters)

1-3

- 2

Clockwise, when viewed from the front

Maximum Torque (at

1800 rpm)

42

lb-ft (5.8 kg-m)

Compression Ratio

Compression Pressure

Valve Timing

Valve

Seat Angle

Valve Clearance
(engine cold)

Engine

Speed

Dimensions

Weight

Fuel Consumption

Inclination

23:1

398

psi (28 kg/cm

2

)

at 280 rpm

Intake Opens

19°

BIDC

Intake Closes 51 ° ABDC

Exhaust

Opens

51

° BBDC

Exhaust Closes

19° A

IDC

Intake 45°
Exhaust 45°

Intake 0.0098 inches (0.25 mm)
Exhaust

0.0098 inches (0.25 mm)

1800 rpm 60 hertz
1500 rpm 50 hertz

Length:

27.8 inches (706.1 mm)

Width:

16

inches (406.4 mm)

Height:

19.9 inches (505.46 mm)

340 lbs (154.22 kgs)

0.53 U.S. gph

(2

Iph)

at

full rated output

(approximately)

Not to exceed

25°

9

WESTERBEKE

GENERATORS

7.6

KW

BTD SYSTEM

SPECIFICATIONS

FUEL

SYSTEM

General

Fuel

Injector Pump

Injectors

LiftPump

Air cleaner

Air Flow (engine combustion)

COOLING

SYSTEM

General

Operating Temperature

Fresh Water Pump

Raw Water Pump

Raw Water Flow.

at

1800 rpm
(measured before discharging into exhaust
elbow)

System Capacity (fresh water)

LUBRICATION

SYSTEMS

General

Oil Filter

Sump Capacity (including filter)

Operating

Oil Pressure (engine hot)

Oil Grade

WESTERBEKE

GENERATORS

Open flow - totally self-bleeding

No.2

Diesel (cetane #45 or better)

In-line plunger

type (Bosch type)

Throttle type

12-volt DC; electric

Plastic Intake

Silencer

30.2 cfm (0.85 cmm)

Fresh water-cooled block, thermostatically­controlled with heat exchanger.

170 - 1900 F (77 - 88

0

C)

Centrifugal type, metal impeller, belt-driven

Positive displacement, rubber impeller,

mechanically-driven

6.5 -

7.0 U.S. gpm (24.6 - 26.5 Ipm)

4.0 qts (3.79 liters)

Pressure type

by Trochoid pump, gear-driven,

with external pressure relief valve.

Full flow, paper element, spin-on type

3.7

U.S. qts (3.5 liters)

35 -55

psi (2.5 3.8 kg/cm2)

API specification

of

CC or CD

10

7.6

KW

BTD

SYSTEM

SPECIFICATIONS (continued)

ELECTRICAL

SYSTEM

Starting Battery

Battery Capacity

Starter

DC No-Load Current

DC Cranking Current

DC Alternator

ACGENERATOR

General - Single Phase

Voltage - Single Phase

Rating (Volts AC)

60 Hertz 1800 RPM

7.6KW

50 Hertz 1500 RPM

AC Circuit Breaker

Generator Electrical

End

Cooling

Air Requirements (60 Hertz at

1800 RPM)

12-volt, ( - ) negative ground

350-400 Cold Cranking Amps

12-volt, 1.2 KW, Reduction type, solenoid
mounted.

90 Amp (max) at 11.5 volts

175 -

200 Amps (engine cold)

12

Volt,

DC

- 40 amps

Brushless, four -pole, revolving field, transformer
regulation. Prelubricated, single bearing design.
Reconnectable 120 volts or

1201240 volts, single

phase.

120 or

1201240 volts - 60 Hertz; 220 volts - 50
Hertz. Voltage regulation: ± 5 % no load to full
load. Frequency regulation:± 3 Hertz no load

to

full load.

120 volts
120/240 volts

220 volts

63.3 Amps

63.3/31.6 Amps

26 Amps

To

be

rated at 120%

of

the generator's rated

amperage and voltage output

175

- 200 cfm (4.95 - 5.66 cmm)

NOTE:

Increase

air

supply

15%

for

50

hertz

operation (1500

rpm)

Engine Block

100 cfm or more to remove heat produced by the

engine block during

operation

11

WESTERBEKE

GENERATORS

7.6

KW

BTD

SYSTEM

SPECIFICATIONS (continued)

TUNE-UP SPECIFICATIONS

Injector Pressure

Engine Timing

(Spill Timing)

EMISSION CONTROL SYSTEMS

WESTERBEKE

GENERATORS

1988 psi ± 142 psi

(140 kg/cm

2

±

10

kg/cm2)

16° ± 1°

BIDe

Static

12

Smoke

Puff

Limiter

INSTALLATION CHECKS

General

Because the crafts in which Westerbeke engines and generators are installed vary in design, installation
procedures will vary according to your craft's specific design. It is not the intent of this section

to

advise
boatyards or installers on procedures already well-developed and well-understood. However, it is
important that the owner/operator realize there are details

of

the installation which require periodic

checks to ensure the best operating conditions for the equipment and safe operating conditions

for

the
personnel on board. Proper location and installation of the generator set in the vessel are of prime
importance.

Factors in the installation that

must

be

considered are ventilation,

so

as to cool the generator and to
provide air for engine combustion; exhaust system, to properly discharge raw cooling water, to quiet the
exhaust and to expel the exhaust gas; cooling water supply; the electrical connections, both AC and DC,
and a

fuel

system that will provide an unrestricted fuel supply and properly filtered fuel

to

the fuel pump

on the engine.

II

CAUTION

II

For safety reasons, the generator's engine is not filled with lubricating oil for shipment.
Before leaving the factory, however, each generator set

is

thoroughly tested with oil in
its engine. This testing, among other things, provides all internal parts with a coating of
oil. This oil acts as a preservative, providing reliable protection against corrosion for at
least one year

if

the generator

is

properly stored.

Inspection of Equipment

The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is

shipped in a separate small box, usually packed within the generator's crate.

Before accepting shipment of the generator set from the transportation company, the crate should be

opened and the contents inspected for concealed damage.

If

either visible or concealed damage is noted,

you should require the delivery agent sign

"Received in damaged condition" on the proper delivery

receipt. Also, check the contents of the shipment against the packing list and make sure that the proper

notation is

made

if

any

discrepancies exist. These

noted

discrepancies

are

your

protection

against loss

or

damage. Claims concerning loss or damage must be made

to

the carrier, not to Westerbeke Corporation.

13

WESTERBEKE

GENERATORS

Rigging

and

Lifting

The generator is fitted with lifting eyes. Rope or chain slings capable

of

supporting the generator's weight

should be attached to the eyes and the generator lifted by means

of

tackle attached to these slings.

Th

lifting eyes have been designed to carry the full weight

of

the generator; therefore, auxiliary slings are not

required or desired.

II

CAUTION

II

Slings must not be so short as to place significant stress on the generator's lifting eyes.
Strain placed on the generator's lifting eyes by the lifting sling must not be in excess

of

10° from the vertical pain.

ENGINE

SLING LIFTING

ANGLE

SHOULD

BE

AS

SMALL

AS

PDSSIBLE

LIFTING
EYE

The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed
in place. Move the engine a little at a time

and

see that it is firmly supported. Eliminate the possibility

of
accidents by avoiding haste. Do not lift the generator by its crankshaft position. Certain situations exist
by which the engine must be lowered endwise through a small hatchway which cannot be made larger.
Under these conditions,

if

the

opeuingofthe

hatchway is extremely small, it is possible to reduce, to some

e,,"(ent,

the outside dimensions

of

the generator by removing external components such as the cooling

system's accessory equipment should be removed

by

a competent mechanic

and

special care should be

taken to avoid damage to any exposed parts.

In addition, be careful not

to

allow dirt from entering any

opeuing created

by

the removal

of

equipment. Removed parts should be returned to their respective
position once the generator is in its installation area. Replace gaskets as needed for the parts that were
removed.

In case it becomes necessary to hoist the generator front-end upwards

or

generator-end upwards, the

attachment

of

lifting slings must be done carefully

to

avoid the possibility

of

damaging the parts on

which the weight

of

the slings may bear. Special rigging work is best done by someone experienced and

competent in handling heavy machinery.

WESTERBEKE

GENERATORS

14

Generator Mounting - Location

The complete generator unit is mounted on lightweight rails by means

of

four flexible isolator mounts that

help prevent the transfer

of

vibration from the generator to the rails. Each generator mounting rail has

several

112

inch bolt holes

so

bolts can be employed to properly secure the generator to its mounting

platform.

The mounting location

must be dry, above low-lying vapor areas, and

in

an area where bilge water and

water from above cannot splash or drip on the generator or drive engine. The drive engine and generator

must be accessible for minor servicing and repairs. Access for major repairs should be given

consideration as well. The generator set

must be properly ventilated to provide fresh cooling air for the

generator end, for engine combustion needs, and to remove heat produced by the engine while operating.
The generator set needs fresh cool air in whatever location in the vessel it

is

installed. Hot generator

discharge air

!!lli§!. be removed from the generator area. The platform on which the generator and its

mounting rails are located

must be strong enough to support the generator during all angles

of

vessel

operation.

15

WESTERBEKE GENERATORS

Exhaust System

I WARNING I

Carbon

monoxide gas is deadly! Carbon monoxide is a dangerous gas that can cause

unconsciousness and is potentially lethal. Some

of

the symptoms or signs of carbon

monoxide inhalation or poisoning are listed below.

• Dizziness

• Vomiting

• Intense Headache

• Muscular Twitching

• Weakness and Sleepiness

• Throbbing in Temples

The generator

must have its own separate exhaust installed

so

that the entry of raw water into the engine's

exhaust manifold and cylinders is prevented while the engine

is

not running, or while the vessel is under

sailor

power in which case the vessel

may

experience heeling, backing down from following seas, or any

other condition. Special attention

must be taken to make certain the exhaust system is secure, tight and

free

of

leaks.

The raw water supply through-hull sea cock fittings

must be

of

the flush-hull type. High-speed scoop

types or weedless scoop types must not be used, as they tend to encourage siphoning.

When a water lift type exhaust system is used, the
exhaust muflIer should be mounted

as

close

to

the

engine

as

practical. The exhaust discharge should

always drop downward into the exhaust muflIer.

Loops

in

the exhaust hose between the water-injected

exhaust elbow and the water lift muflIer should be

avoided,

as

these will trap and hold water.

For installations where the exhaust manifoldlwater­injected exhaust elbow is within 8 inches or below
the vessel's water line, provisions

must be made to

install a siphon-break or a vent in the raw water
supply hose to the water-injected exhaust elbow.
This stops the flow

of

raw water that runs through
the raw water cooling system from filling the
exhaust and engine cylinders when the engine

is

shut

down. This raw water supply hose

must be looped

above the water line and the siphon-break or vent

must always be above the water line during all angles

of vessel operation

to

prevent siphoning. The vent,

when used, must have its vent hose or tube routed

so

it can remain above the water line and empty

of

water when the engine

is

shut down. This allows air

to enter through this vent to prevent siphoning.

WESTERBEKE

GENERATORS

16

Wlnl1l1

IUR

...

tn

LIlt

Exhaust Back-Pressure

The exhaust discharge hose must be

of

adequate size

and minimal run to prevent excessive exhaust back-

pressure. Exhaust back -pressure should be checked

before a generator

is

put into service. (Refer to

illustration.) Excessive back-pressure will affect the

engine's performance which affects generator AC

power output.

To measure for back-pressure, use a mercury

manometer, a pressure gauge,

or

a water column. A

boatyard

or

marine mechanic should have a

manometer

or

a pressure gauge.

If

the generator set
does not have a tapped hole in its exhaust elbow, one
must be drilled and tapped for a

1/8

inch NPT fitting

in the dry area

of

the elbow.

A water column can be made

by

taking a clear

plastic tube and taping one end

of

the tube along a

yardstick and fitting the other end

of

the tube with a

1/8 inch NPT (National Pipe Tap) pipe fitting.

Measure the engine's back-pressure at the exhaust
elbow while the generator is under a full-load.

Refer to the pressure specifications listed below.

Dimension A cannot exceed

39

inches

of

water.

Back pressure, as measured

by

a gauge instrument,

should not exceed the following specifications:

2 inches of mercury
27 inches of water

in

a water column

15.6 ounces

PSI

1.0

PSI

Mercury

Manometer

\

Exhaust
Elbow

...........

/Exhaust

\

Excessive back-pressure can be caused

by

a small diameter exhaust hose, a small muffler, sharp bends in

the exhaust hose, improper fittings, water pockets, and a high volume

of

water in the exhaust system due

to the length

of

the exhaust discharge hose. The use

of

elbows and fittings in the exhaust discharge hose's
routing should be limited since these will create flow restrictions and contribute to exhaust back-pressure.
The generator's exhaust system must be separate from any other engine' s exhaust system. Dry portions

of

the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be

insulated to hold

in

the heat.

17

WESTERBEKE

GENERATORS

Dry stack-type exhaust systems
(shown to the right) must be

at-

tached

to

the generator engine's

exhaust manifold

by

means

of

a
flexible connector pipe. This
system must be properly supported,

insulated, and routed

so

as not

to
allow water to enter the engine's
cylinders

by

coming in through
this piping. Provisions must be
made

for

discharging the engine's

raw cooling water overboard.

Exbaust System Failures

.-

.z.

~I...""

.... ~ ...

CD""'::'"

~

j I

._-,

, .

~===14f.;;;1

\r

71'~.~.

..

..,

........

e:.

':

I:

XM5UL

Txo.1

~

j.

..

,

51:_

••

TI:_

:

.. T ...

::C:

T"ftou,a.-

~"

..

U,-I..

rXTTX

..

c

tf':l.

...

tt. " ....

1

DRY

STACt

EXHRUST

When the engine's

raw

water

is

fed

into an exhaust

system

so

that the

full

stream of this water strikes a

surface, erosion takes place. This erosion

may

cause premature failures. The proper design

of

either a

water jacketed or water injected

"wet"

exhaust system

to

prevent this problem requires that the raw water

inlet

be

positioned

so

that the entering stream

of

raw

water does not directly strike a surface. In addition,

the velocity

of

the entering

raw

water stream should be as

low

as possible, which can

be

achieved

by

having inlet fittings as big in diameter as possible.

The best protection against carbon monoxide poisoning is a daily inspection

of

the complete exhaust

system. Check for leaks around manifolds, gaskets, and

welds.

Make sure exhaust lines are not beating

surrounding areas excessively.

If

excessive heat is present, correct the situation immediately.

If

you
notice a change in the sound or appearance of the exhaust system, shut down the unit immediately and
have the system inspected and repaired at once

by

a qualified mechanic.

