Westerbeke 8.0 BTD, 6.0 BTD, 8.8 BTD, 12.5 BTD, 9.4 BTD Operator's Manual

'

OPERATORS

MARINE

SINGLE

·

8.0

.DIESEL

•

60Hz_.6.0.

-t £ R

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}

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0 . q

litp"''

AND

THREE

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MANUAL

GENERATORS

PHASE

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BJD

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. PUBLICATION

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NO:

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5 - JULY 2018

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BTD

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Wf4STERSEKE

MYLES

STANDISH

WEBSITE:

WWW.WESTERBEKE.COM

CORPOIMTfON • 150

INDUSTRIAL

PAIJK • TAUNTON

JOHN

HANCOCK

MA

ROAD

02780

..

CALIFORNIA

PROPOSITION

·65

WARNING

Marine

exhaust

are

knovin

to

cause

and

other

Exhaust colorless unconsclousnll$$ exposure

•Dizziness

•

•Headache

•

gasses

gas.

can

Nausea

Weakness

and

contain

Carbon

and

Include:

Sleep/nBS$

diesel

and

gasoUn(t

and

some

of

to

the

State

cancer,

birth

reproductive

A

wARNING

Carbon

Monoxide

dealfl~

Symptoms

•

•·

•lfllfbility

engine

Its

constituents

of

California

defects,

harm.

Monoxide,

Is

poisonous

of

Throbbing

Muscular

Vomiting

to

an

odorless

and

Carbon.Monoxlde

In

Temples

'fiNitcbing

Think

and

can

cause

Coherently

IF

YOU

OR

ANJ'ONE

(JET

OUT

INTO

seek

medical

until

it

bas

A

WARNING should generator.

WESTERBEKE MONOXIDE are

Inexpensive

hardware·

DECAL

be

fixed

to a bulkhead

also

DETECTORS

and

store.

ELSE

THE

FRESH

'

attention.

been

inspected

Is

provided

recommends

near

the

easily

obtainable

EXPERIENC~JINY

AIR

IMM.

'EDIA.

Shut

down

and

repaired.

by

WESTERB£KE

near

your

engine

installing

engine

room.

at

OF

TELY.If

tile unit

CARBON

your

and

and or

They local

THESE

SYMPTOMS,

symptoms

dq

not

restart

persist,

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety manual carefully.

caused

by failure

precautions.

take

the

necessary

personne4

PREVENT

A.WARIINS:

11/lite

engine

,_,.I.Biflal

•

Do

not

enclosures

•

Shut

off electrical power before accessing electrical

equipment '

•

Use

insulated mats whenever working

equipment

•

Make

sure

(particularly shoes)

•

Remove electrical equipment.

PREVENT

A

WARNING:

exbaust

system

to

follow

/UUJW

when

dangerous

precautions

and

your

machinery.

ELECTRIC

i$mllllillg,

SHOCK

•

lllltiDul:b

rmttagels

operate

this

machi:nety

and

CO'VetS

your clothing and

when~

wristwatch and

BURNS-

HOT

Dllllllt,.

t:llllfiDIIIIII A fllllllillg

fut«/limental

iw

,_,at

in place;

hot!

• 'Monitor engine antifreeze coolant recovery tank and periodicaJly at

on the

water

location when

the engine

I

AwAIIIIIIIII:

• In

case

of

an engme overheat,

before touching the engine. or checldng the coolant·

jacketed

is

COLD.

___

Most

eonditions

to

protect)ourseff,

AC

elllt:ttit:al

whtilt

t:IJii1iel:tl1t

without electrical

skin

are

an

jewehy

ENG.

bOI

engine

coolant

level at the

exhaUst

.,.,_

allOw

accidents

rules

t11ese

t:tHaJt:tltiDsl.

on

electrical

dry,

electrical equipment.

when

parts

fiii!J/De

the

manifold, hilt only

tb.e

erigine

are

and

exist

and

your

t:III8Cfi1Rls

ttJ

$htJte

not

damp

working on

Ill

gets

very

plastic

filler cap

to

cool

PREVENT

• Prevent

sparks pump, vapors.

removing

•

Do

Backfire can cause severe injuty or death.

•

Do

the

engine/generator clean chances of

• Be aware-diesel fuel

·

PREVENT

A

I

_ ill/lilt

• Follow re·fuclmg safety instructions. Keep the vessel's

batches

after fueling. Check below for fumes/vapor before

running

prior vessel

•

All

when

ventilated

and out

•

Do

• Shut off the fuel service valve at the fuel system. spill. DO

sources

servicing. the fuel system. ·

•

Do

•

Be

• Be certain fuel·line fittings

• Make

BURNS-

flash

to

occur

or other potential sources of spilled fuel or

Use a suitable container

tb.e

not operate

not

smoke

fuel system.

fire.

BURNS-

WAIIIIIIIG:

or

tlealb!

closed

tb.e

blower.

to starting, following the

builder.

fuel

vapors

handling

area

of

tb.e

not fill the fuel tank(s) while the engine is running.

NOf

of

fire

Ensure

not alter or modify the fuel

sure

an

fuel

free ofleaks. ·

sure

a

fire

properly maintained. Be familiar with its Extinguishers for

an

applications encountered in this

FIRE

fires.

Do

not smoke or permit

near

tb.e

carburetor,

fuel line, carburetor,

With

the air

cleaner/sUencer

or

permit

flames

Keep

the compartment

and

free

Wipe

up

an

spilled

Will

burn.

EXPLOSION

--.

when

are

highly

and

away

reach

'Thke

allow any smoking,

near

the

proper

supplies

extinguisher

rated

from

fueling.

Run

~g

from

of

ABC by the

Open

the

engine

rec()1TIJ'Tleililatiin

explosive.

fuels. Store fuel in a well-

spark-prQducing

children. ·

care in·catcbing

fuel

system

ventilation

sys•

have a

are

is

:ftam.es

fuel

line,

filter,

to

catch

all fuel

oi:

fuel

filters.

removed.

or

sparks

to

occur

and

the

of

debris to mininri1.e

fuel

and

engine

fuel

vapiiiS.

t:a11

and ventilate cabin

compartment blower

Use extreme care

equipment

the

engine when servicing

any

fuel that might

open

flames,

or

engine

when

exists

when

posi~ve

adequately tightened

installed

NFPA

shutoff

nea.tby

proper

are

appropriate

environment.

or

fuel

when

near

cause

of the

or

··

serVicing

valve.

and

use.

the

oiL

other

and

is

·

1-w'IWEBTERBEKE

l Engines & Generators

i

•'

.

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

11

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

last.

11

Make certain all personnel are clear of the engine before

starting.

11

Make certain all re-installed before starting the engine.

BAmRY

A

WARNING:

or

death!

11

Do not smoke being serviced. Lead acid batteries emit highly explosive arcing or by lit tobacco products. equipment dming servicing.

11

Never connect the negative positive ( +) connection terminal of the starter

Do

not test the battery condition by shorting the tenmnals together. Ventilate any compartment containing batteries accumulation disturb the battery charger connections while the battery

is being charged.

11

Avoid burns or wristwatch, rings, the battery.

11

Always turn the battery charger off before disconnecting the battery connections. Remove the negative lead and reconnect

BATTERY

A

WARNING:

severe

11

When servicing the battery

level wear rubber gloves, a rubber apron, pron;;ction. destructive.

it off

into

the

caps.

STARTING

Accidental

the

covers,

starting

negative lead first and reconnect

guards,

can

and

hatches are

cause

injury

EXPLOSION

Battery

or

in the vicinity to prevent electrical arcing

Sparks could ignite battery gases or fuel vapors.

of

contacting

sparks that could cause

it

explosion

allow

an open

gas,

which can be ignited

explosive gases.

the

tenninals with tools, etc.,

and any

last when servicing the battery.

can

cause

injury

flame

near the battery

hydrogcm,

by

Shut off all electrical

(-)

battery

cable to the

solenoi~

To

avoid sparks, do not

an

explosion. Remove

other jewelry before handling

electrical

to

ACID

Sulfuric

injury

or

death!

Batteries contain

If

it

at

once with eyes inadvertently when removing electrolyte

acid

in

batteries

or

checking the electrolyte

sulfuri~

comes in contact

water.

Acid

may

can

cause

and eye

acid

wbic~

With

your skin, wash

splash on the skin or

to

a

prevent

first

is

TOXIC

11

. A

11

II

11

AVOID

11

EXHAUST

A

WARNING:

Ensure that the exhaust system is adequate to expel

discharged from the engine. Check

regularly for leaks and

water-injected elbow

Be sure the unit and its surroundings are well ventilated.

Run

blowers when running the generator set

Do not

run

equipped with a functioning marine carbon monoxide detector that complies with ABYC A-24. Consult your

boat builder or dealer for installation of approved

detectors.

For additional information, refer to ABYC 1H-22

(educational information on Carbon Monoxide).

WARNING:

odorless

nausea

gas.

or

death!

Do

not use copper tubing in diesel exhaust systems.

Diesel fumes

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

Do

not install exhaust outlet where

through portholes, vents, or

exhaust discharge outlet is near the waterline, water could

enter the exhaust discharge outlet and close or restrict the flow

of

exhaust:

Although diesel engine exhaust fumes from gasoline engines, carbon monoxide gas

is

present in diesel exhaust fumes. Some

symptoms or signs of carbon monoxide inhalation or poisoning

Vomiting Dizziness Headache Nausea Weakness and sleepiness

MOVING

A

WARNING:

or

death!

Do not service the engine while situation arises make operating adjustments, touching moving parts and hot exhaust system components.

GASES

Carbon

the generator set or engine unless

Inhalation

can rapidly

Exhaust sulfur causes rapid deterioration

are:

monoxide

make

is

securely attached. ·

carbon

monoxide produces

destroy

Avoid

overloading the craft.

exhaust

Inability to Throbbing

. Muscular twitching

(CD)

the

sure

the

(CD)

flu-like

copper

emanst

air

conditioners.

gases

think

in temples

is a deadly

exhaust system

exhaust manifold/

or

engine.

the

is

an

invisible

symptoms,

tubing

in

can be

If

the

are not as toxic

of

the

coherently

PARTS

Rotating

in which it is absolutely necessary to

parts

use

can

cause

it

is running.

extreme care

injury

If

to

boat

a

gas!

ga8es

is

exhaust

of

<kawn

engine

as

avoid

Engines & Generators

ii

• Do

not

wear loose clotbing or

equipment;

rings,

moving

• Make sure all

Keep places

• Do not check

the

engine

•

Stay

when

be

~ught

HAZARDOUS

A

WARNI.

I

.

IIISS!

• ·

Never

• Do not run an

removed.

A

WARNING:

IIIINifally

OPERATORS

Many

of

in

your Operators

notes to highlight critical information.

carefiill.y,

procedures.

avoid

wearing

necklaces

parts. ' ..

protective

at

clear

the engine

or bracelets that

attaching

shields

all

times.

fluid

levels

is operating.

of

the

drive

shaft and the transmission

is

running;

in these rotating parts.

NOISE

NG:

lligb

lltlise

operate

111

phpit:aiJy

an

engine without

engine

with the air intake (silencer)

liD""' wmi'llll

i11capat;/tatBII

MANUAL

the

preceding

maintain

safety tips

Manuai

your

equipment,

jewe]ry

loose

hardware is properly

and

guards

or the

drive

hair and clothing can easily

levels t:all t:allSB

mat:hillett

and

along with

SAFETY

when servicing

jackets~

and

shirts,

could

be caught in

in

their respective

belt's tension

.

itS

nmffler

installed.