Make sure there are

no

unnecessary objects suspended from any portion of the exhaust lines. Rigidly
constructed exhaust risers installed off the exbaust manifold must not exceed 8 Ibs in total weight.
Excessive unsupported weight could cause deflection or distortion

of

the manifold resulting in damage

and/or internal leaks. Rigidly constructed riser assemblies that

do

exceed 8

Ibs.

must be supported

to

the

engine, not

to

the hull. Inspect insulated portions of the exhaust system

to

ensure there is no deterioration

of the insulation.

II

CAUTION

II

Prolonged cranking intervals without tbe engine starting can result in filling the
engine-mounted exbaust system witb sea water coolant. This may halJpen because
tbe sea water pump

is

pumping sea water tbrougb tbe sea

water

cooling system

during cranking. This sea

water

can enter tbe engine's cylinders by way of tbe
exbaust manifold once tbe exhaust system fills. Prevent tbis from balJpening by
closing tbe sea water supply througb-bull sbut-off, drain tbe exbaust

mumer,

and

correct tbe cause for the excessive engine cranking needed to obtain a start. Engine

damage resulting from tbis type of sea water entry is not a warrantable issue; tbe

owner/operator should keep tbis in mind.

WESTERBEKE GENERATORS

18

Exhaust Elbow Installation

The Westerbeke Corporation offers a

45° and

90°

exhaust elbow as

well

as an exhaust riser

you

can

install

on

your engine. Refer

to

the instructions

below

when installing the exhaust elbow purchased.

NOTE:

Fabricated exhaust elbows or risers attached

to

the exhaust manifold must not exceed 8 Ibs when

unsupported.

L Coat only one side

of

the exhaust gasket with

High Tack adhesive sealant (manufactured

by
Permatex Company, Brooklyn, NY). Place this
coated surface against the exhaust manifold's
exhaust port flange (the gasket should stick

to

the

flange without falling

off).

2.

Place the clamp over the elbow's flange. Place
your exhaust elbow against the exhaust manifold's
flange

so

the exhaust manifold's flange rests snug
against the exhaust elbow's flange with the gasket
centered between the

two.

Now

slip the exhaust

clamp over both flanges.

3.

Tighten the clamp just enough

so

the exhaust

elbow

can remain attached

to

the manifold and still

be

rotated.

The exhaust elbow discharge

must

be

directed

downward

so

the mixture of raw water and exhaust
gases will flow/fall downward into the exhaust
mnlller which

must

be positioned below the exhaust

elbow.

There shonld be

no

loops or rises in the
exhaust hose connected between the exhaust elbow
and the mnlller, as these would trap water and
possibly allow water

to

flow back into the engine

during starting or at shut

down.

4.

Adjust the elbow

by

rotating

it

until the desired

alignment with the exhaust piping is acquired.

5.

Carefully tighten the clamp between 8

to

10

Ib-ft,

or

96

to

120

Ib-in., or

LI

to

1.3 kg-m.

II

CAUTION

II

Approach the

10

lb-ft torque limit
with caution. The clamp's threads
will break

if

more than

10

Ib-ft

is

applied

to

the clamp.

If

a leak exists, correct it immediately.

19

ELBOW

FL.ANGE

45°

ELBOW

EXHAUST

MANIFOL.D

FLANGE

Kit

#037402

EXHAUST GASKET

•

•

90°

ELBOW

Kit

#037401

EXMAUST

Fl...ANGE

_

EXHAUST

RISER

EXHAUST

MANIFOL..O

FLANGE

WESTERBEKE GENERATORS

FUEL

SYSTEM

The generator must have its own fuel supply line; in other words, it must have its own pickup tubes and

primary filter/water separator.

DO NOT

TEE

OFF

OF

ANOTHER ENGINE'S

FUEL

SUPPLY. The

fuel system should

be

installed

in

such a manner as to allow the engine-mounted fuel lift pump to
maintain a positive iulet pressure to the injection pump under all operating conditions. The minimum
size of the fuel supply line and fuel return line

is

114

inch, inside diameter, and there should be a primary

fuel filter installed between the fuel tank and the

fuel

lift pump. Only one fuel filter is installed on the

engine, between the fuel tank and the fuel lift pump.

Only one filter is installed on the engine, between

the fuel lift pump and the injection pump; this filter has a replaceable element.

The fuel tank's fuel pick

up

tube should be clear and unobstructed.

No

screens or gauze strainers should
be incorporated in the fuel pickup tube. Make sure the fuel supply and return lines are secureley anchored
to prevent chafing and that all fittings are sufficiently tightened to prevent leakage. Also, make sure your
fuel system has a positive shut

-off

valve; kuow its location and how it operates. Do not use a mechanical

check valve for this function.

It

is recommended that an approved filter/separator be used in the fuel supply between the fuel tank and

the generator's engine to help remove contaminants

in

the fuel before the fuel reaches the engine-mounted

fuel lift pump and injection pump.

The fuel return at the tank should extend down into the tank in the same manner as a pickup tube. This
practice is particularly important in installations where fuel tanks are installed below the engine's fuel
system and will help prevent air from entering the fuel system when the engine is shut down. Ensure that
the fuel tank filler is properly sealed to prevent water entry should it become awash. The fuel tank's vent
should be located

so

that its discharge route cannot allow water to enter through

to

the fuel tank(s).

Moisture must no be allowed to accumulate in the vent's line.

Be sure that there is a fire

e>.1inguisher

installed near the unit and that is properly maintained. Be

familiar with its

use.

An

extinguisher with the NFP A rating of

ABC

is

appropriate for all applications in

this

environment.

OIL

DRAIN

An

oil

sump drain hose

is

installed on the engine with the discharge and secured

by

a bracket at the front

of

the engine. Oil

may

be

drained from this hose

by

removing the cap and the discharge end

of

the hose

from the support bracket and lowering the hose into a container. The hose cap fitting is

114

inch NPT and

can

be

extended, or have a pump added, for easier removal

of

the old oil,

if

desired.

CONNECTING

PRESSURE SENSING DEVICES

TO

OIL

GALLERIES

Oil pressure sensing devices, such as senders and switches, must no be connected to an engine's oil gallery
with the use

of

extended nipples or tees. The reason

is

simply that continued engine vibration causes

fatigue

of

the fittings used to make such a connection.

If

these fittings fail during engine operation,

lubricating oil will be lost and internal engine damage will result.

When additional sensing devices such as senders and switches need to

be

installed, these devices must be

bulkhead-mounted and connected to the oil gallery using an appropriate grade

of

lubricating oil hose.

Any fittings used

to

connect the hose to the

oil

gallery must

be

of steel or malleable iron composition.

Brass

must

not

be

used

for

this application.

WESTERBEKE

GENERATORS

20

Raw

Water

Intake

System

Make sure the intake system (raw water cooling system) is in proper order. Check that the hull inlet, sea

cock and strainer are unobstructed. Sea cocks and strainers should

be

at least one size greater than the

inlet thread

of

the sea water pump. The strainer should be

of

the type that may

be

withdrawn for cleaning

while the vessel is at sea and should

be

mounted below the water line to ensure self-priming. Inspect the

raw water lines to make sure there are no collapsed sections, which would restrict water

flow.

Make sure

there are no air leaks at any of the connections.

Cooling System

The generator's engine

is

fresh water-cooled

by

an engine-mounted heat exchanger. Raw water is used as

the heat exchange's cooling medium. Raw water is pumped into the exchanger

by

a raw water pump and
is then injected into the exhaust discharge, carrying with it the heat removed from the engine's fresh water
cooling system.

Raw water should be supplied to the

raw

water pump through a flush-type through-hull fitting using a

wire-reinforced hose between the through-hull fitting and the raw water pump. This raw water should be

directed through a visual-type raw water strainer and then delivered

to

the pump. Hoses routed from the

through-hull fitting to the strainer and

to

the raw water pump should be wire-reinforced

to

prevent the

hose from collapsing during the generator's operation (suction from the pump

may

collapse a non­reinforced hose). Raw water strainers should be mounted at or below the water line to make sure the raw
water line remains primed after shutdown.

II

CAUTION

II

Do not use a scoop-type through-hull fitting as a means of supplying raw water to the

generator. Water pressure against this type fitting, while the vessel is under way, can
push raw water past the raw water pump's impeller into the generator's exhaust system,

filling it and the engine as well. Flush-type, clear, through-hull fittings are

recommended and should be located on the hull

so

as to

be

below the waterline during

all angles

of

boat operation.

The use of common-type street elbows is not recommended for plumbing the

raw

water circuit. These

generally have very restrictive inside diameters. Machined fittings are preferred.

Electrical System

The electrical system should be checked to make sure all wiring harnesses are properly tied down with

clamps or plastic ties and that all wiring harnesses are spaced at intervals close enough to prevent chafing
from vibration. Check to make sure all engine harness connections are tight and that they are made to the
appropriate terminals.

DC Electrical Connections

A common ground for the negative (-) DC terminal connection

is

found at the bet! housing of the

generator, next to the starter,

in

the form of a threaded grounding stud. The battery ground should be

connected at this stud.

Connect the battery's positive

(+) connection to the starter solenoid tagged for this connection.

21

WESTERBEKE

GENERATORS

II

CAUTION

II

To avoid

an

overcharging condition, and a possible equipment failure, do not disconnect

tbe DC battery source while tbe engine is running.

Automatic

Shutdown

High Exhaust Temperature Shutdown Switch (normally closed)

An exhaust temperature is located on the exhaust elbow.

Should tbe switch's sensor indicate

an

excessive

exhaust temperature, tbe switch will open and shut tbe generator off (an inadequate supply

of

raw water

coolant causes high exhaust temperatures). This switch opens

at

260 - 270°F (127 - 132° C) resets

at

approximately 225°F (107°C).

High Water Temperature Shutdown Switch (normally closed)

A high water temperature switch is located on tbe thermostat housing.

Should the fresh water coolant's

operating temperature reach approximately

205° F (96°C), the switch will open

and

shut

the

generator

off.

This switch resets

at

195°F (107°C).

Low Oil Pressure Shutdown Switch (normally open)

A low oil pressure shutdown switch is located off tbe engine's oil gallery. The switch's sensor monitors

tbe engine's oil pressure. Should the engine's oil pressure fall to 5 -

10

psi, the switch will open

and

turn

the generator off.

Generator

(AC

Output)

Make sure tbat tbe AC output connections within tbe generator's AC terntinal block are correct

and

in
accordance witb the specific AC Load Connections diagram found later in this manual. (See tbe "BT
GENERATOR" section

of

tbis manual.) Make sure tbe AC leads are protected against chafing as they

exit tbe generator housing.

I WARNING I

Do not smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen,

a highly-explosive gas.

Batteries

Make sure tbe positive (+) battery connection is connected

to

the battery connection

of

tbe starting

solenoid. The negative (-) battery connection should be connected to the ground stud tagged

at

the rear

of

the engine block.

WESTERBEKE GENERATORS

22

I

WARNING

I

When servicing the battery or checking the electrolyte level, wear rubber gloves, a
rubber apron, and

eye

protection. Battery acid may splash on the skin or into the eyes

inadvertently when removing the electrolyte caps.

Check the battery's electrolyte level and specific gravity

to

ensure maximum engine starting efficiency.

Make sure the

battery'S terminals are clean and tight.

Ventilation

The ventilation requirements of the generator sets include the following: combustion air is required for
the engine cylinders; cooling air is required for the generator end and also for removing the heat produced
by

the generator's engine during operation; and ventilating air is required to clear the bilges below the

generator, as well as the compartment in which the generator

is

located,

of

potentially toxic and

flammable diesel vapors,

Keep in mind that hot air rises,

so

heated air should be removed from the upper area of the generator
compartment and cool fresh air should be directed to the lower areas of the compartment. Ventilation
should be accomplished with the aid

of

blowers especially when the vessel

is

not underway. Refer to the

"SYSTEM SPECIFICATIONS" section of this manual for the airflow requirements

of

the generator set.

23

WESTERBEKE

GENERATORS

NOTES

WESTERBEKE GENERATORS 24

General

o

DESCRIPTION

OF

INSTRUMENT

PANEL

PREHERT

4

w

START

~

WJ

STOP

®

GENERRTOR

o

o

o

The manually operated series

of

Westerbeke generators

is

equipped with toggle switches and optioual
remote panels. The Standard Instrument Panel (shown above) includes two gauges which indicate water
temperatnre in degrees Fahrenheit (WATER

OF)

and oil pressure in pounds per square inch (OIL PSI).
This panel is also equipped with two meters which indicate DC control circuit voltage (VOLTS) and the
generator's running time (ELAPSED TIME) in HOURS and

in

1/19 hours. The water temperature and oil

pressure gauges and the DC volt meter are illuminated; the ELAPSED

TIME

meter is not illuminated.

I.

PREHEAT: The PREHEAT switch energizes the engine's glow plugs, activates the electric fuel
pump, bypasses the engine's oil pressure switch, and activates the fuel run solenoid. In addition, this
switch energizes the START switch.

2.

START: The START switch, when pressed, energizes the starter's solenoid which cranks the

engine. This switch will not operate electrically unless the PREHEAT switch

is

pressed and held at

the same time.

3.

STOP: Through the STOP switch power

is

provided to the fuel solenoid. Opening this switch

deactivates the fuel solenoid and shuts off fuel to the engine, thereby stopping the engine.

NOTE: When the engine is manually shut down, the water temperature gauge and oil pressure

gange will continue to register the last temperature reading and oil pressure reading indicated
by the gauge before electrical power was turned

off.

The temperature gauge and oil pressure

gauge will return to zero once electrical power

is

restored to these gauges.

25

WESTERBEKE

GENERATORS

Remote Operation

For starting and stopping the generator at a remote location, the same three switches are used.

The
PREHEAT and START switches are connected in parallel with the local panel's switches and serve the
same functions as in the local panel.

The

STOP switch is connected in series with

the

local panel's STOP

switch and serves the same function as in the local panel. The generator may be stopped from local

or

remote positions.

REMOTE

CONTROL

PANEL (REAR

VIEW)

1··-----------------------------------------------'

, I

i

:S$ASIJRGE

, I

~2/fI~~ART

RED

CD

i

F-··-----------------------------------------------;------------------~

, I

I :
I 0

I

i

!

I

i

I

r---

I '

j

j

j

STOP

SWITCH

START

SWITCH

CD

110

R(tl

u

.

j

I

j

I

i

®RED/WKIH

r-----------------T------------------.

, !

___________

~_~

~

___________

!~R!~E..J..

, ,

rh~+-'

I

j

PREHEAT

'

SW

ITCH ! U

~

;~~;~

'3

A RI)ll

REO

~---,~-----------r------------------~

I

i

I

114

RED

1)4

RED

i

:

114

RED

:

1~ ~

~¥~~~

WHlH

L

_____________________________________________________

--r------------------~

i

, ,

L

__________________________________________________

,

P.N.

24943

,AU

MODEL

V~!T$

.H~

TWO

~ELUS

Ta

1-'2

Te I-GROUND

T82-1

TB2-2

HII-l

T81-S

Refer to the control circuit wiring diagram when installing the remote start/stop panel.

UNITS

WITH

u~ln

WllKOUl

TERMINAL

BLOCU

TU~IHAt

BLOCKS

TO

TIl

I-I

TO

STOP

SWITCH

TO

T5 I-GilD

TO

P~NEL

GROUND

TO

TBl_

I

TO

PREHEAT

SWITCII

TO

TB2-2

TO

PREIIEAT

SWITCH

TO

TBI-2

TO

PIIEHE

...

T

SWITCH

TO

T81-~

TO

ST

...

~T

SWITC"

NOTE: Reference the DC wire sizing chart on the fOllowing page for wire sizes connecting between the
engine panel and remote.

WESTERBEKE

GENERATORS 26

®

Revised

Nov.

2000

DC

WIRE

SIZING

CHART

Stranded

Conductors for

12

Volt Circuits

10%

Voltage Drop

A.

Society

of

Aut.omotive

Engin.eers

Type

Wire

B.

National

Electrical

Code

Type

Wire

Wire

Sl~e

Standing

Circular

~II

Area

Circuit

Curre-nt

In AMPS

I.

2-

3.

••

5.

••

7.
O.

9.

'0.

'5.

20.
3D.

'0.

50.

55.

60.

75.

90.

'0

,.

14

'2

'0

0

•

•

,.

14

'2 '0

0 0

•

2

,

'6X3D

,

....

1511(27

19x2S

,.x2:\

19:a1

"9x23

..

ax21

,.

" "

,.

,.

37

Bl

127

127

1537

2336

3702

5833

93<13

14810

25910

37360

.503

.'07

6530

10380

16510

26250

4'740

66370

.3690

Maxim.

um

Lengt.h

of

Cond

uclor

'n

Feet.

fro:tn

Power

Source

t.o

Load

and

Return

'"

26D

.0.

17 130

"0

330

,

..

227

SS

".7

,

..

'21)

....

,.,

240

43.7

B'

'D.

16.

26

•

71

113

'00

285

34.7

52

..

132

2'0

57 57 143 232

3

'3.3

70

110

175

270

47.3 75.3

,21)

,

..

3D3

2".7

37

eo

••

'50

240

40.7

".7

103

,

..

26D

21.7

32.7 52.7

82.7

'31

210

35.3 58.3 89.6

,

..

227

<19.3

28.7

.S.7

73.3

11.

18.

300

31.7

SQ.3

70.'

'27

202

321

17.3

26

'2

66

,os

,

..

271

28.3

'5.3

7.

".

'8'

2

••

'7.3

2 •

..

70

112

'80

2.5

,.

3D

••

7.

12'

"3

3D6

.,

33 52.7

03.7

135

211

22.7

3.

57

9'

,

..

230

22

3.

58

90.3

,

..

..

""

60.7 96.3

'53

2'3

306

26.3

..

.7.3

'07

2'.3

'5.3

72

".

'.2

23D

2'

33.7

54 1S.3

23

36.3

57.7

92

14'

'84

30.7

4.

77.7

33

'2.3

83.3 133

,67

45

7'.3

••

76.3

121

'53

36

57

-«7.3

38.3

.,

97.3

'23

The

volt.age

drop

for

specific

conductor

len.gths

:Lnay

be

calculated.

by

the

formuhc:

Volt.a.ge

drop

10.75

x I % L

CM

I =

loa.d

in

amperes

where:

L =

conductor

length

in

feet

eM

=

conductor

circular

MIL

area

'When a circuit,

including

t.he

ground

return.

uses

several

different

si%e

conduct.ors.

t.he

voltage

drop

at

the

elect.rical

device

is

the

SUIn

of

t.he

drops

calculated

for

each

si%e

segment

of

the

circuil.

"

81

27

WESTERBEKE GENERATORS

'02

Description of

Starting

System

Westerbeke diesel engines use electric starters assisted

by

glow plugs for both normal and cold weather
starting. The fignre below shows a cross-sectional view of one cylinder. The glow plug is located in the
combustion chamber

so

that its tip is in the injector nozzle's spray path. When the glow plug is energized

by

the PREHEAT button, the plug glows red at the tip and assists in igniting the fuel. The result is a

rapid start with less wear on the starter.

This system is common to Westerbeke Diesels. The start circuitry is designed

so

that the PREHEAT

button

must be depressed for the time specified in the "Preheat" chart. Then, while keeping the

PREHEAT button engaged, the

START button

is

depressed to crank the engine.

Combustion Chamber

GLOW

PLUG

Glow Plug

BODY

CENTER

JJ.I,.--SHAFT

rllt-_

CAP

TUBE

NOTE: The START switch will not energize unless the PREHEAT button

is

depressed. When

depressing the preheat switch, we are activating the glow plugs in the cylinder head

so

use the preheat

intermittently to avoid overheating the glow plugs.

WESTERBEKE

GENERATORS

28

PREPARATION

FOR

STARTING

This section

of

the manual provides the operator with preparation, initial starting, break-in, starting (cold

or warm)

and

stopping procedures. Follow the procedures as presented, for the conditions indicated, and

your Westerbeke generator set will give you reliable performance and long service life.

Take the steps described below in starting your
engine for the first time

or

after a prolonged

shutdown

or

lay-up.

Fill your engine with oil up to

or

near the upper limit
on the dipstick (the installation angle may have an
affect on the dipstick reading).

Select readily

available lubricating oil with

an

API specification

of

CC or CD

and

an

SAE number suitable for the
temperature in your operating area. For the quantity
of

oil needed in your engine, refer to the "System

Specifications"

section

of

this manual.

Fill the tank with a good grade

of

No.

2 diesel fuel

and

prime the fuel system up to the engine. When

returning fuel is free

of

air, the engine's fuel system

is bled and

the

engine is ready to start.

UPPER

LlMIT

~F::::::::::;::;;~--

(N

0 R

IoIAL

LEU

C

L)

LOWER

LIIIIT

Each unit is supplied with a coolant recovery kit (#24977) as standard equipment which must be installed
and

the following applies:

A.

Remove the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling

system with a mixture

of

water

and

antifreeze suitable for your temperature zone. Operate the

engine and observe the coolant level in the manifold. Maintain this level to the base

of

the filler

neck.

Once

the

engine reaches its operating temperature (170 - 190°F), make sure there is no

problem with a coolant flow through the manifold. Top

off

the cooling system and install the

pressure cap.

B. Make sure the plastic recovery tank is properly mounted near the unit (with the bracket

provided), in a location where it can be monitored and filled easily. The recovery tank should be
mounted at manifold level or above. In these installations that require it, the plastic recovery tank
can be mounted below the exhaust manifold's level. Fill this tank halffull.

C.

Monitor the coolant level in the plastic recovery tank daily and add coolant as needed. Some
coolant will be lost through evaporation. This will be minimal. Periodically check that the manifold
is full

of

coolant when the system is cold.

Make sure the Installation

Checks have been made in accordance with those specified in the

"Installation Checks" section

of

this manual

29

WESTERBEKE

GENERATORS

STARTING

PROCEDURE

1.

Depress

and

hold the preheat switch. Preheat according to the following chart.

2. While still depressing the

PREHEAT switch, depress the START switch. As soon as the engine runs,

release the START switch but continue to hold the

PREHEAT switch depressed for an additional 2 - 3

seconds. This allows the engine to build

up

enough oil pressure to close the oil pressure shutdown switch

and

allow the engine to continue to run.

NOTE: Should the engine not start when the START switch is depressed for

10 -12

seconds,

release both switches and wait

30 seconds; repeat the previous procedure. Never run the starter

motor for more

than

30 seconds

at

a time.

3. Check all instruments on the panel for proper operation. Make sure raw water discharges with the

exhaust discharge.

Atmospheric Temperature

+410 F (+50 C)

or

higher

+410 F (+50 C) to +

230 F

(_50

C)

+230 F

(_50

C) or lower

Limit

of

continuous use

Once the engine starts, allow it to run for a few
minutes to warm up and stabilize while the engine's

instruments are checked for proper oil pressure and
battery charging voltage. Never attempt to engage
the

starter while the engine is running.

NOTE: Some unstable running may occur

in

a cold engine,

but

this condition should

smooth out as the operating temperature

of

130 - 1500 F (55 - 560 C) is reached.

Proper glow plug function is indicated by a voltmeter

drop when the

PREHEAT switch is depressed. This

drop will be slight but discernible.

If

no voltage

drop is noted,

it

may indicate defective glow plugs or

a faulty preheat circuit (check for loose connections).

Preheating Time

Approx.

10

sec.

Approx.

20

sec.

Approx. 30

sec.

30 seconds before
cranking

II

CAUTION

II

Prolonged cranking intervals without the engine starting can result

in

filling the engine-mounted exhaust
system with sea water coolant. This may happen because the sea water pump is pumping sea water
through the sea water cooling system during cranking. This sea water can enter the engine's cylinders by
way

of

the exhaust manifold once the exhaust system fills. Prevent this from happening by closing the sea
water supply through-hull shut-off, drain the exhaust muffler, and correct the cause for the excessive
engine cranking needed to obtain a start. Engine damage resulting from this type

of

sea water entry is not

a warrantable issue; the owner/operator should keep this

in

mind.

WESTERBEKE GENERATORS

30

Engine

Break-In

Procedure

Although your generator has experienced a minimum

of

one hour

of

test operations to make sure accurate

assembly procedures were followed and that the generator operated properly, a break-in time is required.

The service life

of

your engine is dependent upon how the engine is operated and serviced during its

iuitial hours

of

use.

Your new engine requires approximately

50 hours

of

initial conditioning operations to break in each

moving part in order to maximize the performance and service life

of

the engine. Perform this

conditioning carefully, keeping

in

mind the following:

1.

Start the generator according to the "STARTING PROCEDURE" section. Run the engine while

checking that all systems (raw water pump, oil pressure, battery charging) are functioning.

2.

Start

the

generator and allow the engine to warm up until the water temperature gauge moves into the

130 - 1400 F range.

3.

Use caution not to overload the generator. The presence

of

a gray or black exhaust with loss

of

engine

rpm (hertz) are signs

of

a possible overload.

4.

Run the generator at

112

of

its rated capacity for the first

10

hours then increase the load to 3/4

of

its

rated capacity. For the remainder

of

the break-in period, the generator may be run

at

different load

intervals.

Breaking-in a new engine basically involves seating the piston rings to the cylinder walls. Excessive oil
consumption and smoky operation indicate that the cylinder walls are scored, which is caused by
overloading the generator during the break-in period.

As indicated above, operate the generator with a moderate load during the

50 hour break-in period. (On

one hand don't baby the engine, but on the other hand, don't abuse it.)

Remote

Starting

Procedure

The remote start panel is the same as the engine-mounted start panel except that it has a green LED light.
When starting

at

a remote location, the green LED lights faintly when the preheat is depressed.

It

will

dim or flicker when the start switch is depressed and the starter cranks the engine.

Once the engine starts

the green LED will glow bright signaling

to

release the start switch in that the starting

of

the generator

may not be audible at the remote start/stop panel location.

A.

When starting the generator set at a remote location, release the START switch when the green

LED lights bright but continue depressing the

PREHEAT switch. After releasing the START switch,

continue holding the

PREHEAT switch until the oil pressure is sufficient to close the oil pressure

safety switch providing the normal B+ path to the fuel run solenoid. This will

be just a few seconds.

B.

After the generator is started and the starter switch is released, the generator's starter will not crank

until someone again operates the

PREHEAT switch first because this switch supplies voltage to the

START switch.

31

WESTERBEKE

GENERATORS

Starting

Under

Normal Conditions

Follow the procedure below for normal starting

of

the generator.

1.

Make sure there is sufficient fuel on board. Keep fuel tank(s) as full as possible. Check the fuel filters

and water separators for the presence

of

contaminants and/or water. Drain and clean them as needed.

2. Check the coolant level in the plastic recovery tank. Add coolant solution as needed.

NOTE: Excessive loss

of

coolant from the plastic recovery tank indicates a cooling system leak. Check

the entire cooling system

and

pressurize the system using a common automotive radiator pressure tester to

locate the leak. In cases

of

excessive coolant loss, the system must

be

refilled

as

outlined under the

"PREPARATION FOR STARTING" section

of

this manual.

3.

Check the oil level

in

the engine sump

and

look for fuel leaks, particularly

if

signs

of

such leaks are

found on the bottom

of

the engine

or

below the engine.

Start the generator in accordance with the "STARTING PROCEDURE" instructions in this manual and
allow the engine's operating temperature

to

reach 140 - 1500 F before placing a load

on

it.

Starting

Under

Cold Conditions

Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed

below when operating your engine

in

cold weather.

Lubricating Oil Turns Viscous - Make certain that the lubricating oil used conforms with the ratings for

the prevailing atmospheric temperature. Refer to the "LUBRICATING

SYSTEM" section

ofthis

manual

for

an

atmospheric/oil viscosity specification table.

Voltage Across the Battery Terminal Drops - Make certain that the battery is fully charged to ntinimize

voltage drop across the battery terminals.

The

Temperature

o/the

Intake

Air

is

Low

and

the Compression Temperature does not Rise

Enough-

Allow the glow plugs to operate sufficiently to aid in starting during the preheat period whenever the

temperature

of

the intake air is low and when the compression temperature does not rise enough. Refer

to

the preheat chart found

in

the "STARTING PROCEDURE" section

of

this manual.

WESTERBEKE

GENERATORS

32

STOPPING

PROCEDURE

1.

Remove the AC electrical loaf from the generator and allow the generator

to

run for 3 to 5 minutes to

stabilize its operating temperature.

2.

Depress the STOP switch and hold it until the generator is completely stopped.

3.

Now release the STOP switch.

Remote Stopping

Procedure

To stop the generator, depress the STOP switch which opens the normally closed B+ path for voltage to
the engine's run circuit. The bright green LED will

go

dim/faint when the generator slows and stops.

Then it will

go

out, indicating the engine has stopped. The STOP switch must be held open until the

generator comes

to

a complete stop. Remote start panels may be connected

to

the generator set as

indicated. A jumper has to be removed between the T

-1

and T -2 connections

at

the panel connection

terminal board. (Refer to the wiring diagram in the "ELECTRICAL

SYSTEM" section

of

this manual for

remote start/stop panel connections.)

33

WESTERBEKE

GENERATORS

NOTES

WESTERBEKE GENERATORS

34

FUEL

SYSTEM

Diesel Fuel

Use

No.2

diesel fuel with a cetane rating

of

45

or higher. Never use kerosene or home heating oil since

these fuels do not have the same lubricating properties as

No.2

diesel fuel.