..

by

fatigue/

warnings

other

cautions

Read

your

follow all safety

sleeves,

tightened.

hearbig

are~

manual

INSTRUCTIONS

while

coupling

,

atB

and

ABYC,

INSTALUNG

Read

for

tions ABYC

"Safety Standards

Order

A_BYC

'613

Annapolis.

(410)

www.abycinc.org. NFPA

''Fire Protection Standard for Motor Craft"

Order

NFPA

lB~Park:

P.O.

·

Quincy,

USCG (United States

"CFR

Code

Order

U.S.

WashingtoJt.

NFPA

the

following

safety

Codes

when

installing your

(American Boat

from;

ThirdDtreet, Suite

MD 21403

990-4460

(National FJie

From:

Box

9101

MA

33

AND

of

Federal

From:

Government Printing Office

AND

.USCG

MARINE

and

()2269.:.9101

CFR46"

Regtilations

D.C. 20404

ENGINES

ABYC,

standards.

and

for Small Craft"

10

Protection

Coast

PUBUCADO.

AID

GENERATORS

NFPA

and

USCG

Follow

UNIVERSAL

Yacht

Guard)

their

engine

Council)

Association)

FOR

publications

recommenda-

ENGINE

Preparations

ough examination

(ABYC) sources including the USCG

Sections

All

Regulations (FCR).

AND

GENERATOR

to

install

standards.

of

the

ABYC

H-32Ventilati.on H-33

Diesel

P-1

Instal1atiion

and

Auxilliary

P-4

Marine

E-ll

AC & DC

TA Batteries

installations

must comply with the Federal Code of

an

engine.should begin with a

of

the American Boat and

These

standards

standards of particular interest

for boats

Fuel

Systems

of

Exhaust

Engines

Inboard

Elec1rlcal

and

Battery

Engines

INSTALLAnONS

Yacht

Council's

are

a combination of

and

the NFPA

using

diesel fuel

Systems

and

Systems on Boats

Chargers

for

Propulsion

Transmissions

thor-

are:

j...,.,.IWESTERBEKE

f Engines & Generators

iii

When

iilstalling

attention·

WEST.BRBEKE

be

paid

to

the

following

INSTALLATION

engines

information:

and

generators

· ·

it

is

important

that

strict

CODES

· S~ when

AND·-ULATIONS

federal

reguiations,

installing

engines

ABYC

and

SIPHON-BREAK

For

installations

or

-Will

be

break

in

minimum

the

ex1uzust

raw

water damage

If

you

have

to

the

vessel's

rtphon..bretilc.

NO'I'E:

A.

operation.

engine

dimiilge~'

EXHAUST-SYSTEM

The

exhaust'

Exhaust~

and-~

and

toms.

system

MU$'1'·

under

any

where

the~

beloW

die

·v-essers

the

raw

water

supply

of

20''

abo'Ve

the

manifr!ld injection port

to

tk;e

~anti

~y

doubt

about

waterline

· · · · ·

sq,hoti-b~k

Failure_

CiJMiift

under

reqili.rns

tp_properly_

the

...

system's

without

In

tbis

sea

hase

is

recommended..

the

need

~~

a

single

be

designed·to

conditions·

aixl

.

guid8nnes,

generators

manifold/water

waterlirie,

hose

to

the

vessel's

water~

is

pQssibk

the

position

the

~·s

Periofl!.c

mabitain

sijihmi-break

MUS'J;

be

certified

The

use

of

additional

lengtb

prevent

at

-any

the

angle

and

sa.fety

codes

in a

marine

environment.'

inject.Cd

proViSiOnS

exhaust

lit

or

of the

flwJection

a

siphon-break

manufacturer

of

fitting

of

.entry

iniist

~

elbow.

This

Failare to

below

jl.ooding.

water

various

use a Biphon-bretilc

the 'to¢

of

the

..

injected

operating

and

cleaning

can

for

marine

use.

this

tYPe

of

hose

and.

clamps to

corrugated~

of

waterlnto the

of

vessels

heel.

ml¥Jt

be

cornpU~

exhaust

maae

waterline

'io

hose

elb9w

is

'llisfiill a

must

be

will

resrilt in

!Joat.

exhaust

conditi~

result proper

Conugated

allows for

accomplish

hose

elbow

inBtall

to

ensure

p10per

in

catastrophic

riuiintenance.

Marine

eXtreme

these beMs .

can

be

used

exhaust

system

with

close

to

'SipliOii-

looped

when

~ve

a

bends

The

a

AVAILAB~FROM

:aWES'IEM.EKE

SIPHON-BJ:iEAK

LOOP'

WITH

STAiNLESS

A

detailed

engines

to

download

Marlne.lnstallatiiJD

and

Manual

generators,

frail

oar

wibsite

Is

supplied

at

v.ritb

\VViW.westerbeke.com.

IW'IWESTERBEKE

l Engines & Generators

iv

covering

each

gBSQiine

unit A pdf

and

diesel,

is

available

·

TABLE

Parts

Identification

Introduction

Diesel Generator

Preparations

Safety

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

Fuel,

Engine

Control

for

Shutdown Starting/Stopping Generator

Break-In

Maintenance

Cooling

Air Fuel

Engine

DC Starter

Engine

Valve

System

Raw Water

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

Heat Exchanger .......................................... .14

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

Zinc Anode .................................................. 16

Intake

Fuel Filters ...................................................

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

Silencer

System

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

Lubricating

Oil Change ................................................... 19

Oil Pressure ................................................. 19

Electrical

Alternator .....................................................

Motor

Testing .................. , ...................................... 22

Disassembly ................................................. 23

Adjustments

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

Injector ......................................................... 24

Throttle Control/Generator Frequency ........ 25

Drive Belt Adjustment.. ............................... 25

Clearance

11.0 BTD and 12.5 BTD(A) ........................ 26

8.0 and 10.0

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

Oil

and

.Panels

Initial

Switches

Procedure

Schedule

Engine

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

Start-Up

and

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

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

Coolant.

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

Sensors

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

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

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

Pumps .......................................

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

Oil

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

System

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

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

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

and

Timing

BTD

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

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

OF

CONTENTS

.2

3

......

5 10.0 Kw

6 11.0 Kw

7 12.5 Kw BTD(A) ......................................... 34

8 9

.1

o

11

13

14 14

15

16

17

17 18 19

20 20 22

24

26

Specifications

8.0 Kw

BT

Generator 6 and

Voltage Regulator ........................................ 38

BT

Troubleshooting Chart ........................... 38

Internal

Resistance Values ........................................ 39

Generator

No

Load .......................................................

Full Load .....................................................

Generator Frequency ..................................

6 Stud

Internal

Resistance Values ....................................... .42

Internal

3

Phase,

AC

Voltage

Shore

w ..

Power

o·

1nng

#34651 - 8 #36412#36412#36412 #36412 #41479-

#41479 #43853#43853 #43944#43944

Remote Power Lay-Up

Take

and

Suggested

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

BTD

................................................ 28

BTD

.............................................. 30

BTD

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

12

Stud

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

Wiring

sagrams

Oil

Schematic

Voltage

AC

Adjustment

Connections ..............................

Schematic

(12

Stud)

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

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

(&Stud)

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

Diagram

12

Wire,

Connections

Reconnectable

Transfer

Switch

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

BE 3 Phase

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

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

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

BT

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

No Relays ..................................... 47

Schematic No Relays ................... 48

-Two

- Schematic Two Relays ................. 50

- Schematic .....................................

-Schematic

-

Fill Recommissioning

Spare

Relays .................................. .49

BTD

and BTD(A) .......................

BTD and BTDA ........................... 53

..................................... 54

BTDA Diagram ............................ 55

BTDA

Schematic ......................... 56

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

Off

System

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

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

Parts

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

.

37

.39

.40

40

40 .41 .41 .42

.43

44

.45

.

46

.51

52

57 58 59 61

Engines & Generators

1

·

PARTS

IDE.NTIFIC.ATIO

N.

/ALL

MODELS

The Control Panel faces aft on some of these models

_with the .emergency Stop

Swi~ch

on the back .

CONTRO

L

PANEL

.

OIL Fi

ll

AC

CONNECTION

OUTLET

DRIVE

BEl

COVER

REA

R

THERMOSTA

Ti

ASSEMBLY

RAW

WATER

PUMP

FRONT

RIGHT

SIDE

MANIFOLD

PRESSURE

CAP

COOLANT

FILL

,_

,-~ _

OIL

SUMP

2

AIR

INTAKE

SILENCER

-

DC

ALTERNAT

OR

FUEL-RUN

SOLENOID

OIL

PRESSURE

SWITCH

OIL

DRAIN

HOSE

FRONT

GENERATOR

EMERGENCY

STOP

SWITCH

ART

SOLENOID

This

WESTERBEKE WESTERBEKE's technology. dependable

Thank

In

order

is

important manual manual throughout. your

This

is

an Manual ordered Dealer

We performance

you

for

to

get

that

is

designed

carefully

Should

nearest

WESTERBEK;E

is

your

operators

Installation

is

available

in

book

WARRANTY

Your

WESTERBEKE

product

documentation Registration Corporation register Customer registering. your

date

Customer

Card or

your

products

Identification

If

'you

product

available.

model

Identification

Diesel

Generator

long

years

of

take

great

pride

of our

engines

selecting the

WESTERBEKE.

full

use

and

benefit from your

you

operate

and

to

help

you

do

and

observe

your

Manual

in

fonn

from a WESTERBEKEIUNIVERSAL

generator

manual.

and

Parts

pdf form

all

dealer for

Along

on

is

experience

in

the

superior durability

and

maintain

this.

Please~

the

safety

require

assistance.

wi~

Information. A Serv1ce

our

website

PROCEDURES

go

Warranty

you

can

to

our

warranty

do

not,

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package.

card

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out

and

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website:~.westerbeke.com

on

line.

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in

the

mail

within

please

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the

serial

number

Card

I.....,.IWESTERSEKE

J Engines & Generators

Customer

MR.

MAIN

HOMETOWN,

Model

Expires

NOTES,

As maintenance engine, CAUTIONS,

NOTE:

A

observed,

your

Identification

GENERATOR

STREET

______

USA

_____

CAUTIONS

this

manual

An

takes

schedules,

critical.infonnation

and

operating

CAUTION:

can

result

engine.

OWNER

_

AND

WARNIN~S

you

through

and

troubleshooting

will

WARNINGS.

procedure

Procedures,

In

the

essential

damage

Serial#

the

operating

be

highlighted

An

explanation

which

or

____

to

if

not strictly

destruction

INTRODUCTION

a product of

and

advanced

generators.

generator

it

correctly.

re8.d

this

precautions

servicing,

this

is

included

Warranty

to

should

factory

and

of

note.

contact

manual,

or

can

Westerbeke

rece1ve

60

days

and

in

service

procedures,

your

marine

by

NOTES,

follows:

of

This

.there

be

in

~d

of

have

_

and

the

·

it

.

a

PRODUCT

Pioduct brochures WESTERBEKE

WESTERBEKE

CONTENT WARRANTIES THEREJ'O, COMPLETENESS

BE

UABLE

iNCURRED

.