In cold weather particularly, water vapor

is

produced

by

condensation when air is present in the fuel tank.

Keep fuel tank(s) full and completely free of dirt and water.

Fuel

FilterlWater

Separators

A primary fuel filter

of

the water separating type must

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

Most installers include with the generator installation
package a

type

of

filter/water separator for they are aware

of

the problems contaminants in the fuel can cause - all of

which are not warrantable through Westerbeke.

A typical fuel filter/water separator

is

illustrated at the

right. This is the Raycor Model

220

F.

Keep in mind that

if

a water separator type filter is not installed between the

fuel supply tank and engine-mounted fuel system, any

water in the fuel will affect the fuel pump, engine filter,
and injection equipment. The owner/operator is
responsible for making certain the

fuel

reaching the

engine's injection equipment is free

of

impurities. This

process is accomplished

by

installing and maintaining a

proper filtration/separation system.

In addition, any gasoline in the

fuel

system will damage

the engine's fuel injection pump assembly and injectors

as

gasoline does not have the same lubricating qualities

as

diesel fuel.

Priming

the

Fuel System (Self-Bleeding)

The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature

of

the

fuel system allows for easy servicing

of

the fuel filters. Simply remove and replace the filter element (take

care in catching any fuel that may drain out

of

the fuel filtering assembly as described in the "Replacing

the Fuel Filter Element" section. Energize the

PREHEAT switch to allow the electric fuel pump to

operate for

20 to

30

seconds to prime and bleed air from the system.

(No

fittings should be opened.)

Then proceed to start the engine as

you

normally would.

If

the engine does not start, stop and wait a

few
moments, and then repeat the bleed procedure as indicated below. When the PREHEAT switch is
depressed, the preheat elements (the glow plugs) are energized,

so

take care not to overheat them.

35

WESTERBEKE

GENERATORS

II

CAUTION

II

Prolonged cranking intervals without the engine starting can result in filling the engine-mounted exhaust
system with sea water coolant. This may happen because the sea water pump

is

pumping sea water
through the sea water cooling system during cranking. This sea water can enter the engine's cylinders by
way

of

the exhaust manifold once the exhaust system fills. Prevent this from happening by closing the sea

water supply through-hull shut-off, drain the exhaust mufiler, and correct the cause for the excessive

engine cranking needed to obtain a start. Engine damage resulting from this

type

of

sea water entry is not

a warrantable issue; the owner/operator should keep this

in

mind.

Replacing the Fuel Filter Element

While

it

is

unlikely that the operator will

be

forced to service the system

at

sea, the possibility does exist.

Therefore,

it

is recommended that banjo washers, injector sea washers, a fuel system hardware kit, fuel

filter

and

gasket be carried

on

board

at

all times. Select the parts for your engine from the Parts List and

purchase spares from your local Westerbeke Dealer or Distributor. For example, filter kit

#30200 includes

replacement elements with gaskets (items

#21

and 20).

If

a leak should develop

at

a fuel banjo or sealing

washer location that cannot be remedied

by

a slight tightening, the sealing washers

and

banjo bolts

contained

in

the fuel system hardware kit for your particular model will come

in

handy to remedy these

leaks.

After the first

50 hours

of

operation, loosen retainer ring #23 and discard filter element #21. Clean bowl

#22

and

install a new filter using a new #20 gasket. Be careful to catch any fuel that may spill forro

within these fuel assemblies.

After

the

first 50-hour change, the change period may be increased to 200 hours

or

once

per

season.

The

fuel pump has no filter element within it. The only maintenance it reqnires is to ensure the

connections to it, both fuel

and

electrical, are secure and tight and that fuel supplied to this pump is free

of

impurities.

Fuel

Supply

(out)

V

DC

(+)

Connection

Fuel

Pump

~2'

Fuel

Supply

(in)

(In..t

..

ller'

..

CQnnection.)

Ground

Wire

WESTERBEKE GENERATORS

36

Fuel Injection Pump

The illustration below shows the 7.6 KW

BID's

fuel system. The fuel injection pump, located to the

right,

is

one

of

the most important components

of

the diesel engine and, therefore, calls for the utmost

caution

in

handling. Furthermore, the fuel injection pump has been thoroughly bench-tested and should

not

be

tampered with.

Speed (hertz) and timing adjustment are the only adjustments the servicing dealer can perform on the
injection pump.

Other types

of

adjustments or repairs must be performed by a qualified injection service

shop.

FUEL INJECTION PUMP

---'~

FUEL SOLENOID

r--...!.._ FUEL RETURN

t

FUEL

LINE

OIL FILTER

FUEL

LINE

FUEL

FilTER

ELECTRIC FUEL PUMP

" FUEL SUPPLY

To obtain long and satisfactory service from the injection pump, always use fuel which is free from
impurities and maintain a good filtration and water separation system between the fuel tank and engine.
Service this system regularly: the injection pump it saves will

be

your own.

37

WESTERBEKE

GENERATORS

DC

ELECTRICAL

SYSTEM

Engine

12-Volt

DC

Control

Circuit

The Westerbeke 7.6 KW

BID

generator has a 12-volt DC electrical control circuit, as shown

on

wiring

diagram #039284. Refer to this diagram when troubleshooting or servicing electrical components

on

the

engine.

II

CAUTION n

To

avoid damage to the battery charging circuit, never shut off the engine battery switch

while the engine is running.

Shut off

the

engine battery switch, however, to avoid electrical shorts when working

on

the engine's electrical circuit.

Battery Specification

The miuimum recommended capacity

of

the battery used

in

the engine's 12-volt

DC

control circuit is 350-

- 400 cold cranking amps.

Fuel

Pump

The engine mounted fuel pump requires little

or

no maintenance. Ensure fuel being supplied to this pump

is free

of

water or other types

of

contaminants that will hinder the pump's operation.

Periodically check the fuel connections to and out

of

the pump and make sure that no leakage is present

and that the fittings are tight and secure. The DC ground connection at one

of

the pumps mounting bolts

should be clean

and

well secured by the mounting bolt to ensure proper pump operation.

II

WARNING

II

Fuel leakage

at

the fuel pump or its

.connections is a fire hazard

and

should
be corrected. Make sure proper
ventilation exists whenever servicing
fuel system components.

WESTERBEKE

GENERATORS

Fuel

Supply

(out)

V

DC

(+)

Conn.ection

Ground

Wire

38

Fuel

Pump

::'uel

Supply

(in)

(Inste..ller'lJ

Connection)

7.6 BTD

Control

Circuit

Wiring

Diagram #039284

paoe 1

of2

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39

WESTERBEKE GENERATORS

+

12

vIX

r-

-,

1 ; C.B.

:(

:20.1,

. ,

r "

I :

EMERGENCY

L JSTOf>

SW.

r 1

:

lSToPSw.

l "

r

,

7.6MINIBTD

Schematic Diagram #39284

page 2

00

GLOWP!.UGS

:,'(

1

c.s

.

I

IDA

-

I (PREHEAT

SW.

L _

L--+--+-_-(

P

EXHAUST

TEMP.

SWITC"

WATER

TEMP-SWITCH

OIL

PIIESS.

SWITCH

•

"

rU'EL SOL.

o

STARTING

AND STOPPING INSTRUCTIONS

START,

I.

ALWATS

PUS"

Pll(oE:AT

SWITCH

riIlST.

HOLD

fOR

I!>

TO

'0

SECOtlOS

AS

REQUIRfO.

2:

WI1ILE

COtlTltII,IlNG TO

PUSH

PRE~AT

SWITCH, PUSH START SWITCH.

3.

WHEN

GENERATOR

SlAlfTS,

RELEASE START SWITCH OtILY,

......

HEtI OIL Pl!£SSURE

REACHES

APPROXIMATELY

201'S1,

RELEASE

"IlEHEAT SWITCIi.(TI1E

PREI1EAT

SWITCI1

OVERRlOES

THE

LOW

O1L

PRESSURE

SI1UT

DOWN

CIRCUIT~

STOP:

I.

PUSH

lotiO

HOLD

THE

SToP

SWITel1

UtlTIL

GENERATOII

STO~

COldPLETELY,

NOTES,

I.

"HIS

PRO~UCT

IS

Pl'IOT[CTEO

BY

A IotAtlUA\.

RESET

CIIiCUIT

I!R'EAKER

LOCATED

tI(

....

1I

THE

SUIITEP

1."10

AS

CLOSE

TO

THf

eURIIEtlT

SOURCE

AS POSSIBLE EXCESSIVE CURREtlT

DRAW

ANYWI1ERE

IN

TI<E

ItiSTRUMENT

PAtlEL,

WIIIlNG.

011

ENGINE

WILL CAUSE

THE

SREAKEiI

TO

TIIIP.

IN

THIS

(VENT

"'OST

GEtlERATORS WILL SHUT

DOWN

BECAUSE

THE

OPENED

BREAKlR OISCOtlN(CTS

THE

ruEL

SUPPLY,

T>lEREFOIlE

THE O

....

NER/BUILOER

IotUST

SE

SUIIE THAT

THE

'NSTRUIoIEtI~

PANEL

.....

'1111'110.

AND

ENGINE

"liE

lWST"LLEO

TO

PIIEVENT CONTACT BETWEEN ELECTRICAL DEVICES

"NO

SAL!

WATER,

z.

AN

em-OFF SWITCH SHOULD

BE

INST"LLED

IN

TI115

CIRCUIT

TO

O1SCONNECT

THE

STAI'ITEII

rl;Olool T ..

r

BA11EI'IY

IN

AN

EldERGENCY

AND

WHEN

LE"VING

HIE

BOAT. TWELVE VOLT DIESEL ENG!tlE STARTERS

TYPICALLT OIlAW

200

10

300

"1001~

WHEN

CRANKIN!>.

THE

OURATION

Of

INQiVIDUAL

CRAN~ING

CYCLES

SHOULD NOT EXCEEO

~O

SECONOS_" SW'TeH

WITH A CONTINUOUS

IIATING

or

17~

A",ps

AT

\2 vOC

HILL

NOl'lloiALLT SERVE THIS F"\.INCTION,

BU1

A SWITCH MUST

NEVER

eE USED

TO

·~Af(E-THE

ST/l.RHR

CIIICUIT.

WESTERBEKE GENERATORS

40

G"(lUM"

TO

BlQ('

IS

PIN

REMOTE

CONNECTOR

.

• "

T"

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,,.>(Olvl(\

"o""iIO(O

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@ 1

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elKIW"T

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7.6 BTD Control Circuit DC Wiring Diagram #044121

(Two Relays)

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QII

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011

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,tc/RED

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TO

Tal-I

TO

rBr-,o

1"",,8,,·,,·1

Of>T!ONAI..

HC!!..f!MITEB

a,,·

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-

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let

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51A

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cow

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41

WESTERBEKE GENERATORS

PIIMI>

I'

I

L.;

l---,

~i

EMERGENCY

I

STOP

1-1

SWI

TCH

'~81-1

r'

I

L.;

FUSE

8A

t1

STOP

ISWITCH

1-1

-

--c-

7.6 BTD DC Schematic Diagram #044121

(Two Relays)

+

•

12

VDC

•

-

r'

~

BATTERY

I

W SWITCH

20

AMP

L.;

STARTER

CIRCUIT

BREAKER

SOLENOID

STARTER

[r~"l

,--l

L_..J

1 1

t

I I

-L

__

...J

PREHEAT

SOLENOID

GLOWPLUGS

,--l

i

I

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L

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AL

TERNATOR

87

=..,

KI-START

B

30

)\

K2-RUN

pm

I

FUEL

SOL.

30

I 187

HOlD~

, r

FUEL

PUNP

EXHAUST

TEMP

WATER

TEMP

OIL

PRESS.

-U-

~H

~H

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AUX.

OIL

PRESS.

~H

--zy

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~

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85

VI

PREHEAT

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KI-START

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T81-2

T81-3 T81-4

T82-2

TBI-5

T62-1

T82-3 T82-8

TB2-4

T82-5

'7'

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CD

WESTERBEKE GENERATORS

42

COOLING SYSTEM

Description

Westerbeke marine diesel generators are designed and equipped for fresh water cooling. Heat produced in
the engine by combustion and friction is transferred to fresh water which circulates throughout the engine.
This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred
e,,"lernally from the fresh water to raw water

by

means

of

a heat exchanger; similar in function

to

an

automotive radiator. Raw water flows through the tubes

of

the heat exchanger while fresh water flows
around the tubes; engine heat transferred to the fresh water is conducted through the tube walls to the raw
water which

is

then pumped into the exhaust system where finally it is discharged overboard. In other

words, the engine is cooled

by

fresh water, the fresh water is cooled by raw water, and the raw water
carries the transferred heat over the side through the exhaust system. The fresh water and raw water
circuits are independent

of

each other. Using only fresh water within the engine allows the cooling water

passages to stay clean and free from harmful deposits. The two independent circuits and their components

are discussed in the following paragraphs.

Fresh Water Circuit

NOTE: Refer to paragraphs A and B in this section for the recommended antifreeze and water
mixture to be used as the fresh water coolant and for information on filling the fresh water

system.

Fresh water is pumped through the engine by a belt-driven circulating pump, absorbing heat from the
engine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through

the thermostat into the exhaust manifold, to the heat exchanger where it is cooled, and then is returned to
the engine block through the suction side

of

the fresh water circulating pump. When the engine is started
cold, external fresh water flow is prevented by the closed thermostat (although some fresh water flow is
bypassed around the thermostat to prevent the exhaust manifold from overheating). As the engine warms
up, the thermostat gradually opens, allowing full flow

of

the engine's fresh water coolant to flow

unrestricted to the external portion

of

the cooling system.

A.

Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should be used year-round in the cooling system. Water, when it

freezes, e"'Pands sufficiently to split the heat exchanger and crack the engine block. A water/antifreeze

mi"iure

of

proper concentration will prevent freezing (see the antifreeze/water mixture chart).

Use soft water with

few

impurities, such as tap water (potable

water)

or rainwater. Never use hard

or

foul water. Use

of

hard water or water containing impurities will lead

to

the collection

of

scale in the

engine and heat exchanger which will reduce the cooling system's efficiency.

Antifreeze

of

poor quality or without rust inhibitors will cause corrosion within the cooling system.
Always use antifreeze which is compatible with aluminum cooling system components and is made by a
reliable manufacturer. Never mix different brands

of

antifreeze. Make sure that the cooling system

of

the

engine is well cleaned before adding antifreeze. Recommended antifreeze for year round use is ZEREX

or

PRESTONE with rust inhibitors.

In order to control the concentration

of

the mixture, mix the antifreeze and freshwater thoroughly before

adding it to the cooling system.

43

WESTERBEKE

GENERATORS

ANTIFREEZE CONCENTRATION

DATA

Antifreeze
Concentration

Freezing
Temperature

%

13

23

(-5)

23

14

(-10)

B.

Filling

the

Fresh Water System

30

5

(-15)

35

-4

(-20)

45

-22

(-30)

50

-40

(-40)

60

-58

(-50)

A coolant recovery

tank

kit is supplied with each Westerbeke diesel engine.

The

purpose

of

this recovery

tank

is

to

allow for engine coolant expansion

and

contraction, during engine operation, without the loss

of

coolant

and

without introducing air into

the

cooling system.

This

coolant recovery tank kit is supplied with

each

Westerbeke diesel engine.

The

purpose

of

this

recovery

tank

is to allow for engine coolant expansion

and

contraction, during engine operation, without

the

loss

of

coolant

and

without introducing

air

into

the

cooling system.

This

coolant recovery tank should be installed at,

or

above, engine manifold level,

in

a location where it

can

be

easily monitored

and

where coolant

can

be

easily added

if

needed (see

the

figure below). A

stainless steel mounting bracket is supplied with

each

kit along

with

a 30

inch

length

of

clear

plastic hose

and

clamps to connect

the

hose between the engine's manifold fitting to

the

hose spud on

the

base

of

the

recovery tank.

FUNCTION

OF

MANIFOLD

PRESSURE

CAP

From

Coolant

Tank

COOLANT RETRACTION

COOLANT EXPANSION

Coolant

from

the engine,

when

heated during engine operation, will expand, lifting

the

spring-loaded

manifold pressure cap,

and

enter the recovery

tank

by way

of

the

hose connecting the recovery

tank

to

the

manifold.

When

the

engine is shut down and cools, a small check valve in the pressure cap is opened by

the

contraction

of

the engine coolant, allowing some

of

the

coolant in the recovery tank to

be

drawn

back into

the engine's cooling system, free

of

air without loss. Periodically check

that

the passage (A) between

the

90° fitting

on

the

manifold

and

the filler neck in the manifold is clear so coolant flow

in

either direction.

WESTERBEKE GENERATORS

44

COOLANT

RECOVERY

TANK

PRESSURE CAP

COOLANT

PASSAGE

EXHAUST

MANIFOLD

Coolant Recovery Tank, Recommended Installation

Fill the fresh water system as follows:

I.

Remove the pressure cap from the manifold.

2.

Pour a clean, antifreeze mixture into the manifold and allow enough time for the coolant to fill the

fresh water cooling system.

3.

Start the engine and allow it to come up to its operating temperature. Monitor the coolant in the

manifold and add antifreeze coolant as air is expelled.

Once all air is expelled from the system, fill the
manifold to the filler neck and install the pressure cap. Open the air bleed petcocks, each in turn, located
on the upper inboard side

of

the manifold

to

allow any air in that area

of

the manifold to escape. Close

the petcock securely.

4.

Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway

between the ADD mark and the MAX mark. Replace the plastic cap.

5.

Run the engine and observe the coolant's expansion flow into the plastic recovery tank.

6. Check for leaks between the pressure cap/filler neck and the plastic recovery tank.

Stop the engine and
allow it to cool. Coolant should be drawn back into the cooling system as the engine's temperature comes
down. Check the coolant passage in the filler neck to ensure it is open to flow. Clean it with a heavy
piece

of

wire periodically to ensure it remains open. Once a season or more should you find it necessary.

7. Add coolant to the recovery tank, as required, to top off the fresh water coolant system and periodically
check to see that the manifold is full

of

coolant by removing the pressure cap when

the

engine is cold.

45

WESTERBEKE

GENERATORS

Thermostat

Generally, thermostats are

of

two

types. One is simply a choking device which opens and closes

as

the
engine's temperature rises and falls. The second type has a bypass mechanism. Usually, this is a disc on
the bottom

of

the thermostat which moves downward to close off an internal bypass passage within the

head.

Since 1980, each type

of

thermostat has a hole punched through it. The hole is a bypass

to

prevent

the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats

must

have this design characteristic.

Raw

Water

Circuit

The raw water flow is created

by

a gear-driven, positive displacement, neoprene impeller pump. The
pump draws raw water directly from the ocean through the sea cock and raw water strainer and passes the
water to the heat exchanger's raw water inlet. The raw water passes through the heat exchanger's tubes,
from which heat from the fresh water system that circulates around these tubes is absorbed, and then the
raw water is discharged from the cooling system overboard through the water-injected wet exhaust system.
Be sure to clean zinc debris from the area inside

of

the heat exchanger where the zinc anode is positioned

as this debris lays in front

of

these tube ends and blocks them.

Zinc Anode

A zinc anode, or pencil, is located in the raw water cooling circuit within the heat exchanger. The
purpose of the zinc anode

is

to

sacrifice itself to electrolysis action taking place in the raw water cooling

circuit, thereby reducing the effects of electrolysis on other components

of

the system. The condition

of
the zinc anode should be checked monthly and the anode cleaned or replaced as required. Spare anodes
should be carried on board.

NEIf

ANODE

REPLACE

REPLACE

CLEAN

DR

REPLACE

NOTE: Electrolysis action is the result of each particular installation and vessel location; not that
of

the generator.

If

the zinc pencil needs replacement, hold

the

hex boss into which the zinc pencil is threaded with a
wrencb while loosening the anode with another wrencb. This prevents the hex boss from possibly
tearing off the exchanger shell. After removing the zinc, note the condition

of

it.

If

the zinc is in poor

condition, there are probably a lot of zinc flakes within the exchanger. Remove the end

of

the heat

exchanger and clean the inside

of

all zinc debris. Always have a spare heat exchanger end gasket in

case the present one becomes damaged when removing

the

end cover. Replace the gasket (refer to

your engine model's heat exchanger end gasket part number), cover, and install a new zinc pencil.

WESTERBEKE GENERATORS

46

Raw

Water

Pump

The raw water pump

is

a self-bleeding, gear-driven, rotary pump with a non-ferrous housing and a
neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate within the
impeller housing, producing the pumping action.

On

no account should this pump be

run

dry. There

should always be a spare impeller and impeller cover gasket aboard (an impeller kit). Impeller failures

occur when lubricant (raw water) is not present. Such failures are not warrantable and the operator's are
cautioned to make sure raw water flow is present at start-up. Know your pump, know its location on the
engine and know how to change the impeller in it.

SCREWDRIVER

NEOPRENE

IMPELLER

CURVED CAM

SCREWORIVER

Remove the impeller with the aid

of

two small screwdrivers, as illustrated, and carefully pry the impeller

out

of

the pump. Install the impeller

by

positioning the hub pin to align with the slot in the drive shaft.

Move the blades to conform to the curved cam plate and push the impeller into the pump's housing.

Water

Pump

Drive Belt Tension

Generator models

COme

equipped with belt guards that cover over the belt(s) on the front

of

the engine.

("OUt

of

sight -out

of

mind." The belt guard

is

not installed for that purpose.) Operators are advised that

the inspection, service, and maintenance spoken

of

below should be followed.

II

WARNING

II

Never attempt to adjust the drive belt's tension while the engine

is

in operation.

II

CAUTION

II

Excessive water pump drive belt tension can cause rapid wear

of

the belt and reduce the service

life

of

the fresh water pump's bearings. Excessive slack or the presence

of

oil on the belt can

cause belt slipping, resulting in high operating temperatures.

The water pump drive belt is properly adjusted

if

the belt can be deflected no less than 3/8 inch and no

more than

112

inch (I0mm, 12mm) as the belt is depressed with the thumb at the midpoint between the

two pulleys on the longest span

of

the belt. A spare drive belt should be carried on board.

47

WESTERBEKE

GENERATORS

Cooling System

Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw water flow
through their independent cooling circuits. Refer to your generator's Parts List for part numbers and part
descriptions

if

you need to order cooling system parts for your engine.

------

PRESSURE CAP

INJECTED

ELBOW

--_

INCOMING
RAW WATER

FRESH

WATER

~

RAW

WATER

...

WESTERBEKE

GENERATORS

48

EXHAUST

MANIFOLD

WATER

~--~~;----TEMPERATURE

SWITCH

HEAT

"A"nAA'"

ZINC

FRESH WATER DRAIN

WATER DRAIN

LUBRICATION

SYSTEM

Engine

Oil

For engine lubrication, use lubricating oil designated for diesel service. These oils are classified
according to the

API specifications into service grades CA, CB, CC

and

CD.

The

use

of

CC or higher

(CD) grades, made by well-known manufacturers is recommended.

Engine

Oil Viscosity (SAE Number)

Use

an

oil having a viscosity best suited to the atmospheric temperature. Use

of

an

all-season oil SAE

IOW-30

with minimum viscosity change under different temperatures is suggested.

Atmospheric Temperature

68° F (20° C) or higher
41° F (5° C) - 68° F (20° C)
41° F (5° C) - or lower

Viscosity

SAE 30 or IOW-30
SAE 20

or

IOW-30

SAE IOW-30

NOTE:

Do

not use

an

engine lubricating oil with

an

SAE number greater than 30

in

the engine.

Oil

Pressure

The engine's oil pressure, during operation, is indicated by the oil pressure gauge

on

the instrument panel.

During normal operation, the oil pressure will range between

35

and 55 psi.

NOTE: A newly started, cold engine can have

an

oil pressure reading upwards

of

60

psi. A

warmed engine can have

an

oil pressure reading as low as 35 psi. These readings will vary

depending upon the temperature

of

the engine and the load placed

on

the generator.

Engine

Oil

Change

(to include filter)

I. Draining the Oil Sump

Discharge the old oil through the sump drain hose
(attached to the front

of

the engine) while the engine
is still warm. Drain the oil oil completely, replace
the hose

in

its bracket, and replace the end cap

securely.

Always observe the oil as it is removed. A
yellow/gray emulsion indicates the presence

of

water

in

the oil. Although this condition is rare,

it

does
reqnire prompt attention to prevent serious damage.
Call a competent mechanic should water

be

present

in the oil. Raw water present

in

the oil can be the

result

of

a fault

in

the exhaust system attached to the

engine andlor siphoning through the raw water

cooling circuit into the exhaust, filling it up to the
engine.

49

~1!'\1

\\IIII!lllllli!III1I!\ln'!W::;i~;:"

llill

.

\'

I' . ;'

,!

':'

:

.!,

:'

'.

"I

::"

'.

'I'

11:\

'

.

1':

,

:,~~;':;

,

WESTERBEKE

GENERATORS

2.

Replacement

of

the Oil Filter

When removing the used oil filter,

you

may

find it

helpful and cleaner

to

punch a hole in the upper and

lower portion

of

the old filter

to

drain the oil from it

into a container before removing it. This helps

to
lessen spillage. A small style automotive filter
wrench should be helpful in removing the old oil
filter. Place some paper towels and a plastic bag
around the filter when unscrewing it

to

catch any oil

left in the filter.

(Oil or any other fluid on the

engine reduces the engine's cooling ability. Please

keep your engine clean.) Inspect the old oil filter as
it

is removed to make sure that the rubber sealing

gasket came off with the old oil filter.

If

this rubber
sealing gasket remains sealed against the engine
block, gently remove it. The replaceable cartridge-

type oil filter requires no cleaning inside,

so

it

may

be properly disposed

of

properly.

When installing the

new

oil filter element, wipe the filter gasket's sealing surface on the engine block free

of

oil and apply a thin coat

of

clean engine oil

to

the rubber gasket on the new oil filter. Screw the filter

onto the threaded

oil

filter stub, and then tighten the filter firmly

by

hand.

NOTE: Generic filters are not recommended, as the material standards or diameters

of

important items on generic parts might

be

entirely different from genuine parts.

Immediately after an oil filter change and oil fill, run the engine

to

make sure the oil

pressure is normal and that there are

no

oil leaks around the new oil filter.

3.

Filling the Oil Sump

Add

the new oil through the oil filler cap

on

the top

or side

of

the engine. After refilling the oil, run the

generator for a

few

moments while checking the

engine's oil pressure. Make sure there is

no

leakage
around the new oil filter or from the oil drain
system, and stop the generator. Then check the

quantity

of

oil with the lube oil dipstick. Fill

to,

but

not over, the high mark

on

the dipstick, should the

engine require additional

oil.

WESTERBEKE GENERATORS

so

Top

Oil

Fill

-~::--:::I

Rod:er

Cover

Side Oil

Fill

-----\

..

'l'..J

Oil

Dipstick

Upper

[Hor

••

l

---,;;.--

-

Dil

Lower

li.it

====

-~

Crankcase

BT GENERATOR

This generator is a brushless self-excited generator, which requires only the driving force

of

the engine to
produce AC output. The copper and laminated iron in the exciter stator are responsible for the self­exciting feature

of

this generator. The magnetic field produced causes an AC voltage to be induced into

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

to DC and supply it to the windings of the rotating field. This creates

an

electromagnetic field which

rotates through the windings

of

the main stator, inducing an AC voltage which is supplied to a load. A

transformer is connected

in

parallel

to

the AC output of the main stator. An AC voltage is produced in

the auxiliary windings of the transformer and main stator and is, in turn, supplied to a full-wave bridge
rectifier. The rectifier produces a DC voltage

to

further excite the excitor stator windings, enabling the

generator to produce a rated AC output.

No-Load Voltage Adjustment

Voltage adjustment is made with the compound transformer goveruing generator regulation.

1.

Operate the generator and apply a moderate load momentarily; then remove the load. Note the voltage

output from the generator's

l20-Volt leg(s) (110 Volts at

50

Hertz). The no-load voltage should be

between

121 -123

Volts at 61.5 - 62 Hertz

(Ill

-

113

Volts at 51.5 -

52

Hertz).

NOTE: The no-load voltage should be adjusted to the voltage produced by the generator

when: the generator

is

started, a momentary load

is

applied to excite the transformer, and

then removed. The voltage produced

by

the generator after this momentary load is removed

is the no-load voltage.

2.

To raise or lower the voltage, non-<:onductive shims

of

varying thickness are inserted or removed from

under the laminated steel bar that is situated on top

of

the compound transformer. The material used for

shimming should not soften at temperatures in the

1760 F (80

0

C) range. A small reduction in no-load

voltage

(1

to 3 volts) sometimes can be accomplished by gently tapping the top

of

the laminated steel bar

to reduce the air gap between the existing shims and the transformer core.

II

CAUTION n

Under no circumstances attempt

to

increase the no-load voltage by increasing the gap between

the laminated steel bar and the transformer core without the use

of

shims. Magnetic forces

created within the transformer during the generator's operation

may

close the air gap and

reduce the no-load voltage output.

3.