OF

THE

WESTERBEKE time software WESTERBEKE provided WESTERl3EKE be

relied

the

respective

but

is WESTER.BEKE to

determine

product

SOFTWARE

software,

FURNISHING

span

between

and

with

upon·

imperative

software being consulted

(tech

and

catalogs),

are not

CANNOT

OF

SUCH

OR

REPRESENTATIONS

INCLUDING

THEREOF

FOR

ANY

IN

CONNECTION

customers

printings of

the

l.inavoidable manuals.

WESTERBEKE

or other suppliers,

exclusfvely

product.

the

It

that appropriate or

the

accuracy

data,

provided within

SOFIWARE,

TYPE

OR

not qnly

supplier

paltS,

lists,

manuals,

from

sources

WESTERBEKE's

BE

RESPONSIBLE

MAKES

WITH

ACCURACY;

AND

OF

USE

should

WESTERBEKE

existence

In

summation,

products, whether

as

the

and currentness of

TIMEliNESS

WIU

IN

DAMAGE

WITH

OR

ARISING

OF

SUCH

also

keep

of

earlier

product

must

not

definitive

makes

representatives

in

questi,on

by

good

the

customer.

authority

other

than

control.

FOR

THE

NO

RESPECI'

NO

EVENT

OR

INJURY

OUT

SOFIWARE.

in

mind

the

product

·

software

from

and

cannot

on

sense

of .

be

consulted

the

. ·

OR

.

PROTECTING.Y~UR.INVESTMENT

Care

at

'f:4e

factory

during assembly and

have

resiuted maiJy manufiicturer

install~·

operaftd

buyer/owner.:.Operator.

NOTE:

•

Proper

• An efficient ananf:t.siphon

engine.

w

Changing

mainte~UZ'nce

•

Proper

n.eitts

manuaL

a

Use

•·

Wmterize

Recommis~rtin~'

in a WESTERBEKE

thousands of hours of dependable

cannot

control how or where the

in the vessel

'and

serviced

SiX

imp~'(tant

engine

or

in

steps

and

generator

·

the mannerin

the

well-designt!fd

breafc

to prevent waterfrom

· .

the

engine oil and

sclledule.

maintettillibe

i:Zecording

to

of

the

· · ·

cledli;:filter{!d

your engine

#2 dieaelfnet.

ticcoramg

section

field.

to

ensure

ex1uiust

oil

all

engine and

m.ai:tttenance

in

~orough

generat9r

This

long

instDllaiion

capable

~ervice;

which

is

up

to

generator

and.

systt!fm

fi1ters1

(lCcording

generator

schedule

to

the

~'LD.y·tzp

this

manual.

testing

However

generator

the

unit

the

life:

alignment.

that

includes

entering

in

this

atul

of

the

is

the

..

io

tlie

colf!.PO•

A

WARNING:

followed,

can

result

Procedures,

in

personal

which

injury

if

not

or

loss

properly

of

life.

Engines & Generators

3

INTRODUCTION

SERIAL

The

nameplate

a eJiliaust

The the the

~tion

NUMBER

engine's

engine's serial number

engine

side

below

model

mounted

manifold.

block

oil

flU

opening. Take time

on

the

LOCATION

and

serial number are lqcated. on

on

the side ofthe water jacketed

is

also found stamped

on

a flat surface just above the

to

enter this infonn-

illustrated nameplate.

in

NOTE:

A

carbon

monoxide

by

WESTSRBEKE.

engine

room.

UNDERSTANDING

The

diesel

engine closely resembles

since

the

mechanism

are

arranged

the

same diesel cbnnecting

Therefore, same most important factors maintenance Replacement time

periods contanlination (that is, system of

the

designed The diesel engine does differ fromthe gasoline

however, carburetor their

place which

above a closed

general

type

engine

has

the

rods

and lubricating

to

a great extent, a diesel engine

preventive

is

same

performs

maintenance

of

the

of fuel and lubricating

specifi~d

also

essential.

brand

of

specifically

in

its

methodof.han.~g

and

ignition systems

is

a single component-

the

warning

Affix

this

decal

THE

DIESEL

is

essentially the same

crankcase; the crankshaft

as

that of a gasoline

same

types

of valves,

system.

as

a gasoline

are

proper ventilation

fuel,

·lubricating

is a

must,

and frequent

water,

sediment, etc.) in

Another important

high

detergent

for

diesel

engines.

ttre

function of

both.

decal

has

in a visible

ENGINE

the

gasoline

..

The

engine;

camshaft,

requires

engine.

and

arid

cooling

filter

elements at

factor

diesel

lubrication

and

firing

done

away

the

fuel

injection

been

provided

position

engine,

cylinders

and

the

The

proper

systems.

checking

the

fuel

is

the

engine,

of

fuel.

with

and

pump

in

the

is

of

the

pistons,

the

for

use

oil

The

in

-

An

identification

displays

CARBON

WES1ERBEKE detector even

The from elbow/exhaust entering

If air

the

engine

MONOXIDE

in

the

vessels

in small amounts,

presence

the

carbon

and

engine·

your

monoxide

correct

of

hose,

boat.

the

plate

on

the

model

and

DETECTOR

recommends

living

is

carbon

monoxide

or

generator

or

the

is

present,

problem

top

of the engine

serial

number.

mounting

quarters.

deadly.

or

fumes

immediately!

Carbon

indicates

from

the

from

.

ventilate the

a carbon

an

exhaust

a nearby

area

air

intake

also

monoxide

mono:xide,

exhaust leak

vessel

are

with

clean

ORDERING

Whenever provide and

generator serial number black provide your description separately furnished Parts WESTERBEKE parts original

SPARES

Certain spares WESTERBEKE dealer See

the

Generator

INSTALLATION

The

Westerbeke

supplied

PARTS

replacement/service parts

the

generator

name

plate located

us

with

generator set.

and

are

frequently

equipment.

AND

will

assist you in preparing

SPARE

Accessories,

. . .

model

this

information so

In

addition,

part number for each part

packaged parts because will

not made

ACCESSORIES

will

be

needed

generator.

PARTS

page in this

MANUAL

Installation

with

this

unit.

see the

number,

as

they

appear on

on

the generator

we

include a complete

List).

Also insist

to

the

same

to

support

Your

local WES'IERBEKE

an

manual.

ACCESSORIES

Manual

are

needed,

engine serial

rnay

and

inventory of spare

publication

always

number,

the

silver

end.

You

must

properly

part

needed

(see

upon

fit

or

generic

specifications

maintain

For

Engine

brochure.

#043268

GENERATOR 10

and

identify

the

as

your

parts.

and

is

DECAL

Engines&. Generators

4

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a diesel SAE J 313

dies~!

Care

Use

in dirt secondary is fuel improper the following

Purchase a well-known combat mended

'Klee~1

diesel

Install fiHeriwater

The such

ENGINE

Use a good brand of engine oil, with and

manual. Change the engine oil and oil hours of engine break-in operation and of

Westerbeke Corporation does not the use of synthetic

break-in

change intervals must

SCHEDULE

if

NOTE:

statements regarding synthetic

FUEL

fuel

that

meets

the

requirements

and

fuel

Of

The

only

clean

your

engines

particles

important

can

be

storage

tank

for

practice

BACTERIAL

such

+

Cetane

fuel

and

Raycor

filters. A 10

has a Cetane

according

Fuel

diesel

fuel

which

filters

can

to

buy

rendered

facilities.

your

engine's

as

Bio-Bor

Boost

when

an

regularly

separator

500

MA

micron

injection

might

clean

is

Ultra

service a good,

rating of

to

ASTM

0975.

Supply

fuel!

The

clearance

pump

pass

through

damage

unsatisfactory

advisable:

between

or

fuel,

To

daily

brand

growth

and

to

help

Low

230

filter

these

and assure

use

of

fuel.

on

an

additive

restore

Sulfur

the

RMAM

element

the

OIL

SAE

as

stated in the

operation thereafter.

must be performed using conventional

section

synthetic oil is

The

infonnation above supersedes all previous

SPECIFICATIONS

oil.

If

synthetic oil

be

as

of

this manual and not

used.

listed

oil.

#45

is

finely

keep

by

that

is

clean

The

fuel

diesel

visual-type

fuel

are

approve

in

of

No.

2-D

or

higher

grade

of

the

components

very

critical;

invisible

the

primary

machined

it

clean.

careless

the

use

tank

such

lubricity

tank

and

.good

is

recommended.

an

API

filter

then

is

used,

the

MAINTENANCE

and parts.

The

best

handling

fuel

going

and

pure,

the

of

additives

is

recqm-

as

Diesel

back

intO

is

being

used.

fuel

the

engine.

examples

classification

section of this

after the initial 50

every

100

or

disapprove of

engine

oil.

Oil

to

be extended

of

It

or

into

to

the

of

hours

ENGINE

WESTERBEKE

and

chemicals The

run engine circuit antifreeze (SCAs) to

The being

NOTE:

antifreeze

PURCHASING

Select a brand Antifreeze additive cylinder brands. engines. mixture needed. MAINTENANCE

COOLANT

50%

distilled

that

antifreeze

at

proper

to

the

from

that

long

term

distilled

poured

Look

that

speci11~d

to

protect

walls.

that

offer

Select will Change

recommends a mixture

water.

Distilled

can

corrode

performs

temperatures

coolant,

rust

contains

keep

protection.

water

into

for

the

is

double

and

corrosion.

Supplemental

the

antifreeze

and

antifreeze

the

cooling

new

environmentally-friendly

1ww

available.

ANTIFREEZE

of

antifreeze

for

diesel

against

Prestone

the

always

·and

antifreeze

pre-mixed

be

added

the

antifreeze

SCHEDULE

MAINTENANCE

Change number protect

COOLANT

TI1e contraction without provided water operating

the

engine

of

operating

and

lubricate

RECOVERY

coolant

recovery

of

the

introducing

with

fresh

coolant

conversion

the

engine.

coolant

hours the

allows

engines

air

into

water

engine

kit

water

internal

duty.

by

transferring

lubricates

Look chemically

should

circuit.

specified

engines

cavitation

Zerex

specifically

variety to

the

mixture

in

every

five

as

the

chemical

have a limited

TANK

for

the

coolant

the

system.

cooled

models

and

must

of

50%

is

free

engine

surfaces.

It

allows

heat

and

protects

for a good

Cooling

balanced,

be

premixed

for

diesel

contains a special

erosion

'of

are

two

nationally

for

use

in

so that

the

cooling

system

according

this

manual.

years

regardless

additives

expansion

during

engine

This·recovery

and

with

be

installed

antifreeze

from

the

engine

away

from

the

cooling

quality

Additives

crucial

before

long

lasting

engines. the

engine's

known

(fiesel

cO!TeC:t

when

to

the

of

that

life.

and

operation

tank

the

fresh

before

to

the

'

the

is

NOTE:

T7lis

located

at

can

be

located

particular

Engines & Generators

5

tank,

with

or

above

the

below

installation

its

sh01t

level

the

level

makes

of

this

run

the

of

plastic

engine's

the

engine's

necessary.

hose,

is

manifold,

manifold

best

but

if

it

the

GENERATOR

CONTROL

PANELS

DESCRIPTION

Thls

manually

diesel

generators

engine

control

All

three

following

PREHEAT:

preheating bypassing turns

on

the excitation. When

the

·panel

lights,

activate.