To remove the laminated steel bar, remove the

two

upper securing bolts from the compound
transformer and lift the bar from the transformer. The addition of shim thickness will raise the no-load
voltage and, conversely, the removal

of

shim thickness will lower the no-load

Voltage.

Varying shim thickness by .001 inch (0.025 mm) will change the no-load voltage by 4 to 6 volts.

51

WESTERBEKE

GENERATORS

"

Securing

....

7.6

BID

- View of Generator Backend

©©

~

©©

#2

©©

#S

VOLTAGE

BAR

WESTERBEKE GENERATORS

VOLTAGE BAR

The voltage bar has three leads coming in

on

one

side from the transformer and a single lead on the

other routed

to

the bridge rectifier. The single lead

can

be

pOSitioned

at either

of

the three connections.

These connections are used

to

change the output

voltage of the generator under load.

Should the

voltage

go

below minimum. Reposition this

connection

to

increase output voltage under load.

52

r

,

I

1

,

[~

1

1>+

1

1

~

i

•

4

31

1

1
1

I

I

c

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1

1

3

L

_____________

J

I

r----

--

--------,

: , Btl

r-------,

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:

\1

I [

L

_______

J

G

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i

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T

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w

L.!lif!-t-

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WitT

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6 E

5 R

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ORANGE

+

AC

BLACK

..,

1

J

5

T

U

D

-KJ-

AC

GREEN

YELLOW

BID

7.6 KW Generator's Internal Wiring Diagram

A.

EXCITER STATOR WINDINGS

1.

Exciter Stator Windings

B.

EXCITER ROTOR

1.

Auxiliary Windings (a-b-c)

2.

Diodes (6)

3.

Rotating Field Windings

4.

Pozi Resistor

C.

MAIN STATOR

1.

Main Stator Windings

2.

Main Stator Windings

3.

Main Stator Auxiliary Windings

53

D.

COMPOUND TRANSFORMER

1.

Compound Transformer Windings

2.

Compound Transformer Windings

3.

Compound Transformer Auxiliary
Windings

E.

BRIDGE RECTIFIER

WESTERBEKE GENERATORS

Generator Frequency

Frequency is a direct result

of

engine/generator speed:

1800 RPM - 60 Hertz
1500 RPM - 50 Hertz

To change the generator's frequency, refer to the "MAINTENANCE AND ADmSTMENTS" section

of

this manual.

Load Connections

The generator's data plate gives the voltage, current and frequency rating

of

the generator. An AC wiring

decal is affixed to the inside

of

the louvered cover on the generator end. A diagram

of

the various

AC
voltage connections is provided on the decal. The information on the decal is similar to the figure shown
on the following page.

The generator is a single-phase, reconnectable

120

volts AC two-wire or

1201240

volts AC three-wire, at

60 Hertz; or 110 volts

AC

two-wire,

1101220

volts

AC

three-wire, or 220 volts AC two-wire,

at

50 Hertz.

Refer to the

"SYSTEM SPECIFICATIONS" section

of

this manual for ratings, located

at

the beginning of

this manual.

WESTERBEKE GENERATORS 54

120V 60Hz

120/240V 60Hz

0

( )

T

( )

o FR

....

ME

0

( ,

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0

0

0

0

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,

10/220V

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220VSDHz

=

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= 0 = 0

0

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N o

0=

a:::::::@)

0

TO

Fa

....

C

'ilFt<:r::~o~

IQO~':3=

L,

'n

u

l..

N

N

L,

AC Voltage Connections (12 Stud Terminal Block)

NOTE:

The

frame ground wire must

be

moved when changing from 110 volts,

50

Hertz to

220 volts,

50 Hertz,

For making connections to the AC terminal block, use terminal ends for #10 studs which will accept

#6

or

#8 multi-strand wire,

55

WESTERBEKE GENERATORS

Shore

Power

Connections

If

the installer connects shore power to the vessel's AC circuit, this must be done by means

of

the SHORE

POWER/OFF/SHIPS GEN, center position-off transfer switch as shown below.

Use

of

this switch

prevents simultaneous connection

of

shore power

to

generator output.

II

CAUTION

II

Damage

to

the generator can result ifutility shore power

and

generator output are connected

at

the same time. This type

of

generator damage is not covered under the warranty; it is the

installer's responsibility to ensure that all AC connections are correct.

-

N

G'

1

ROf[:

DHIGRllIII

SHOWS

COUEenONS

FOR

TWO-

G2

illitE,

121-\lOI,.T

SYSHII.

FOR

lHREE-WIU

t

.:.

SYSTUC

USE

DOllED LINtS

FOR

TN£

DINU

HOI

LEGS.

L-

__

-----,

--,

I

I

I

I

L

->-----i''Gl

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

, I

, I

SlIiP-lO-SHDR(

SlflTCH

(3

rOl£)

PM

32

..

8

(41

AIoII'S/PDlO

,.

12

..

,

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

"

Ll

L--

l

+-

i

--1j'--l-l-t-+"¢~-'-':::

I

Noon,.'

II,N

;::"

ae

IIHPS/POLE)

...

32111

C12S

hIPSIPOl[)

I'll

ntH

(218

liMPS/POLE)

~

,52

t

$,

N

NOTE,

OIAGRA~

SHOWS

CONNECTIONS

FOR A TWO-

WIRE,

12B-VOLT

SYSTE~

FRO~

THE

GENERATOR,

WITH

THREE-WIRE, 12B-VOLT

BOAT

SYSTE~.

,

,

,

,

",',

,

,

~'

..,..~

'"

,

I

,

-

-,'

L2

/

--

......

,

'---_C,

if?

".:.'

-+-'Nll~~";C'

-.

N

~

I

(WHT)

,

--'

"G~'~""""'-_

......

___

-il'·

(GRN)

Ship'$load

N~'

NO

240,vOft

equipmeol

PH

32.""8

,4.e

AMPS/POLE}

PH

328"'"

(88

AMPS/POLE)

PH

328.18

(.1.25

,n

..

PS/POLCl

PH

32133

(211111

FlMPO

....

POLC)

\

52

S1

..

N

Shore

Power

SWITch

Connection Diagrams

WESTERBEKE

GENERATORS

56

GENERAL

INFORMATION

AND

CARE

OF

THE

GENERATOR

Use

of

Electric Motors

The

power required to start

an

electric motor is considerably more

tban

is required to keep

it

running

after

it

is started. Some motors require much more current to start

tban

otbers. Split-phase (AC) motors

require more current to start, under certain circumstances,

tban

other types. They are commonly used

on

easy-starting loads, such

as

washing machines,

or

where loads are applied after

tbe

motor is started, such

as

small power tools. Because they require 5 to 7 times

as

much current to start

as

to run, tbeir use should

be

avoided, whenever possible,

if

tbe

electric motor is to be driven by a small generator. Capacitor

and

repulsion-induction motors require from 2 to 4 times as much current to start

as

to run.

The

current

required

to

start any motor varies witb the load connected to it. An electric motor connected

to

an

air

compressor, for example, will require more current

than

a motor to which no load is connected.

In

general,

tbe

current required to start

lI5-Volt

motors connected to medium starting loads will be

approximately

as

follows:

MOTOR

SIZE

(HP)

lI6

1/4

1/3

lI2

3/4

AMPS

FOR

RUNNING

(Amperes)

3.2

4.6

5.2

7.2

10.2

13

AMPS

FOR

STARTING

(Amperes)

6.4 to

22.4'

9.2

to

32.2'

10.4 to

72.8'

14.4 to 29.2

20.4 to 40.8
26 to 52

'NOTE:

In

tbe

above table

the

maximum"

Amps for Starting" is more for some small motors

tban

for larger ones.

The

reason for this is that the hardest starting types (split-phase) are no

made

in

larger sizes.

Because tbe heavy surge

of

current needed for starting motors is required for only

an

instant,

tbe

generator

will not

be

damaged

if

it

can

bring

tbe

motor up to speed

in

a few seconds.

If

difficulty is experienced

in

starting motors,

tum

off

all otber electrical loads and,

if

possible, reduce tbe load

on

the

electric motor.

Required Operating

Speed

A1tbough individual units

may

vary slightly,

the

normal voltage

and

frequency

of

typical 60-(50-)Hertz

engine-driven generators described in

tbis

manual are approximately

as

follows:

run

first

witb

no

load

applied,

tben

at

half

tbe generator's capacity,

and

finally loaded to its full capacity

as

indicated

on

tbe

generator's

data

plate.

See tbe rpmlHertzlfrequency chart

on

tbe

next page.

57

WESTERBEKE

GENERATORS

Load Applied

4-Pole Speed

Frequency

Generator Voltage

(rpm) (Hertz)

120V (110) 240V (220)

Plants Plants

None

1830 62

122

240

(1530) (52)

(ll2)

(224)

Half

1800

60 120

240

(1500) (50) (110) (220)

Full 1755 59 110 220

(1455) (49) (100) (200)

The output voltage should be checked periodically to ensure proper operation

of

the generating plant and

the appliances it supplies.

If

an

AC

voltmeter or ampmeter is not installed to monitor voltage and load, check it with a portable

meter and amp-probe.

Preventive

Maintenance

(Generator)

Maintenance on the generator is minimal.

1.

Keep the generator clean,

dry

and

well-ventilated.

2.

Ensure that all connections are clean and tight and that cables carrying AC voltage are properly

supported and protected against chafing.

3.

The rear armature bearing

is

lubricated and sealed; therefore,

no

maintenance is required.

If

the

bearing becomes rough or noisy, replace it.

Generator

Troubleshooting

A complete and illustrated test on troubleshooting the

BID

series

of

generators is furnished in the

Technical Manual which is available through your local dealer.

WESTERBEKE

GENERATORS

58

YOUR NOTES

59 WESTERBEKE GENERATORS

ENGINE

TROUBLESHOOTING

Introduction

The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the
probable causes

of

the problems, and the recommendations to overcome these problems.

Note that the engine's control system (electrical system) is protected

by

a 20-Ampere manual reset circuit

breaker located on a bracket on the right side

of

the engine, just forward

of

the generator's end plate. The

preheat solenoid is close

by,

as is the emergency STOP switch, which may be mounted on the same

bracket

or

on the back

of

the standard instrument panel, depending upon the model.

Problem

Probable

Cause Verification/Remedy

PREHEAT switch is depressed:

I.

Battery switch not on.

I.

Check switch andlor battery

no panel indications, fuel connections.
solenoid, electric fuel pump
and preheat solenoid not

2.

20-Amp circuit breaker

2.

Reset breaker;

if

breaker trips

energized.

tripped.

again, check preheat solenoid
circuit and check circuit for shorts
to ground

START switch is depressed:

I.

Connection to solenoid

I.

Check connection.

no starter engagement. faulty.

2.

Faulty START switch.

2.

Check switch with ohmmeter.

3.

Faulty solenoid. 3. Check that

12

volts are present

at

starter solenoid energizing spade

terminal when switch depressed.

4. Loose battery connection.

4. Check battery connection.

5.

Low batteries.

5.

Check battery charge state.

START switch is depressed: I.

Poor connections to fuel

I.

Check connections.

panel indications

OK; start solenoid.

solenoid OK; fuel solenoid not

functioning.

2.

Defective fuel solenoid.

2.

Check mechanical positioning

of

fuel solenoid for plunger

bottoming.

3.

Manually check movement

of

fuel solenoid plunger and throttle

arm.

4.

Check for voltage drop at
solenoid during preheat. Check
wire size from remote panels.

WESTERBEKE

GENERATORS

60

No ignition: cranks, but does

I.

Faulty fueling system,

I.

Check for fuel to generator

not start; fuel solenoid

engine.

energized.

2.

Check for air in fuel system.

Bleed point on filter.

3.

Fuel lift pump faulty.

4.

Filters clogged. (Replace filters
and allow system to self-bleed by
depressing only the PREHEAT

switch.

Failure to stop.

I.

STOP switch failure.

I.

Stop engine

by

depressing

emergency

STOP switch on engine
or manually moving the shut off
lever on the injection pump side.
Test switch with ohmmeter.

2. Fuel solenoid return spring.

2.

Stop engine by manually

moving the throttle lever to shut

off.

That failing, shut off fuel and

air. Check fuel solenoid linkage

and repair for free movement.

3.

Fuel injection pump failure.

Engine stops.

I.

Low oil pressure

or

1.

Check oil level; check fresh and

overheated. sea water cooling.

2.

Low oil pressure switch

2.

Check for satisfactory operation

opens. with switch bypassed. Check with

an

ohmmeter.

3. High temperature switch

3.

Check for satisfactory operation

opens at too

Iowa

temperature. with switch bypassed. Check with

(water temperature) (exhaust

an

ohmmeter.

temperature)

4.

20-Amp circuit breaker

4.

Check for high

DC

amperage

tripping. draw during operation. Ensure

switch is not overly sensitive

to

heat which would cause tripping

..

5.

Emergency STOP switch

or

5.

Check operation

of

switch with

STOP switch in panel defective,

an

ohmmeter.

opening fuel run solenoid

circuit

6. Switches andlor wiring. 6. Inspect all wiring for short
circuits and loose connections.

Inspect switches for proper
operation

61

WESTERBEKE

GENERATORS

Battery not charging.

1.

Alternator drive.

1.

Check drive belt tension. Be

sure alternator tnrns freely. Check
for loose connections. Check
output with voltmeter. Ensure

12

volts are present

at

the R terminal.

Battery runs down.

1.

Oil pressure switch.

1.

Observe

if

gauges and panel
lights are activated when engine is
not running. Test the oil pressure
switch.

2.

High resistance leak to

2.

Check wiring. Insert sensitive

ground.

(0-.25 Amp) meter in battery lines.
(Do not start engine.) Remove
connections and replace after short
is located.

3.

Low resistance leak.

3.

Check all wires for temperature

rise to locate the fault.

4.

Alternator.

4.

Disconnect alternator at output,

after a good battery charging.

If
leakage stops, remove alternator
and bench test. Repair

or

replace.

WESTERBEKE GENERATORS

62

MAINTENANCE AND ADJUSTMENTS

Introduction

This section contains a scheduled preventive maintenance program and several adjustment procedures the
owner/operator can perform without the benefit

of

sophisticated and

e".-pensive

tools and instruments.

Preventive

Maintenance

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.

Adherence to these schedules will ensure the equipment is maintained in the best possible condition and

that it will perform to expectations. Those items marked by an asterisk (

* ) are recommended to be

performed by

an

authorized dealer or distributor.

Daily (before

each

use)

1.

Check the oil sump level. Maintain the oil level at or near the upper level mark on the dipstick.

2.

Check the coolant level in the plastic recovery tank. Maintain this level

at

or above the level marked

ADD. Periodically, check the coolant level in the manifold. It should be filled to the top

of

the filler

neck.