START:

The energizes While

the

START

switch

begins

to PREHEAt pressure

reaches 5 -

STOPPING:

switch a

switches to the nates this engine.

To

stop the engine, simply depress the STOPswitch. The

DC

path

the

relay should be held depressed until completely.

NOTE:

When

gauge

and

last

temperature

will

retwn

OF

SWITCHES

controlled

is

panel

switches are momentary contact type

functions:

TI1e

PREHEAT

the

engine

the

engine

fuel

solenoid

PREHEAT

gauges

START

the

starter solenoid and activates the starter

PREHEAT

engages·

fire,

the

switch

The STOP toggle switch is a nonnally closed

DC

path through the three automatic shutdown

K2

DC

path to the

to

the

K2

and

the engine shuts

the

engine

the

oil

and oil press

to

zero

,series

of WES1ERBEKE marine

equipped with toggle switches

and,

optionally, at remote

toggle switch serves two purposes:

for

easy starting and defeating of

oil

pressure switch. The defeat function

..

instrument power

switch

is

depressed,

and

meters

and

fuel solenoid

toggle switch closes the

switch

is

still depressed, depressing

the start solenoid. When.the engine

START

pressure

switch should be released. The .

should

not

be released until

10

psi.

run relay. Opening this switch termi-

K2

run relay shutting

run relay is terminated, de-energizing

down.

The STOP switch

the

generator shuts

is

shut

down,

the water temperature

gauge will continue

we

readings displayed.

once

electrical power

and

the

Kl

is

restored.

panels. and

alternator

voltmeter,

will

relay that

the

down

to

on

the

serve

..

oil

the

down

register

They

the

EMERGENCY

stop switch is

normally closed.

will

open the panel and shut the engine down. switch is not toggled petforming maintenance.

DESCRIPTION

Coolant

Engine coolant (water) temperature should normally

175°

to

Engine

Oil pressure (psi) load but should

DC

Voltmeter

Indicates the amount

13.5V

STOP:

on

the

DC

circuit

OF

Temperature

195° F (80°

Oil

Pressure

may

range between between 30

to

14.4V.

The EMERGENCY.

side of

the

control

box.

When

depressed, it

to

the

control

As

~he

it

can

be

used

when

GAUGES

to

90°

C).

fluctuate depending

the

battery is being charged should

.

on to

the

60

psi.

Hourmeter

Registers elapsed time and is used petform scheduled maintenance.

REMOTE

For remote operation of switches are connected serve the same functions switch serves

WIRING

PANEL

used.

The PREHEAT

in

parallel

is

in

series with

the

same function. There

DIAGRAM

with

in

the

the gauge panel's switches

as

the

this

as

a guide for

generator system,

and

START

in

the

gauge panel.

gauge panel's STOP switch

is

a REMOTE

manual.

when

the

same

switches The

START/STOP

GENERATOR

:J%

~l~

RELEASE STARTER

::

PREHEAT

•

MUST

PRESS.

1ST.

-

tO

e

·wESTERBEKE.

NOTE:

For

additional information STARTING/STOPPING PROCEDURE, DC DIAGRAMS and TROUBLESHOOTING

ty

.

STOP

START

~').

(

,f~~

on

Control

PRESS

2ND

,

.....

,:

Panels.

WIRING

GAUGES.

indicate

generator

show

to

three

are

and

STOP

and

Refer

to:

£Engines

6

& Generators

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

This section of

ration,initial starting, break-in, starting stopping procedures.

the

conditions indicated

will

set Before starting your generator set

prolonged layoff, check

0 Check the engine

at

0 Check the

tor bowls·for contaminants.

INSPECTION

the

manual

provides the operator

Follow

and

your

give reliable performance

the

following

oil

level.

the high mark

on

the dipstick.

fuel

supply and examine

(warm

the procedures

WESTERBEKE

and

long

for

the

first

items:

Add oil

to

the

0 Check the DC electrical system. Inspect

and

battery cable connections. Make certain the(+) tery cable is connected negative (-) cable is connected

the

coolant

the

manifold.

is

(this location

0 Check

and

at

0 Visually examine

parts, disconnected threaded connections.

0 Check load

the

wiring diagrams.

leads

0 Examine air inlet 0 Be sure

to

0

Be

the system requires, connected 3-phase systems ply

loads.

no

other generator or utility power

load lines.

sure that

neutral is properly grounded (or

the

in

power systems

to

the

wrong

line-to"neutral voltage

0 Make sure the mounting installation

0 Make sure that

the

to.

the starter

tagged).

level

in

both

the

unit.

Look

wires,

unattached

for

correct connection

and

outlet

and

that the generator

load neutral.

an

incomplete or

generator

solenoid

to

the

plastic

for

loose or

for

air

flow

with a neutral

ungrounded)

In

single

open

on

is

properly

hoses,

with

or

cold)

as

presented

service

time

maintain

fuel

filter/separa-

wire

connections

and-the

engine

ground

recovery

missing

and

as

specified

obstructions.

is

connected

line

neutral

phase

and

neutral

unbalanced

secure.

grounded.

prepa-

and

for generator life.

or

after a

the

level

bat-

stud

tank

check

in

that

as

the

is

properly

some

can

sup-

A

CAUTION:

recommended

be

switched

and,

in

cold

will

prevent

of

the

AC

When

that

all

OFF

until climates, damage

machinery

starting

AC

loads,

the

engine

starts

caused

and

will

the

generator,

especially

has

come

to

warm

up.

by

unanticipated

prevent a cold

stalling.

GENERATOR

The speed however, it is advisable to verify.

60 hertz The engine no-load speed is set

50

hertz The engine no-load speed is set at

The speed of the generator engine however adjusted

·VOLTAGE

actual service load or test load the load adjusted to suitable your authorized WESTERBEKE service

VOLTAGE

of

the generator engine is adjusted at the factory,

At rated amperage hertz output may decrease

58.5-

59.0 Hz.

At rated amperage hertz output may decrease

48.5 - 49.0 Hz. is

adjusted

it

is

advisable

to

optimum

ADJUSTMENT

to

be

used

to

values

in

service.

values

verify.

The voltages

no-load and full-load (refer

in

this manual). If possible,

of

the same power factor

If

the

voltage cannot

and

a fault seems evident,

dealer.

it

large

up

to

This

precaution

operation

engine

at

61.5 - 62

51.5

at

the

are

is

motors, speed

from

Hz.

to

Hz.

to

factory,

easily

to

apply

as

be

contact

RECAP

DIPSTICK~

GLOW

PLU

CONNECTION

SIDE

Engines & Generators

7

OIL

FILL

CAP

OIL

FILL

CAP

SAFETY

SHUTDOWN

SWITCHES

AND

SENSORS

SAFETY

The engine is protected

switches. Should shutdown

without

SHUTDOWN

finding and

correcting

SWITCHES

by

three automatic shutdown

occur,

do

not attempt

the

cause.

Refer

to

restart

the heading "Engine Stops" in the TROUBLESHOOTING section

The following switches:

High

An exhaust temperature switchis located on injected exhaust

The switch's contact open at 260° The switch's contacts:elose when the temperature lowersto

of

this

manual.

is

a description

Exhaust

If

the

contacts open

DCruncircuitisinterrupted and

approximately

Temperature

elbow.

due

225°F (l07°C).

EXHAU$1

TEMPERAfURE

(HIGH)

of

Its

contacts are normally closed.

to

a high coolant temperature, the

SWITCH

these automatic shutdown

Switch

the

water

the

unit shuts

"270°F(l27°

down.

-127°C).

Low

Oil

Pressure

A

low

oil

pressure switch gallery adjacent open when monitors the engine's oil pressure. Oil pressure closes contacts. Should the engine's contacts open interrupting the down.

the

Switch

is

located off the engine's

to

the oil

filter.

Its contacts

engine is in a static state, this switch's sensor

oil

pressure

DC

run circuit shutting the unit

OIL

PRESSURE

SENDOR

are

fall

to

normally

5-l 0 psi, the

oil

the

Engine

A high engine coolant temperature switch located thermostat housing. contacts open circuit contact contacts close when the coolant

195°F (107°C).

Coolant

due

is

interrupted and

open

at

approximately 210°F (99°C). The switch's

Temperature

Its

contacts

to

a high coolant temperature,

the

SWitch

are

norma1ly

unit shuts down.

tem.perature.lowers

closed.

The

THERMOSTAT ASSEMBLY

on

the

If

the

DC

switch's

to

the

run

Engine

The engine's DC circuitis protected

230 amp DC breaker. Should amperage in excess of 20 amps

by engine's Investigate This

The·

shown

DC

Circuit

draw

through the breaker caused by an issue

DC

circuit, it will open and shut

the

is·

done by pushing the red

wiring

connections

in

the

WIRING

Breaker

issue and then manually reset

b1.1tton

ENGINE

DC

BREAKER

CIRCUIT

to

·these

components

DIAGRAMS

in

b}'~'l

engine mounted

the

in.

.

this

manual.

with

the

unit down.

the

breaker.

are

/"W'JWESTERBEICE

. · E'ngfnes & Generators

' 8

STARTING/STOPPING

PROCEDURE

THE

STARTING

Westerbeke glow

plugs illustration der.

The

glow

that

its

tip

glow

plug glows

red at the

is

a rapid start

This

system circuitry depressed while button

NOTE:

HEAT activates HEAT

START:

the Upon release

5 -

low will

is

keeping

is

depressed

The switch

the

intermittently

GLOW

While

START

engine

the

10

psi.

oil

pressure

remain

SYSTEM

diesel

generators use electric starters assisted

for

both

below

shows

plug

is

in

the

injector nozzle's

is

energized

tip

with

is

common

designed

for

the

time

the

PREHEAT

START

switch

is

depressed.

glow

plugs

still depressing

switch.

starting,

PREHEAT

Then

as

protective

energized

normal

and cold weather starting. The

a cross-sectional

is

located

in

the

by

the

PREHEAT

and

assists

in

igniting

less

wear

on

the

to

WESTERBEKE diesels.

so

that

the

PREHEAT

specified

to

crank

in

button engaged,

the

engine.

will not

energize

Depressing

in

the

cylinder

to

avoid

overheating

the

PREHEAT

This

will

engage

release the

switch until the oil pressure reaches

long

as

and

START

the

high water temperature

circuits

continue

view

of

combustion chamber

spray

path.

When

button,

the

fuel.

starter.

button

the

preheat

the

do

not

to

run.

NOTE:

A

voltage when is

depressed.

unless

the

PREHEAT

head

so

the

glow

switch, depress

starter

switch.

activate,

When

drop

the

preheat

chart. the

the

use

solenoid.

Do

starting:

will

by

one

cylin-

so

the

plug

The

result

The

start

must

be

Then,

START

PRE-

switch

the

PRE-

plugs.

not

and

the

engine

occur

~witch

Failure

Should depressed wait longer.

'A

engine

filling pump lng engine's the closing

draining

of lng

to

Start

the engine

for

10

30

seconds;

Never

run the

CAUTION:

starting

with

raw

Is

pumping

system

during

cylinders

exhaust

the

from

system

the

raw

the

exhaust

e,x~esslvsengine

raw

water

owner/operator

Remote

The start gauges. lights rpm. since

A.

B.