3.

Visually inspect the unit; check for loose belts, chafed or broken wires, loose brackets and fittings,

damaged hoses, loose clamps and other equipment not properly secured.

4.

Check the fuel supply. Fill tank(s) with a good grade

of

No.

2 diesel fuel,

if

required.

5.

Check the primary filter/water separator. Drain and service as required. (A primary filter/water
separator is optional, but strongly recommended as damage to fuel equipment on the engine from fuel
contaminants is not warrantable.)

6. Check the generator's gauges or lights for proper oil pressure, operating temperature,

and

starting

battery charging voltage once the engine is operating.

7.

Check the generator's output meters (when installed) for proper AC voltage and output frequency.

Monthly

Check the condition

of

the zinc anode in the heat exchanger's sea water circuit. Clean

or

replace the

anode, as required. Keep the area inside the heat exchanger clean

of

zinc anode debris.

Servicing

After

Initial

50

Hours

of

Olleration

1.

Change the engine's lubrication oil and oil filter.

2.

Replace the fuel filter element in the engine-mounted secondary fuel filter. Change the fuel filter

element and clean the filter/water sedimentor,

if

a separator has been installed, and

if

the model type

pennits cleaning.

63

WESTERBEKE

GENERATORS

*3. Retorque the cylinder head bolts.

*4. Adjust valve clearances.

5.

Adjust the water pump drive belt tension,

if

required.

*6. Adjust the engine's no-load speed,

if

required (Hertz)

and

the regulator board's voltage output

adjustment as needed. Please note

that

these adjustments are not a warrantable adjustment during or after

the unit's break-in.

7.

Check electrical connections to the fuel solenoid. Make sure the fuel solenoid operates properly when

10-12 volts are present at the solenoid during preheat.

Servicing After Every 100 Hours

of

Operation

1.

Change the engine's lubrication oil and oil filter.

2. Adjust

the

alternator and water pump drive belt tension,

if

required.

3.

Check siphon break assembly for proper operation (when installed).

Servicing After Every 250 Hours of Operation

1.

Replace the spin-on fuel filter element on the engine-mounted filter assembly.

Servicing After Every 500 Hours of Operation

*

1.

Adjust the valve clearances.

*2. Torque the cylinder head bolts.

3.

Drain, flush

and

refill the fresh water cooling system. There are two drain plugs for the fresh water

system.

One on the lower side

of

the heat exchanger and the other behind the hose adjacent to the engine-

mounted fuel filter.

*4. Check the condition

of

the starter motor drive pinion; lubricate pinion.

5.

Check the resistance

of

the glow plugs (.4 to

.6

ohm). Remove the glow plugs from the engine and

clean the carbon build up from the pencil end.

Use anti seize compound on the threads when reinstalling.

6. Check the internal condition

of

the water injected exhaust elbow. Inspect the exhaust and water

passages. Remove any carbon and/or corrosion build up.

7.

Check the raw water pump for internal wear. Examine the pump's cover, cam,

and

internal housing.

Replace worn parts as needed. Check for leaks at seals or gaskets and repair them, as needed.

Note: Items highlighted

by

an

asterisk ( * ) should be performed

by

a competent mechanic.

WESTERBEKE GENERATORS

64

Servicing After Every 800 Hours

of

Operation

*1. Remove

and

check fuel injectors.

Injector spray pressnre:

1988 psi

± 142 psi

(140 kg/cm

2

± 10

kg/cm

2

)

Eliminate undesirable injection conditions including

after dripping.

*2. Check

the

engine's compression pressure. Remove

each

glow

plug

and

check each cylinder's compression

pressure.

The

engine's

cranking

speed is

at

280 rpm.

Standard

Minimum

A®~f"t4a;::;r..

..

4;';;;;;.----""1cf!\

GOOD

397.6 psi
(28 kg/cm2)

312.4 psi

(22 kg/cm2) (Maximum difference between cylinders: 35.5 psi [2.5 kg/cm2])

*3. Check

the

DC

Charging

Circuit for proper operation.

*4. Check the tightness

of

bolts, nuts,

and

clamps.

Servicing After Every 1000 Hours

of

Olleration

1.

Remove, clean,

and

pressure test the primary heat exchanger.

(A

local automotive radiator shop

should

be

able to clean

and

test the heat exchanger.)

NOTE:

Operating

in

silty

and/or

tropical waters may require

that

a heat exchanger

cleaning

be

performed more often

than

every 1000 hours.

*2. Check the injection pump's timing.

(Static method spill time.)

A.

Rotate the engine's crankshaft to position the #1 piston

at

the

Top

Dead

Center

of

its compression

stroke. Observe the opening

and

closing

of

the valves for this cylinder so

as

not to place

the

piston

at

IDC

of

the exhaust stroke.

Align

the

IDC

mark

on

the crankshaft front pulley with the timing

marker

on

the front

gear

case

cover

when

positioning

the

# I Piston

at

TDC

of

its compression stroke. Confirm this by rotating

the

crankshaft approximately 200 before

and

after this point and

the

two valves for the # I cylinder should

not

move.

Adjust the valve clearances for both the intake and exhaust valves for this cylinder

65

WESTERBEKE GENERATORS

B. Rotate the crankshaft 240° (degrees). This puts the

#3

piston at the TDC position in it's cylinder.

Adjust the valve clearances for the intake and exhaust valves

of

the

#3

piston at the TDC position in it's

cylinder. Adjust the valve clearances for the intake and exhaust valves

of

the

#3

cylinder.

C.

Rotate the crankshaft another 240°. This puts the #2 piston at the TDC position in its cylinder.

Adjust the valve clearances for the intake and exhaust valves

of

the #2 cylinder.

Torquing

Cylinder

Head

Bolts

Tighten the cylinder head bolts according to the

sequence shown in the illustration to the right.
Make sure the engine is cold when this is done.
Before applying the specified torque to the bolt,

loosen it

114

to

1/2

of a tum

and then apply the

torque. Follow this procedure according

to

the

numbered sequence shown in the illustration

to

the right.

Cylinder

Head

Bolt

Tightening

Sequence

Bolts #1,2, and 3, (12 mm socket) 2.0 - 3.0 kg-m (14 - 22 ft-Ib)

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

11

(14 mm socket) 7.5 - 8.5 kg-m (54-61 ft-Ib)

(Rockershaft Hold Down Bolts -

12

mm socket - 1.5-2.2 kg-m

(11-16

ft-Ib)

Valve

Clearance

Adjustment

II

CAUTION

II

Adjust the valve clearance when the engine is
cold. Valves are adjusted by cylinder in the
firing order

of

the engine.

Tighten the cylinder head bolts to the specified
torque before adjusting the valves.

1.

Pull

off

the air breather pipe from the rocker

cover,

and

take off the cover bolts and the rocker
cover to expose the rocker shaft and valve
assembly.

Mark

on

gear

case

TDe mark on

crankshaft

pulley

Timing mark

2.

Adjust the valve clearances at TDC for each cylinder when they are on their compression stroke.
Remember the engine's firing order is 1 - 3 - 2. You may find that turning the engine's crankshaft is more
easily accomplished when the engine's glow plugs are removed before the crankshaft is rotated.

WESTERBEKE

GENERATORS

66

I

I

Adjust each valve's clearance

by

inserting a 0.010

inch (0.25 mm) feeler gauge between the rocker arm

and the valve stem.

Injection Pump Timing Adjustment

(Spill Timing)

If

your engine's fuel injection timing

is

not properly
adjusted, the engine will not operate properly and
may

be

difficult to start. Have the injection pump

delivery rate checked

by

a well-established

fuel
injection shop. Adjust the injection timing as
follows:

NOTE: The fuel shut-off lever must be in the
RUN

position while making the adjustment or

no

fuel will

flow

from the

fuel

injection

pump.

Refer to the illustration below when servicing the

fuel

injection pump. First remove the high-pressure

fuel

line from between the

No.

I injector and the

No.

I

fuel

delivery valve holder. Remove the

No. I fuel
delivery valve holder and remove the delivery valve
spring beneath the holder. Reinstall only the
delivery valve holder and reattach the high pressure
fuel line to the delivery holder. Attach it

so

that the

end that would connect to the

fuel

injector is
pointing away from the engine. Fuel will flow from
this line during the timing check.

RDJUST

VALVES

TO

0.010

INCHES

(0.25

1(10

DELIYEiY

YRLYE

HOLDER

DELIVERY

V~LVE

SPRIN£

PlUJfHR

cunOl

PUIlO"

PlUN6ER

SPIIN6

Fun

CexUOl

Rlicr:

Rotate the engine's crankshaft in its normal direction

of

rotation to position piston

No.

I at the beginning

of its compression stroke.

Move the throttle lever to its full open position and operate the electric lift pump.

Slowly rotate the

crankshaft clockwise (as viewed from the front), catching the fuel from the

No.

I fuel line, until the

instant the fuel completely stops flowing (no drips).

At

this instant, the

16°

BTDC timing mark on the

crankshaft pulley should be directly aligned with the timing indicator on the front of the gear case ±

.5

degrees.

If

the specified injection timing (16° BTDC) cannot be attained, adjust the timing

by

increasing or

decreasing the thickness

of

shim material under the injection pump's mounting flange to change the

injection timing point. Changing the shim thickness

by

0.004 inch (0.01

mm)

changes the injection

by

approximately one degree. To advance the timing, decrease the shim thickness,

as

required. To retard the

timing, increase the shim thickness,

as

required. Refer to your generator's Parts List

for

shim part

numbers.

67

WESTERBEKE GENERATORS

Adjustments (Generator)

Once the diesel generator set has been placed

in

operation, there may be adjustments required for engine

speed (hertz) during the engine's break-in period (first

50 hours) or after this period. A no-load voltage
adjustment may also be required in conjunction with the engine's speed adjustment. These are not
warrantable adjustments as they relate to normal break-in and maintenance.

II

CAUTION

II

When starting the generator, all AC loads, especially large motors, should be switched off until
the

engine has come up to speed and,

in

cold climates, starts to warm up. This precaution will

prevent damage caused by unanticipated operation

of

AC machinery and will prevent a cold

engine from stalling.

Generator

Frequency Adjustment (Hertz)

Frequency is a direct result

of

engine/generator speed, as indicated by the following:

When the generator is run at

1800 rpm, the

AC

voltage output frequency is 60 Hertz.

When the generator is run at

1500 rpm, the AC voltage output frequency is 50 Hertz.

Therefore, to change the generator's frequency, the engine speed must be changed.

To

accomplish the

frequency change, perform the following:

1.

Connect the AC output leads to the AC terminal block

in

accordance with the AC voltage connections
diagram specified for your generator set, and change the hertz connection to the capacitor. These
connections are illustrated

in

the "BC GENERATOR" section

ofthis

manual.

2. Adjust the engine's speed to obtain the frequency corresponding to the voltage selected by adjusting the

stop bolts and positioning the throttle

arm

against these stop bolts to either increase or decrease engine no-

load speed to adjust hertz produced.

To

arrive

at

the appropriate frequency, either monitor the speed of the engine/generator with a

tachometer, or monitor the frequency with a frequency meter, the latter method being the more precise

of

the two.

Fuel Shut-off Solenoid - Installation Instructions

The fuel shut-off solenoid #037100 is mounted in a threaded boss

on

the engine's block

just

aft

of

and

below the engine's fuel injection pump. Proceed as follows when installing a replacement

or

new fuel

shut -off solenoid.

WESTERBEKE

GENERATORS

68

1.

Visual access to the

fuel

injection pump's

fuel

rack is needed. To obtain this, remove the small square

side

coverlbracketry just below the fuel injection pump. This

is

shown

as

cover part #037045 and gasket

#036981 in the parts

list

2.

Thread the locknut #034669 onto the solenoid and then apply a small amount

of

Teflon sealant to the

threads on the solenoid.

3.

Thread the solenoid into the boss on the engine and observe the solenoid plunger through the cover

opening. Allow the plunger to contact the fuel rack and move it fully into the injection

pump. Do not

thread further

so

as to push the plunger into the solenoid.

4.

Back the solenoid out

114 -112

of

a tum and secure it in position with the locknut

5.

Properly connect the three electrical leads from the solenoid. Two

of

the connections plug into the

engine harness and the third grounds

to

the engine block at an adjacent inboard threaded boss with an

8mmbolt

6.

Reassemble the coverlbracketry and test run the

unit

Ensure that the unit stops when the solenoid is

de-energized.

1.

FUE"

SHUT

OFF

SOLENOID

#037100

2.

LOCKNUT

#034569

3.

SOLENOiD

?LUNGER

69

WESTERBEKE GENERATORS

LAY-UP AND RECOMMISSIONING

General

Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up
during the off-season or for long periods

of

inactivity. Others prefer

to

accomplish lay-up preparation

themselves.

The procedures which follow will allow you to perform your own lay-up and recommissioning, or to use
as a check list

if

others do the procedures.

These procedures should afford your engine protection during a lay-up and also help familiarize you with

the maintenance needs

of

your engine.

If

you have any questions regarding lay-up procedures, call your local servicing dealer; he will

be

more

than willing to provide assistance.

Fresb

Water

Cooling System

A 50-50 solution

of

antifreeze and fresh water

is

recommended for use in the fresh water cooling system at

all times. This solution may require a higher concentration

of

antifreeze, depending on the area's winter

climate. Check the solution to make sure the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more
concentrated mixture. Operate the engine to ensure a complete circulation and mixture

of

the antifreeze

concentration throughout the cooling system.

Now

recheck the antifreeze solution's strength.

Lubrication System

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

(place some paper towels and a plastic bag around the filter

to

catch the oil during its removaL)

When installing the

new

oil filter, be sure

to

apply a small amount

of

oil on the rubber sealing gasket at

the base

of

the filter. Fill the sump with the correct amount

of

oil for your engine. (Refer to the

"SYSTEM SPECIFICATIONS" section

of

this manuaL)

Use

an oil with

an

API specification

of

CC or

CD.

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

II

CAUTION

II

Do not leave the engine's old lubricating oil in the sump over the lay-up period. Lubricating oil
and combustion deposits combine

to

produce harmful chemicals which can reduce the life

of

your engine's internal parts.

WESTERBEKE

GENERATORS

70

Fuel System

Top off your fuel tanks with

No.2

diesel fuel. Fuel additives should be added at this time to control algae
and condition the fuel. Care should be taken that the additives used are compatible with the primary
filter/water separator used in the system. Change the element in your primary fuel filter/water separator,

if

the fuel system contains one, and clean the separator sediment howl.

Change the fuel filter element on the engine and bleed the fuel system, as needed. Start the engine and
allow it to run for 5 -

10

minutes to make sure no air is left in the fuel system. Check for any leaks that

may have been created in the fuel system during this servicing, correcting them as needed.