Starting

remote

start

panel

except

When

when

the

This

indicates

the

starting of

When

the start/stop START engine the START

depressed

up the green

engine

After released,

PREHEAT

supplies

switch is depressed

this

LED

light

switch.

which

series

LED

is

running.

the

generator the

voltage

starting

PREHEAT

panel

LED

for a few closes path

will

switch

not

start

when

to

20

seconds,

repeat

the

procedure

starter

for

Prolonged can water.

raw

cranking.

by

water

result

This

water

way

fills.

Prevsnt

supply

cranking

In

may

through

This

of

muff/sr,

cranking.

entry

Is

not a warrantable

should

keep

this

Procedure

panel

is

the

same

that

it

has a green

at a remote

generator is

when

the

will

Continue

for

remain

generator's starter

generator

LED

light

brighten

seconds

the

oil

i2V

is

operated

to

the

running

the

START

switch

light

will

dim.

to

pressure

B+

brightly

started

START

the

START

release both

above

more

than

Intervals

the

engine

exhaust

happen

the

because

the

raw

water

exhaust

this

from

manifold

through-hull and

correcting

Engine

in

mind.

as

the

engine-mounted

LEP

light

location,

may

is

depressed

will

and

When

signaling

hold

to

allow

to

the

and

will

first

switch.

the

at

approximately

switch

not

be

illuminate.

the

starter

the

to

release

the

PREHEAT

oil

safety

switch

fuel

run

illuminated

the

START

not

crank

because

switch

is

switches

and

30

and

preheat

seconds.

without

system

the

water

cool·

can

enter

once

happening

shut-off,

the

cause

damage

result·

issue;

and

no

green

LED

600

can

be

released

audible. at

the

remote

When

cranks

the

engine

starts

the

pressure

that

solenoid.

while

switch

unless

this

switch

to

is the

the

by

the

build

in

The

is

the

Once

the

engine starts, check

proper

oil

pressure light'load temperature applying

NOTE:

to

heavy

Some Depressing will

help

stabilize temperature the

engine.

the

generator

to

come

loads.

unstable

the

PREHEAT

reaches

and

the

up

running engine

140-

the

engine's

battery charging

and

allow

the

to

140-150°

switch

may

rpm

occur

for

until

(60-66°

10-15

150° F and a load

the

instruments voltage. engine's

C) before·

in a cold

second

operating

is

applied

for

Apply

a

operating

engine.

intervals

STOPPING

1.

·

2.

3.

Remote·Stopping.

To

stop

to

Engine., & Generators

the

-circuit. generator goes

9

Remove allow

the

stabilize Depress

is

coinpletely

Now

release

PROCEDURE

the

AC

electrical load

generator·to run

its

operating temperatures.

the

STOP

stopped.

the

STOP switch.

switch

.

and

Procedure

the

generator, depress the STOP switch

normally

out.

The

closed

B+

STOP

switch must

comes

to a complete stop

path for voltage

for

be

from

three

to

hold it

to

hel'd

open until the

and

the green

the

generator

five

minutes

until

the generator

which

the engine's run.

LED

and

to

opens

light

GENERATOR

BREAK·IN

PROCEDURE

DESCRIPTION

Although

hour assembly operated life ated

Breaking-in a new piston and scored, the

Your conditioning to Perform following:

Start section. water

AFTER

Once tion between

A

generator

your

of test

operations

procedures

properly, a break-in

of

your

engine

and

serviced

rings

to

smoky

operation

which

break-in

maximize

new

this

the

engine

Run

pump,

period.

engine

operation

the

conditioning

the oil

START-UP

the

generator

and

then

encourage

20%

and

CAUTION:

by

engine

is

during

engine

the

cylinder

is

caused

requires

performance

according

engine

pressure,

has

60%

Do

running

has

experienced a minbnum

at

the

factory

to

were

followed

dependent

its

initial

basically

walls.

indicate

by

overloading

approximately

to

break

carefully,

to

while

battery

been

a fast

of

full-load

not

attempt

time

is

upon

hours

Excessive

that

the

in

each

and

service

the

STARTING

checking

charging)

started,

warm-up.

for

to

and required.

how

involves

cylinder

keeping

check

the

break-in

without a load.

make

sure

that

the

The

the

engine

of

use.

seating

oil

consumption

walls

the

generator

50

hours

moving

that

part

life

of

the

in

mind

PROCEDURE

all

systems

are

functioning.

for

proper

Run

the

first

10

your

of

one

accurate

engine

service

is

the

are

during

of

initial

in

order

engine.

the

(raw

opera-

generator

hours.

oper-

CHECK

0

0 0

0

To the cuit

NOTE:

draw draw

GENERATOR

Once

be

engine's A

junction

GENERATOR

THE

Monitor

Check

for

Check

for

vibration Confirm

When

the

When

the

When

the

protect

against

generator's

breaker

8e

aware

required

can

be 3 to 5 times

the

generator

adjustments

break-in

no-load

voltage

with

FOLLOWING

the

control leaks abnonnal

and

blow-back

exhaust

engine engine engine

unintentional

output

that

is

of

for

starting

INFORMATION

ADJUSTMENTS

required

period

adjustment

the

engine's

INFORMATION

panel

gauges.

of

fuel

and

engine

noise

such

as

sounds.

smoke:

is

cold

-White

is

warm -almost

is

overloaded~

leads

should

rated

at

the

motor

starting

motors.

nonnal

has

been

for

engine

(first

speed

overloading

be

rated

loads

This

running

in

placed

speed.

50

hours)

may

also

adjustment.

in

this

Smoke. some

output

this

in

oil.

knocking,

Smokeless.

Black

.of

routed

through a cir-

of

the

and

the

starting

amperage.

manual.

operation,

(hertz)

or

after

be

required

See

manuaL

friction,

Smoke.

the

generator,

generator.

high

current

amperage

See

there

may

during

this

period.

in

con-

the

After

the

can

be

cally

vary

Avoid smoky

Monitor

it

within

at

1800

50

Hertz),

the

current

first

increased

the

overload

exhaust

the

current

the

generator's

rpm

to

control

drawn

10

hours to

load.

at

all

with

produce

of

from

of

the

full-load

times.

reduced

being

ratif!.g

60

the

generator's

the

generator's

rated

An

overload

output

drawn

from

•.

Since

hertz

(or

generator.

operation,

output,

then

is

signaled

voltage

and

frequency.

the

generator

the·

gen~rator

at

1500

ipm

to

break-in

is

governed

the

load

periodi-

by and

operates

produce

keep

by

Engines & Generators

10

MAINTENANCE

SCHEDULE

WARNING:

gloves, panel

SCHEDULED

Maintenance

I

DAILY

Coolant Engine Fuel/Water

Fuel

Visual

NOTE:

will

I

INITIAL

Engine

*Exhaust

*Valve

*Cylinder

Fuel

Generator

Engine

Water

Never

and

or

turn

MAINTENANCE

procedures

CHECK

Level

Oil

Level

Separator

Supply

Inspection

Please

inhibit

the

50

HOURS

Oil

and

System

Adjustment

Head

Filter(

s)

Speed

Pump

attempt

use

the

correct

off

the

battery

are

BEFORE

START-UP

(owner

of

Engine

keep

engine

engine 3-ability

OF

OPERATION

Filter

(cold)

to

perform

tools

switch.

all

detailed

installed)

swface

to

remain

for

in

clean.

any

each

this

Dirt

cool.

service

Job.

manual.

anil

oil

while

the

engine

When

servicing/replacing

EXPlANATION

Check Oil

level

Check hours

Use there

Check securing connections.

Initial Check

Ensure Check Torque

Initial Check Adjust Adjust

Is

running.

at

recovery

should

for

water

or

once a year.

properly

filtered

is

adequate

for

fuel,

v·clamp

Look

engine

oil

security

there

are

adjustment

cylinder

change.

that

AC

as

needed.

belt

tension

Wear

DC

components,

OF

SCHEDULED

tank,

if

empty,

indicate

between

and

dirt

in

fuel.

#2

diesel

fuel

for

the

oil

and

water

is

tight.

No

for

loose

and

filter

change

of

water

injected

no

leaks.

of

valves.

head

hold-down

connections

Lubricate

(3/8

- t/2

the

proper

turn

MAINTENANCE

check

at

MAX

and

Drain

filter

with a Cetane

vessel's

needs.

and

exhaust

leaks

at

50

hours.

exhaust

bolts.

with

leaks.

elbow

exhaust

bolts/hardware

are

secure

linkage.

deflection).

safety off

the

manifold.

LOW

on

if

necessary.

rating

Check

around

and

correct

to

exhaust

no

chafing.

equipment

DC

circuit

Add

coolant

dipstick.

Do

Replace

of

#45

or

higher.

that

the

elbow.

as

needed.

manifold.

water

Inspect

the

such

as

breaker

if

needed.

not

overfill!

filter

every

Check

injected

wiring

goggles

on.

the

control

250

operating

that

exhaust and

eiectrical

and

elbow

I

EVERY

50

OPERATING

Drive

Belt

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

I

EVERY

100

OPERATING

Engine

Oil

and

FiHer

Air

Intake

Silencer

Speed

Linkage Impeller Syphon

Break

*WESTERBEKE

recommends

HOURS

this

OR

MONTHLY

OR

YEARLY

service

be

performed

Inspect

for

slipping,

Check off

corrosion Inspect Inspect

your

Change Keep Lubricate Inspect Check

by

an

knowledgeable

for

proper

cracking

electrolyte

for

leaks,

and

clean

own

inspection

engine

air

intake

linkage

impeller

for

proper

tension

and

levels.

if

needed.

ensure

Zinc

schedule.

oil

and

clear

of

between

for

condition.

operation

mechanic.

(3/8'

to

1/2'

wear.

Adjust

Make

~ure

Apply

petroleum

fuel

and

electrical

anode.

Replace

filter

at

1

00

operating

obstructions.

throttle

and

Replace

(when

installed).

deflection)

tension

cables

and

jelly

if

necessary.

solenoid.

as

needed.

and

adjust

or

replace

connections

to

terminals

connections

Note

hours

or

yearly.

as

are

for

are

the

needed.

clean

if

needed.

Replace

in

good

corrosion

and

tight.

condition,

Check

belt

cover.

order.

Clean

protection.

then

determine

{.~

WESTERBEKE

Engines & Generators

11

NOTE:

Use

the

engine

MAINTENANCE

hourmeter

gauge

to

log

your

SCHEDULE

engine

hours

or

record

your

engune

hours

running

time.

SCHEDULED

I

EVERY

Exhaust

Fuel

MAINTENANCE

250

OPERATING

Elbow/Exhaust

Filler

and

*Otlnerator

Ho&e&

Fuel

Water

Separator

DC

Alternator

Impeller

I

EVERY

500

OPERATING

Raw

Water

Pump

COolant

System

*Valve

Clearances/Cylinder

----------

•

:ltarter

Motor

Fuel

InJectors

O·Rings

Filter

HOURS

Svstem

HOURS

Head(

OR

cold)

YEARLY

FIVE

YEARS

EXPLANATION

Remove Check

See

GENERATOR

Engine delaminated.

Inspect

Inspect Check

Remove

Remove and

cover

at

re-assembly.

Drain,

flush condition and

connecting

Torque

Check starter

Check

Check of

the

chaffing.

NOTE:

and

replace

that

AC

connections

hoses

should

Check

bowl

for

wiring,

connections

mounting

impeller

and

disassemble

for

wear

-----

and

of

the

hose.

head

bolts

solenoid

and

motor

pinion

and

adjust

OF

the exhaust

An

INFORMATION.

dirt

bracket

from

re-fill

sealing

then

injection

SCHEDULED

structural

No

exhaust

fuel

be

firm

and

tighten

or

water

and

raw

and

corrosion.

the

gaskets

adjust

motor

drive.

MAINTENANCE

integrity

system

attached

leaks.

leak

will

filter

and

all

are

clean

and

tight.

all

hose

in

fuel.

should

alternator

water

pump.

the

pump

Replace

cooling

system

of

the

valves.

for

corrosion.

opening

of

the

to

Hoses

cause

sealing

and

secure.

Replace

clamps

Drain

and

be

tight.

bolt.

Inspect

and

inspect

the

with

pressure

Remove

pressure

water

injectecl

the

elbow.

and

muffler

exposure

0-rings.

Ensure

if

hoses

as

neeoed.

replace

Alternator All

should

impellers

all

parts:

impeller

appropriate

cap.

Clean

and

spray

~xhaust

All

hose

are

in

to

diesel

wires

have

become

filter.

should

be

tight

condition.

drive

gear,

and

gasket.

antifree4e

out

coolant

lubricate.

conditions.

elbow

connections

good

serviceable

exhaust!

no

chafing.

spongy,

brittle

clean

and

Replace

pump

Lubricate

mix.

Inspect

recovery

Clean

and

lubricate

casting.

should

or

free

of

as

needed.

shaft,

the

tank

Check

be

condition.

corrosion.

wear

plate

impeller

the

l

I

EVERY

1000

OPERATING

Heat

Exchanger

Glow

Plug:;

*WESTERBEKE

HOURS

recommends

this

OR

service

EVERY

be

performed

FIVE

YEARS

Remove Check

by

an

knowledgeable

the

circuit.

heat

exchanger

Remove,

mechanic.

for

clean,

professional

check

resistance.

cleaning

and

pressure

testing.

IW'IWESTBRBEKE.

l Enalnes

&,.QIJnerators

12

DESCRIPTION

Westerbeke for

fresh bustion which water

parts, from exchanger, water fresh ferred tube exhaust other coolant is cooled transferred fresh

·

each allows

harmful

FRESH

NOTE:

ommended

fresh

Fresh lating then heat block

marine

water

cooling.

and

friction

circulates coolant and

the

flows

water

to

walls

system

words,

water

other.

the

deposits.

WATER

Refer

water

water pump,

passes

exchanger whete it

via

throughout the engine. This circulating

cools

the engine

fresh

water

similar

through

coolant

the

fresh

water coolant is conducted

to

the

raw

where

the engine

by

heat

overboard

coolant

Using

only

cooling

water

COOLING

to

the

ENGINE

antifreeze

coolant.

coolant

absorbing

through

the

suction

diesel

engines are

Heat

produced

is

transferred

the

engine

block,

oil.

The

heat

coolant

to

in

function

the

flows

water

raw

and

to

tubes

of

around

which

finally

it is discharged

is

cooled

water,

through the exhaust

raw

water circuits

fresh

water coolant

passages

CIRCUIT

COOLANT

and water

is

pumped

the

side

through

heat

from

thermostat into the

is

cooled,

of the circulating

designed

in

the

engine

to

fresh

water

its

internal

is

transferred externally

raw

water

by

means

an

automotive

the

heat exchanger

the

tubes;

engine heat

through

is

then

pumped

overboard.

by

fresh

water

and the

raw

water

are

within

to

stay

clean

section

mixture

to

be

the

the engine.

and

returned

engine

The

manifold,

pump.

COOLING

and

equipped

by

com-

coolant

fresh

moving

of

a heat

radiator.

coolant,

syste~.

independent of

and

for

used

to

Raw

while

trans-

the

into the

In

this

carries the

The

the engine

free

from

the

rec-

as

the

by

a circu-

coolant

to

the

engine

SYSTEM

When

the

engine

is

started cold, external coolant

vented

by

the

closed thermostat (although

is

bypassed manifold thermostat

coolant

cooling

Coolant

A coolant

and cant ing

system.

engine

CHANGING

The engine's coolant

MAINTENANCE

become

A

critical; a substantlal11umber traced

D~n

engme

the

system with fresh

NOTE:

be

used

A

Wear

around

from

overheating).

gradually

to

flow

unrestricted

system.

Recovery

recovery

contraction

loss

manifold

during

of coolant

This

tank

level

COOLANT

SCHEDULE.

contaminated, it

CAUTION:

back

the

engine coolant

block

The

to

and

drain

help

Proper

to

cooling

opening

petcock

drain

WARNING:

protective

gloves.

the

thermostat

As the engine

opens,

allowing

to

Tank

tank

allows

engine operation, without

and

without

should

and

should

must

be

can

cooling

system

by

loosening the

the

water,

then

on

the

engine

Beware

of

some

to

prevent the

warms

full

flow

the

external

for

introducing air

be

located at or

be

changed according

If

the coolant

lead

to

system

of

portion

engine coolant

above

easily

accessible.

overheating

malllfenance

engine

failures

corrosion.

drain

manifold pressure

start the

heat exchanger

coolant.

the

bot

refill

engine

flow

is

coolant

exhaust

up,

the

of

the

engine's

of

the

expansion

any

signifi-

into

the

to

the

is

allowed

problems.

can

plug

on

cap.

Flush

process.

should

coolant.

pre-

flow

cool-

to

is be

the

also

ENGINE

BLOCK

~

COOLANT

DRAIN

IW'/WESJERBEKE

· f

En_Qines

.

& Generators

13

COOLANT RECOVERY

TANK

t

INSF}ECT

AND

THE

COOLANT

TANK

AND

HOSE

EVERY 3 MONTHS

CLEAN

RECOVERY

ITS

CONNECTING.

CHANGING

Close

and

gasket pliers. Lightly Install of

the

cover.

THE

the

raw

or

0-rlng

Carefully

coat

the

new

curve

of

Open

the

water

pry/pull the impeller out of

inside of

impeller,

the

raw

RAW

WATER

intake

With

the

bending

cam

plate.

water

valve.

Remove

the aid of

pump

the

Re-assemble

intake

valve.

PUMP

IMPELLER

the

two

screwdrivers

housing

blades

the

RAW

WATER

COOLING

pump

cover

or

the

pump.

~ith

glycerine.

in

the

direction

gasket

and

".

PUMP

SYSTEM

:NOTE:

Also

a

[/round.

If

.the

engine temperature

norinal

reading,

may

have been caught

raw

water through

WASHER

follow

the

cause

the

above

gauge

may

up

in

cooling

RAW

procedure

ever

shows

be

that silt, leaves

the

strainer,

system.

WATER

after

having

a higher

or

slowing

the

STRAINER

nm

than

grass

flow

hard

of

INSPECTION:

EACH REPLACE ANY'CRACKS.

CHECK

BLADE

BY

BENDING

THE

IMPELLER

A

CAUTION:

Impeller, cooling

exchanger.

Raw

Water

NOTE:

Always

the

strainer

A

clean engine's strainer in

'the

glass

Perform operation:

1.

Close

2.

Remove

3.

Clean

4.

Replace

s.

Reassemble

6.

Open

7.

Run

fflE

they

circuit.·

Intake

will

raw

water

cooling

when

making

should

the

following

the

raw

and

the

glass.

the

seacock.

the

engine

install

BASE

OF

VIGOROUSLY.·

IF

If

any

of

must

be

found

They

often

Strainer

the

strainer

always

be

intake strainer

system.

washer and

be

water

clean

install

and

your

clear.

Include a

maintenance

seacock.

the

if

necessary.

check for

self-priming.

periodic

strainer

the

can

strainer.

vanes to

prevent

be

found

at

or

is a vital

visual

engine

after

filter.

leaks.

have

broken

blockage

In

the

below

the

component of

inspection of

check.

every

off

In

heat

waterline

The water

100

hours

the

this

of

so

TYPICAL

HEAT

EXCHANGER

The

heat exchanger is a number the engine removes

of small copper

small

copper

is circulated

heat from

CLEAN DEBRIS

Ci.EANd.Jr

DEBRIS

BOTH

RAW

(OWNER

tuJ?es

and

around

the

fresh

AT

ENDS

WATER

INTAKE

STRAINER

INSTALLED)

copper

cylinder which encloses a

tubes.

Raw

water

the

fresh

water

the

copper

tubes.

water

coolant.

HEAT

EJ{CHANGER$

AWJAVA/LABLE

CUPRO·NICKEL

TUBING

is

pumped

coolant

The

ARE

WITH

from

raw

through

the

water

t-w-IWESTERBEICE

l

Engines & Generators

14

COOLING

SYSTEM

Refilling

After

the

replacing

Coolant

the

engme block drain plug, close the heat exchanger's coolant petcock. Then pour clean, premixed coolant

into

the

manifold

the

manifold,

NOTE:

When a steady flow the petcock and fill the system until the manifold remains

Monitor the

manifold

sure

cap.

Remove

coolant the

cap.

flow

into

After

checking Coolant engine needed.

TO

RECOVERY

MAKE

CERTAIN

PASSAGES

ARE

FROM RECOVERY

start

Open the air-bleed petcock

the

coolant

to

the

cap

on

mix

to

halfway between

Run

the

engine and observe the coolant expansion

the

recovery tank.

for

should draw back

cools

down.

Clean

up

any

COOLANT

TANK

THESE KEPT

CLEAR

COOLANT

TANK

and

when

the

coolant

tl1e

engine.

on

the heat exchanger.

of

coolant appears

in

the

manifold

filler neck

and

and add

install

at

the

the coolant recovery tank

LOW

and

leaks,

stop

ilie engine

into

Add coolant

the

to

and

cooling system

the

recovery tank if

spilled coolant.

the petcock, close

as

manifold pres-

and

MAX

allow

is

visable

full.

needed. Fill

fill

wiili

and

replace

it

to

cool.

as

the

in

Replacing

Remove ing

as

ket,

apply a thin

before

the

cap

shown.

pressing

the

screws.

Run

the

engine

there

are

no

leaks

GASKET

THERMOSTAT ASSEMBLY

Thermostat

screws

and

When

installing

coat of sealant

it

into

place.

and

check

at

the

thermostat housing.

disassemble

the

on

Do

not over-tighten

for

normal

the

new

thermostat

both

sides

temperatures

thermostat

and

of

the

gasket

the

cap

and

BLEED

PETCOCK

COOLANT

TEMPERATURE SEND !OPTIONAL)

hous-

gas-

that

OR

COOLANT

NOTE:

Periodically check the condition

cap.

sure good condition closes tightly. Carry a spare cap.

Ensure that the upper

and

check that the vacuum valve opens

THERMOSTAT

A

thermostat, engine, uously

engine from

flowing

thermostat

As

ilie thermostat replaced

located near

controls flows is

ilie coolant temperature

through the closed cooling circuit. When

first

started, the closed thermostat prevents coolant

(some coolant

to

prevent

engine

warms

is

accessible

easily.