Sea

Water

Circuit

Close the through-hull sea cock. Remove the raw water intake hose from the sea cock. Place the end

of

this hose into a 5-gallon bucket

of

clean fresh water. Before starting the engine, check the zinc anode

found in the primary heat exchanger on the engine and clean

or

replace

it

as required, and also clean any

zinc debris from inside the heat exchanger where the zinc anode

is

located. Clean the raw water strainer,

if

one is installed, in the inside

of

the hull.

Start the engine and allow the raw water pump

to

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

Start the engine and allow all

of

this mixture to be drawn through the raw water system. Once the bucket

is empty, stop the engine. This antifreeze

mil,:ture

should protect the raw water circuit from freezing

during the winter lay-up, as well as providing corrosion protection.

Remove the impeller from your raw water pump (some antifreeze mil,iure will accompany it, so catch it in
a bucket). Examine the impeller. Acquire a replacement,

if

needed, and a cover gasket. Do not replace

the impeller (into the pump) until recommissioning, but replace the cover and gasket.

Intake

Manifold

and

Through-Hull Exhaust

Place a clean cloth, lightly soaked in lubricating oil, in the opening

of

the intake manifold to block the

opening. Do not shove the cloth out

of

sight. (If it

is

not visible at recommissioning, and an attempt is

made to start the engine, you may need the assistance

of

a servicing dealer.) Make a note to remove the

cloth prior to start-up. The through-hull exhaust port can be blocked in the same manner.

Generator

End

Remove the louvered cover on the generator end. Check all wire connections on the AC terminal block
and those running to the capacitor(s) and the bridge rectifier making sure they are secure. Should these
connections appear corroded, they should be removed, cleaned, and reconnected. Make sure all AC leads
are properly cleaned and reconnected. Make sure all

AC

leads are properly supported and not chafing as

they exit the generator housing.

71

WESTERBEKE

GENERATORS

Starter

Motor

Lubrication and cleaning

of

the starter drive pinion is advisable,

if

access to the starter permits its easy

removal. Make sure the battery connections are shut off before attempting to remove the starter. Take

care in properly replacing any electrical connections removed from the starter.

Cylinder Lubrication

It

is not necessary to remove the fuel injectors from the cylinder head

to

squirt light lubricating oil into the

cylinders for the few months of normal lay-up. However,

if

you

anticipate a longer lay-up period (12

months or more),

we

recommended that this procedure be performed. The light oil in the cylinders will

prevent the piston rings from sticking to the cylinder walls. Make sure you have replacements for the

injector and return line sealing washers.

Spares

Lay-up time provides a good opportunity

to

inspect your Westerbeke engine to

see

if

external items such

as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on

hand, or replace those items used during the lay-up, such as filters and zinc anodes. Refer to the

"SPARE

PARTS"

section ofthis manual.

Batteries

If

batteries are

to

be

left on board during the lay-up period, make sure they are fully charged, and will

remain that way, to prevent them from freezing.

If

there exists

any

doubt that the batteries will not
remain fully charged, or that they will be subjected to severe environmental conditions, remove the
batteries and store them in a warmer, more compatible environment.

Recommissioning

The recommissioning

of

your Westerbeke engine after a seasonal lay-up generally follows the same

procedures as those presented in the

"PREPARATIONS FOR STARTING" section regarding preparation

for starting and normal starts. However, some of the lay-up procedures will need to be counteracted

before starting the engine.

l.

Remove the oil-soaked cloths from the intake manifold and from the through-hull exhaust port.

2.

Remove the raw water pump cover and gasket and discard the old gasket. Install the raw water pump

impeller removed during lay-up (or replacement,

if

required). Install the raw water pump cover with a

new cover gasket.

II

WARNING

II

Wear rubber gloves, a rubber apron, and

eye

protection when servicing batteries. Lead

acid batteries emit hydrogen, a highly-explosive gas, which can be ignited

by

electrical

arcing or a lighted cigarette, cigar, or

pipe.

Do not smoke or allow an open flame near

the battery being serviced.

Shut off all electrical equipment in the vicinity to prevent

electrical arcing during servicing.

WESTERBEKE

GENERATORS

72

3.

Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making
sure the terminals are clean and that the connections are tight. Check to make sure that the batteries are
fully-charged.

4.

Check the condition of the zinc anode in the raw water circuit and clean or replace the anode as
needed. Note that it is not necessary to flush the antifreeze/fresh water solution from the raw water
coolant system. When the engine is put into operation. the system will self-flush in a short period

of

time

with no adverse effects.

It

is

advisable to, as either an end

of

season or recommissioning service to inspect

the area that the zinc

is

located at in the heat exchanger and clear any and all zinc debris from that area.

5.

Start the engine in accordance with procedures in the "PREPARATIONS FOR STARTING"section of

this manual.

REMOTE

LUBE

OIL

FILTER

KIT

PN#040078

This kit allows

you

to remove the filter off the engine and with the mounting bracket contained in the kit,

mount the filter on an adjacent bulkhead for clean, easy servicing. Contact your local dealer for

information on purchasing this kit.

l..Ui..I!.II1!

'U

Til

R

Ii

,I, ElL!!.

GASKET

CQHI6CJS

BAse

73

'1.1!ll.01i..:.

.tiQIf

THe 1 oeAl!

Oil

Of

TU!

S

WIlliG

If

BEHoyED

fOp

lJi..S.IAI!AJ1QIi

,!,pr!

r

QJ!

TO

Q-R

IIIG

illlllf1i......l1..i..8.Ii......A£.ll

GASKET CONTACTS BASE

WESTERBEKE

GENERATORS

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES

Unless

stated

otherwise

for

a specific assembly. use

the

following

torque

values

when

tightening

standard

hardware.

Pitch lb-ft

kg-m

Grade 4

6nun bolt head/nut

1 2.9 -

5.1

0.4 - .07

8nun bolt head/nut

1.25 7.2 - 11.61.0 - 1.6

10

mm bolt head/nut

1.25 13.7 - 22.4

1.9 -

3.1

10

nun bolt head/nut

1.5

13.0-21.7

1.8 - 3.0

12

mm bolt head/nut

1.25

(ISO)

25.3 - 39.8

3.5 - 5.5

12

nun bolt head/nut

1.5

25.3 - 39.8 3.5 - 5.5

12

nun

bolt head/nut

1.75

21.7 - 36.2

3.0 - 5.0

13

mm bolt head/nut

1.5 32.5 - 50.6

4.5

-70

14

mm bolt head/nut

1.5 36.2 - 57.9

5.0 - 8.0

14

mm bolt head/nut

2 34.0 - 55.7

4.7

-7.7

16

mm bolt head/nut

1.5 54.2 - 79.6

7.5 - 11.0

16

nun bolt head/nut

2

51.4 - 76.7

7.1-10.6

Grade 6T

6mm bolt head/nut

1 4.3 - 6.5

0.6 - 0.9

8nun bolt head/nut

1.25 10.8 - 15.9

1.5 - 2.2

10

mm bolt head/nut

1.25

21.7 - 32.5

3.0 - 4.5

10

mm bolt head/nut

1.5

19.5 - 30.4

2.7 - 4.2

12

mm bolt head/nut

1.25

(ISO)

36.2 - 57.9

5.0 - 8.0

12

mm bolt head/nut

1.5

36.2 - 50.6

5.0 - 7.0

12

nun bolt head/nut

1.75 34.7 - 49.2

4.8 - 6.8

Grade 7T 8T and 8.8

6mm bolt head/nut

1 5.8 - 8.7

0.8 -

1.2

8mm bolt head/nut

1.25 14.5 - 21.7

2.0 - 3.0

10

nun

bolt head/nut

1.25

28.9 - 39.8

4.0 - 5.5

10

mm bolt head/nut

1.5

26.8 - 37.6

3.7 - 5.2

12

mm bolt head/nut

1.25

(ISO)

54.2 - 75.9 7.5 - 10.5

12

nun bolt head/nut

1.5 50.6 -65.1

7.0 - 9.0

12

nun bolt head/nut

1.75

43.4

-61.5

6.0 - 8.5

13

nun bolt head/nut

1.5

57.9 - 86.8

8.0 - 12.0

14

mm bolt head/nut

1.5

72. 3 - 108.5

10.0 - 15.0

14

mm

bolt

head/nut

2

68.7 - 101.3

9.5 - 14.0

16

mm bolt head/nut

1.5

108.5 - 166.4

15.0 - 23.0

16

rom

bolt head/nut

2

101.3 -

159.1

14.0 - 22.0

Grade 5 cap

screw

1/4 UNC

9 -

11

1.2-1.5

114

UNF

11-13

1.5

- 1.8

5116

UNC

18

- 20

2.5 - 2.8

5116

UNF

21

-23

2.9 - 3.2

3/8 UNC

28 -

33

3.7

-4.6

3/8 UNF

30 -

35

4.1-4.8

7/16 UNC

44 - 49

6.1

- 6.8

7116

UNF

50 -

55

6.9 - 7.6

112UNC

68

-73

9.4 -

10.1

112

UNF

73

- 80

1O.1-1l.l

WESTERBEKE GENERATORS

74

Socket Size

Cylinder head

bolt

M 10

(14mm)

54 - 61 7.5 - 8.5

M8(12mm)

14 - 22

2.0 -

3.0

Rocker shaft hold down bolts

M 8 (12 mm)

II

- 16

1.5

- 2.2

(See the "Torquing Cylinder Head Bolts" section

of

this manual.)

Crankshaft pulley nut

M 16

(24mm)

72.3 - 86.7

10-12

Connecting rod cap-nut

M8

(14 mm) 23 - 25 3.2 - 3.5

Oil

pan

drain plug

M18 36.2 - 43.4

5.0 -

6.0

(All models)

Oil

filter

8.0 - 9.4

1.1-1.3

(All models) (or tighten firmly by hand)

Delivery valve holder

M

16

(17 mm)

25.3 - 28.2

3.5 - 3.9

(Injection pump)(All models)

Injector nozzle mounting

M

20 (21 mm)

36.2 - 43.4

5.0 - 6.0

(All models)(To Engine)

Fuel solenoid locknut

M30

(36 mm) 28.9 - 36.2 4.0 - 5.0

Glow

plug

M

10

(12 mm)

10.8 - 14.5 1.5 -

2.0

(All models)

Injector spray pressure

140 ± 10/0 kglcm2 (1990 psi ± 140/0)

Cylinder compression pressure

28 kglm

2

at

280

rpm

(398 psi)

Tightening Torque for Common Bolts

and

Nuts

Designation

of

screw

Head

Mark

thread

4 7 10

M6

0.3 - 0.5

0.8 - 1.0 1.0 -

1.3

M8

1.0 -

1.3

1.5 - 2.2

2.5

-3.5

MIO

1.8-2.5

3.0 - 4.2

5.0

-7.0

M12

3.0

-4.2

5.5 - 7.5

9.5

- 12.0

M14 5.0

-7.0

8.0 - 11.0 16.0 - 19.0

NOTE: Convert

kg-m

to ft-lb by muluplymg by 7.233

75

WESTERBEKE GENERATORS

SPARE

PARTS

Since a possibility exists

in

which the engine may need to be serviced at sea

or

while

in

a port other

than

your home port, certain spare parts should

be

kept

on

board to help minimize delays

in

your voyage.

Please refer to your engine's Parts List for

part

numbers when ordering spare parts. Listed below are those

spare parts

that

should

be

carried

on

board at all times.

1.

An impeller kit.

2. A fuel system hardware kit.

3. A secondary fuel filter element.

4. A water

pump

belt.

5. Hose clamps.

6. A spare oil filter with a spare quart

of

diesel service engine oil along with a gallon

of

premixed

antifreeze.

7.

A few zinc anodes

and

heat exchanger end plate gaskets.

8.

An

oil pressure switch.

Other

parts (listed below), whose life expectancy cannot be accurately predetermined, should

be

carried

on

board (in addition to those listed above) especially

if

the vessel is to be taken

on

long ocean voyages.

I.

Fuel injectors.

2.

Glow plugs.

3.

Cooling system hoses.

4.

A starter.

5.

'A

20

amp

DC

circuit breaker.

6.

An

electric fuel pump.

7.

A sea water pump.

8. Battery terminal connectors.

9.

A fuel

run

solenoid.

The

spare parts listed directly above are those we recommel1d be carried

on

board

during

long ocean

voyages. You may wish to ask other boat owners who have similar crafts

and

who have completed long

ocean voyages

as

to what spare parts they carried on board

and

what parts were needed

at

specific times

on

the voyage. From

the

list provided directly above and from these inquiries, you

can

determine what

spare parts may be needed.

In

addition,

if

you are planning a long ocean voyage, consult your Westerbeke

dealer for a listing

of

the Westerbeke dealers located on your route.

WESTERBEKE GENERATORS

76

NOTES

77

WESTERBEKE GENERATORS

SOUND GUARD INSTALLATION INSTRUCTIONS

For a copy

of

the Sound Guard installation instructions required for your generator set, please contact your

local Westerbeke dealer. A four page installation brochure is available which covers all current Sound

Guard model assembly/installations.

WESTERBEKE GENERATORS

78

BTD 7.6

KW

POWER

TAKE-OFF

(PTO) ADAPTER

The generator housing

of

the

BID

7.6 KW is machined

to

accept the optional power take-off (PTO)

adapter kit #34786. This kit allows the user

to

mount and to operate a hydraulic pump (or similar device)

while the generator is operating.

The operator is advised that the generator's drive engine produces a specific horsepower at

1800 rpm

(continuous), 60 Hertz

(8

HP at 1500, 50 Hertz). This horsepower can be utilized either for generator

AC

output or to operate the PTO device. It cannot do both; that is, it cannot produce 7.6 KW

of

AC electrical

power and furnish horsepower

to

the PTO device, simultaneously.

When mounting a

PTO device using the optional adapter kit #34786, ensure good alignment

of

the device

to the spline coupling and ensure that

if

additional support is needed, it is added. When in doubt, provide

extra support.

o;;CNERATOR

HOUSINC

P.T.O.

ADAPTER

KIT

BPLXME COUPLXNC

AOAPTER

CAPSCRE;;W

(3)

LOCK

....

ACH£R

(3)

I;:TUO

(41

LOCKWAGHf;R

(4)

"UT

(4)

HYDRAULXC

PUMP

HYDI'IE:CO

:t22l.8A4B1R

,"'

__

",

...

TII_IlM_

(PUIroIP

SOURCE)

HVDJlECO

PUIoIPS

KALAMAZOO,

HICH.

(6:16)

349-1511

NOTE: Provisions should be made

to

prevent the PTO device from overloading the generator's engine.

Install a pressure relief valve

On

the hydraulic pump

to

limit maximum pumping pressure.

79

WESTERBEKE

GENERA

TORS