Carry a spare thermostat

the

manifold

is

by-passed

the

exhaust manifold

up,

the

thermostat gradually

and

can

RETRACTION

of

the manifold pres-

and

lower rubber seals are in

SEALS

at

the

front

of

as

the

coolant contin-

through a hole

from

overheating).

opens.

be

checked, cleaned,

and

gasket.

or

the

and

in

The

the

RAW

WATER

The

raw impeller water source (ocean, lake, or river) through a hose water

strainer. through the

heat fresh

ing

the

into ing

the

exhaust gasses. This mixture of exhaust

water

is

COOLING

water

flow

pump.

This pump draws water directly

The raw water

the

raw

water pump

CIRCUIT

is created

by

passes

to

exchanger tubes) where

water coolant. The

raw

water-injected exhaust discharged overboard

by

a positive displacement

from

the

strainer

the

heat exchanger

it

cools

the

engine circulat-

water

is

then

discharged

elbow,

mixing with

gas

the

engine's exhaust

the

to

the

(through

and

cool-

and

raw

gas

discharge pressure.

Raw

The

Water

raw

Pump

water pump

is

a self-priming, rotary

pump

with non-ferrous housing and a neoprene impeller. The impeller has

flexible within On

no lubricant impeller

Raw water)

are

not

raw

NOTE:

(seals and bearings), it may be chase a

vanes

which

wipe

against a curved

the

impeller housing, producing

account should this

for

the

impeller. There should always

and

impeller cover gasket

water

pump

impeller failures occur

is

not

present during engine operation. Such

warrantable, and operators

water

flow

is

present

Should a failure occur with the pump

new pump

pump

be

run

(an

are

cautioned

at

start-up.

more cost efficient

and

rebuild the original pump as a spare.

earn

fue

pumping

dry

as

water

be a spare

impeller kit)

when

lubricant

to

:s-

internal parts

plate

action.

acts

aboard.

failures

make

to

pur-

(raw

raw

a

as

sure

a

Engines & Generators

15

Zinc

Anode

A

zinc

anode,

or

pencil,

circuit

within

the

zinc

anode

is

to

sacrifice

place

in

the

raw

water

effects

of

electrolysis

The

condition

det~rmine

replacement Spare

zinc

NEW

NOTE:

installation

of

its

service

period

anodes

REPLACE REPLACE

Electrolysis

and vessel location; not that

heat

the

zinc life.

can

should

ZINC

action

on

is

located

exchanger.

itself

to

cooling

circuit,

other

components

should

Once

that

be

noted

be

carried

ANODES

is

the result

in

the

raw

The

purpose

electrolysis

thereby

be

checked is

established,

in

your

maintenru;tce

on

board.

of

each

of

COOLING

water

cooling

of

having

the

action

taking

reducing

of

the

monthly

ClEAN

REUSE

particular

the

engine.

system.

to

the

zinc

log.

AND

the

SYSTEM

If

the

zinc

anodes

need

replacement,

which

the

zinc

anode

is

threaded

ening

the

anode

with

another

b~ss

from

possibly

removing

poor the clean

exchanger

aged to ber),

NOTE:

do insulate ing

Heat

After and motive exchanger.)

NOTE:

that a heat exchanger cleaning every

the

condition,

exchanger.

the

inside

end

when

removing

your

engine

0-ring

The,

threads

.not

require

the

preventing electrolysis action

Exchanger

approximately

pressure

radiator

Operating

1

ooo·

hours.

tearing

zinc,

note

the

there

are

probably

Remove gasket model's heat

and

sealant.

zinc from

the

of

all

zinc in

case

the

end

cover,

and

of

the

zinc anodes

Sealant should not be used

the

metal

Service

1000

test

the

engine's

shop

should

in

silty and/or tropical waters

with a wrench

wrench.

off

the

exchanger

condition

a lot of

end

of

the

debris.

Always

the

present

cover.

exchanger

install a new

of

the

on

hours

of

operation,

heat

exchanger.

be

able

be

performed

hold

the

hex

This

prevents

shell.

of

it.

If

the

zinc

flakes

heat

exchanger

have a spare

one

becomes

Replace

to

the

end

gasket

zinc

anode.

are

pipe

threads

heat exchanger

the

zinc.

remove;

(A

clean

and

may

more

boss

while

the

After

zinc

gasket

part

as

local test

the

require

often

into

loos-

hex

is

in

within

and

heat

dam-

(refer

num-

and

it

may

hous-

clean

auto-

heat

than

AIR

INTAKE

The

function

pulsat~ng

operatmg.

Th~

air mamtenance of

any

SILENCER

of

the

air

intake

intak~

silen~er

It

reqUires

obstructions

air intake silencer is

noise

to

produced

has

is

that

air

flow

no

filter

the

into

by a diesel

element

inlet

the

AIR

INTAKE

to

reduce

engine

inside.

opening

silencer.

be

the

The

kept

SILENCER·

while

only

clear

AIR

INTAKE

SILENCER

Engines & Generators

.

16

.

FUEL

SYSTEM

DIESEL

Use a diesel

J

ASTMD975.

313

.filii.

and

has

fuel

that meets the requirements of No.2-D SAE

a cetane rating

of

45

or higher according to

DESCRIPnON

Fuel is drawn into the engine's fuel system by the electric

fuel

pump mounted on the generator's drive engine. Fuel

is drawn from the fuel tank through the primary

filter/water separator through the pressure mounted on the engine. Fuel passes through this filter fuel injection pump where the injection pump delivers it the mjectors, The fuel serves three purposes in the system. It

is

from the injection equipment through the return back fuel

FU~L

(6-8

psi) and delivered

used for combustion, lubrication and carries heat away

tank where it

SYSTEM

is

dissiPated in the cool fuel in the

DIAGRAM

fuel

pump, then under

to

the secondary

(TYPICAL)

fuel

fi,lter

to

tank.

the to

the

;PRIMARY

tO

.

FUEL

FILTER

WATER

SEPERATOP

A primary fuel filter installed between the fuel tank and water and other contaminant's from the be carried to the

A typical fuel filter/water separator is

the Raycor Model500 MA. separator tank and engine-mounted fuel system, any water in the

will affect the fuel pump, engine

equipment The owner/operator

certain the

free and maintaining a proper filtration/separation

type filter

~1

of iniplirities.

SECONDARY

Change the filter element operation then follow the MAINTENANCE in

~s.manual.

of

the water separating type must be

fuel

system on the

is

not installed between the

reaching the engine's injection equipment is

This

ON-ENGINE

:-L.II--~J

the engine

~ngine~_

is

Keep

in mind that

filter,

is responsible for

process is accomplished by installing

FUEL

FILTER

after

the initial 50 hours

MICRON ELEMENT RECOMMENDED

fuel

before

illustrated

and injection

SCHEDULE

to

remove·

they

below.

if

a water

fuel

making

system.

of

can

This

supply

fuel

FOB.

SYSTEM

All

WESTERBEKE

INSTALLATIONS

FUELJWATER

ENGINE/GENERATOR

REQUIRE

AN

SEPARATOR

OWNER-INSTALLED

Changing

1. Shut the fuel supply

2.

Unscrew the retaining ring that holds the filter housing and allow the bowl to come away from the ing. Hive some absorbent towels under the bowl to catch

any

3. Remove the filter element. Replace the element

4. Replace the large sealing Reassemble the bowl ring on carefully retaining ring contacts the by hand. Turn the preheat circuit Then run the engine and inspect for anyleaks.

fuel.

The

fit

on

Fuel

Filter

Element

off.

"0"

to.

Clean the bowl. - · ·

"0"

ring. Install a new

to

the housing. Thread the retaining

so

as

not to cross thread. When the

"0"

ring, tighten 1/4-1/2 turn

on

the fuel supply

·

and

bleed the engine via

bowl

ring that the

e~ement

to

the

hous-

{~IWESTERBEKE

l

Engi~~

.

!ft

Generators

17

FUEL

FILTER

SECONDARY

FUEL

LIFT

PUMPS

Two

types of

same

electromagnetic principle. Earlier model

pump

lift changed at regular maintenance intervals Later model engines require maintenance. Electrical connections clean and tight

When will

purge air

flow

of fuel

fuel

lift

pumps

with a replaceable element.

use

a smaller left pump

with

either

pump.

energized

as

thru

from

the

preheat circuit,

the

fuel

engine

system

is

running.

are

shown,

both operate

This

(at

the

and

provide a continuous

FUEL

dn

the

engines

element should

250

that

should

fuel

use

hours).

does

not

be kept

lift pump

SYSTEM

a

be

TO

PRIMARY

fUELRL~

TO

PRIMARY

·fiLTER

FUEL

SOLID

STATE

LIFT

PUMP>

(LATER

MODELS)

FUEL

LIFT

PUMPS

Engines & Generator.s

18

ENGINE

LUBRICATING

OIL

ENGINE

SUMP

DRAIN

HOSE......,_,___..._

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

the sump drain hose (attached to the front

while the engine is wann. Drain the used oil completely, replace the hose in its bracket, and replace the end cap securely.

NOTE:

Thread

is

114

NPT.

DRAIN

THE

FI

U"ER REMOVING FROM

SPIN

OIL

2. Replacing the Oil Filter. When removing the used oil fil.

OIL

BEFORE

THE

HOUSING

ON

FILTER

ter, you may find it helpful and cleaner to punch a the upper and lower portion oil from it into a container before removing to lessen spillage. A small automotive filter wrench should be helpful in removing the old oil filter.

NOTE:

Do

filter

to

Place some paper towels and a plastic bag around the ter when unscrewing (Oil or any other fluid on the engine reduces the engine's cooling ability. Keep your engine clean.) Inspect the old oil filter

sealing gasket comes off with the old oil filter. ber sealing gasket remains sealed against the filter bracket, gently remove it.

FROM

THE

FILTER

TWiN

!·/AND

O·RING,

213

OF A TURN.

size for

TIGHT

THEN

the

lube

AGAINST

TIGHTEN

of

not punch this hole without first

make

certain it

as

it

is removed to make sure that the fllbber

can

be

it

to catch any oil left in the filter.

OIL

CHANGE

FOR

EXTENSION

1/4"

NPT

6"0.D.

of

the engine)

oil drain

the old filter to drain the

hose

AP.I'LY

CLEAN

ENCi/NE

WHEN

JNSTALL/tvG

loosening

capped

OIL

hole.

it.

'Ibis helps

the

removed.

If

this rub-

end

fil-

in

NOTE:

Generic filters

ial

standards

parts might

or diameters

be Immediately after engine

to

make

there

are

no

oil leaks around

3. Filling the Oil Sump. Add new oil through the oil filler

cap on the top After refilling, run the engine for a few moments while checking the oil pressure. Make sure there is around the new oil filter or from the oil drain system, and stop the engine. Then check the quantity lube oil dipstick. Fill to, but not over the high mark on the dipstick, should the engine require additional oil.

OIL

PRESSURE

The lubricating system is a pressure feeding system using an oil pump. the oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points in the engine. The oil then returns to the oil sump to repeat the continuous cycle. When the oil pressure exceeds the fied pressure, the oil pushes open the relief valve in the oil pump and returns to the oil sump, keeping the oil pressure withln its specified range.

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 60 psi (2.8 and 4.2 kg/cm

NOTE:

reading an

oil readings engine

LOW

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3

+ 0.1 kg/cm

a worn bearings. sure readings, see the

The

A

newly

started,

up

to

60 psi

pressure

reading

will vary

and

the

rpms.

OIL

PRESSURE

2

).

A gradual loss

are

not

recommended,

of

important items

entirely different

an

oil filter change and oil

sure

the

of

the engine or through the side oil

engine oil is drawn from the oil sump by

2

).

cold

(4.2

kg!crrf).

as

low

depending

For

additional information on low oil pres-

ENGINE

from

oil

pressure

engine

the

·can

is

new oil

have

A warmed engine

as 35 psi (2.5 kg/cm

upon

the

temperature

of

oil pressure usually indicates

TROUBLESHOOTING

genuine

normal

filter.

of

an

as

the

mater-

on

generic

parts.

fill,

run

and

that

fill.

no

leakage

oil with the

speci-

40 and

oil

pressure

can

have

2

).

These

of

the

chart.

the

Q)l~

·--~~hl

When installing the new oil filter element, wipe the filter gasket's sealing surface on the bracket free apply a thin coat on the new oil filter. Screw the filter onto the threaded oil filter nipple on the oil filter bracket, and then tighten the filter firmly by hand.

of

clean engine oil to the rubber gasket

of

oil and

19

N.OTE:

To

gauge

as

sure

gauge.

or

more

test the oil shown.

Oil

Pressure should

at 1800

pressure,

Warm

rpm.

install a mechanical pressure

up

the

engine and

be

read

35.0 lb/in2 (3.8 Kg!cnt)

the

oil pres-

ALTERNATOR

The charging

with

a voltage regulator, an engine

Il),OUnted cables. Because of electronic internally or

system

DC

circuit breaker and a

the

voltage

regulator

on

the

back

50

AMP

ALTERNATOR

consists

use

DC

of a DC

of integrated circuits (IC's),

is

very

of the alternator.

belt driven alternator

DC

wiring

harpess,

battery

with

connecting

compact

and

ELECTRICAL·

a

the

is

mounted

SYSTEM

1.

Start

the

2.

After starting multimeter

a. If

the tor to

"Checking

b.If

the exists continue

engine.

the

engine

has

run

for

a few minutes,

battery

voltage

at the battery terminals

set

on

DC

volts.

voltage

is

increasing toward 14 volts,

is

workingi

voltage

with

MUlTIMETER

omit

Steps 3 through 8 and

the

Service Battery"

remains around 12 volts, a problem

either the alternator or the charging

with

Steps

3 through

8.

on

the

measure

using

the

alterna-

go

directly

circuit;

the

a

ALTERNATOR

A

WARNING:

hot.

Do

Use

this

exists

with determined that have

a qualified

The alternator charging circuit charges

and

the

service or a battery selector switch to

isolate the

along

with starting the

Testing

battery

service battery's charging circuit and not

tor.

A

CAUTION:

that

everyone

sheaves

A

WARNING:

DC

Bnd

applicationS.

isolate before made

without a proper

TROUBLESHOOTING.

A

failed

alternator

not

touch

until

the

alternator

troubleshooting

the

charging

the

technician

battery.

batteries

the

service

but

the

Alternator

Is

and

belts

AC

circuits

Always

DC

and

AC

performing

section

to

determine if a

circuit or

alternator or voltage regulator

An isolator

so the starting battery

battery

not

the service

Before

starting

clear

of

during

When

testlqg

are

often

with

check

il

with

is

usually mounted

..

If

the

battery,

the

moving

parts!

test

procedures.

with a multlmeter:

mixed

disconnects converters, DC

testing.

and No

AC

knowledge

alternator is

can

become

has

the·alternator. If it is

the

starting

a diode, a solenoid

the

engine

Keep

together

shore

power

shut

down

tests

of

AC

circuits.

very

cooled

down.

problem

is

faulty,

battery

in

the

is

not

discharged

charging

problem is in

with

the

make

certain

away

in

marine

cord,

the

engine

should

be

circuit

the

alterna-

from

TESTING

THE

STARTING BATTERY/ALTERNATOR (ENGINE

3.

4.

5.

6. Check the battery voltage.

TESTING

BATIERY • ENGINE

RUNNING)

Turn

off

the

engine

..

Inspect all wiring

Ensure

that

the

battery

terminals

connections

A

charging

switch

If

a battery selector switch is in the charging circuit,

ensure that it is on the correct battery.

Tum

condition, the reading should be

THE

are

tight

and clean.

CAUTION:

when

off the battery switch.

circuit,

the

To

avoid

never

engine

STARTING

damage

shut

off

is

running/

If

the battery

and

the

12

the

to

OFF

and

connections.

engine

the

battery

engine

is

in good

13

volts.

ground

battery

Engines & Generators

20

7.

Now minal the tor neither between connections

check

(B+)

alternator

is

in

the

of

the

voltage

and

ground.

will

be

circuit

above

alternator

- look

between

If

the

same

the

alternator

is

true, a problem and

the

for

an

opening

DC

the

alternator output

circuit

is

good,

as

the

battery,

voltage

exists·

battery.

Check

in

the

MULTIMETER

ELECTRICAL

ter-

the

voltage

at

or if

an

isola-

will

be

zero.

If

in

the

circuit

all

the

charging

circuit.

az5J

e

OM

SYSTEM

Checking

Check have a voltage running. If not, there charging circuit. circuit isolator, battery

the

Service

the

voltage of

between

Troubleshoot

by

checking

switch,

MULTIMETER

CKID

Battery

the

service

13

and

is a problem

the

wiring

and

the

battery.

14

the and

battery itself.

This battery

volts

when

the

in

the

service battery

service battery charging

connections,

the

should

engine

solenoid,

i~

TESTING

THE

STARTING BATTERY/ALTERNATOR (ENGINE

8.

Start the engine alternator output

The

voltage should is

over-

service

NOTE:

voltmeter

at

the

tery

yoltage

If

12

wiring

12

VOLT

The

engine shown on diagrams electrical

A

CAUnON:

circuit,

.

the

engine hOWBVIIr, engine's

RUNNING)

again.

and

reading

be

between

or under-cha!ging,

facility.

Before

to

EX.C

volts

is

and

DC

CONTROL

has a 12

the

wiring diagrams that

when

system.

never

Is

to

avoid

electrical

13.5

removing

ensure

tenninal if

at the B

not

present

look

for

volt

troubleshooting

To

avoid

shut

oU

running.

electrical

circuit.

BAnERY

The

minimum

the

engine's

Cranking

recommended capacity of the battery

12

volt

DC

Amps

(CCA).

-c:::=---'

Check

the

voltage between

ground;

for

a properly operating alternator and

14.5

volts.

If

your alternator

have

it

repaired at a reliable

the

that

12

the

output

at

breaks

alternator volts

the

and

for

DC

excitation

test

EXC

tenninal1 trace

po()r

r;ont)et;tions.

repair,

showed only

CIRCUIT

DC

electrical control circuit that

follow.

Refer

or

when

servicing the

damage

the

Shut

control circuit

engine

oU

the

shorts

to

the

battery

batte.ry

engine

when

is

600-900

switch.

battery

working

ENGINE GROUND

the

use

is

present

the

to

these

DC

charging

while

switch, on

used

Coid

a bat-

is

the

in

TESTING

8A,rl~RY

A

CAUTION:

do

not

use a high

.

pertonning

Battery

Review the manufacturer's recommendations and establish a systematic engine's starting

0 Monitor your

0 Check the electrolyte

0 Use 0 Make certain that

0

Care

.engine.operation.

hydrometer.

only

level. ·

tight

to

Keep

your batteries

A

WARNING:

cauu

severe

protective

tests

distilled

the

battery

gear.

To

avoid

voltage

on

the

maintenance

batteries

voltmeter

water

batter)'

posts

Sulfuric

burns

on

damaging

test11r

(I.e. a 111egger}

alternator

and

hou.se

for

proper

level

and

to

bring

cable connections

(and

to

clean

and

free

acid

In

skin

and

schedule for your

specific gravity

da~age

THE

SERVICE

(ENGINE

.t/Je

altematoi

charging

batteries.

charg~ng

electrolytes

your engine).

lead

circuit.

during

of corrosion.

batteries

clothing.

RUNNING)

diodes,

when

then

with

to a proper

are

clean

can

Wear

a

and

STARTER

MOTOR

DESCRIPTION

The

starter can be roughly divided into the following sections:

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an arma-

ture torque, preventing motor overrun after starting.

• A switch section (solenoid) which is operated when actuating the overrunning clutch through a lever and which supplies load current to

The starter is a new type, small, light-weight and is called a

high-speed internal-reduction starter. The pinion shaft is arate from the motor shaft; the pinion slides only ion shaft. A reduction gear is installed between the motor shaft and a pinion shaft. The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The motor shaft is supported at both ends on ball bearings. The lever mechanism, switch and overrunning clutch inner circuit are identical to conventional ones.

ADJUSTMENT

If

any abnormality

should be disassembled and repaired.

Pinion

1.

2. Lightly push the pinion back and measure the return

3.

Gap

Connect a battery (12V) between the starter and the starter body, and the pinion drive should rotate out

and stop.

A

CAUTION:

seconds

stroke (called pinion gap). If

the pinion gap is not within the standard range, (0.5 to

2.0 rnrn), adjust it by increasing of

shims on the solenoid. The gap is decreased as the

number

AND

Inspection

Never

continuously.

of

shims increases.

the

motor.

on

the pin-

REPAIR

is

found by the following tests, the starter

terminalS

apply

battery

voltage

or

for

over10

decreasing the number

sep-

No-Load

1.

Connect the ammeter, voltmeter, and battery to the starter as illustrated.

2. When the switch is closed, the pinion must protrude and

A

tighten

type that starter in

Test

the starter must run smoothly the current semble the starter and repair it.

CAUTION:

contact

or

starter speed is out

Use

thick

every

terminal

starter

which

makes a rotating

of a direct-drive

rotation

with

at the

the

pinion

wires

securely.

type

starter.

pinion

gear

(at

3000 rpm or more).

of

specification, disas-

BATTERY

as

much

as

possible

This

is a solenoid

sound

When

detecting

tip,

be

careful

when

it

protrudes.

louder

not

to

If

and

shift·

than

come

SOLENOID

Perform the following tests. satisfactory, replace the solenoid assembly.

1.

Inspect the solenoid for continuity between terminals (+)and(-) M and the body. There should be no continuity found between terminals S and M. Continuity will be found between terminals S and the body and terminal M and the body.

and between terminals

If

any test result is not

Sand

the body and

0.5-2.0

mm

PINION

GAP

Engines

22

MULTIMETER

NOTE:

Disconnect

2. Connect a battery to the solenoid's terminal S for ( +) and M

for·(-). Have a switch in the + lead and close it.

The pinion drive should extend fully out.

A

CAUTION:

than

10

seconds

&

..

CAen~ra.tors

the

Do

wire

not

apply

when

from

battery

testing

terminal

current

the

solenoid.

M.

for

more

AnRACTION

TEST

STARTER

MOTOR

4.

Return

test:.

With a battery connected to the solenoid terminal M ( pinion fully. when released from holding by hand.

-)

and

to the starter body, manually pull out the

The

pinion must return

to

its original position

3.

Holding

minalS(+) pinion fully. y.'hen

HOLDING

STARTER

1.

Disconnect the wire from the solenoid terminal M (-).

2. Loosen the the solenoid assembly.

3. Remove the

fastening the

4. With the brushes pulled away

remove the yoke and brush holder assembly.

the armature out.

5. Remove the cover, pry the snap ring out,

washer.

6. Unscrew the bolts and remove the center bracket.

same time, the washers

adjustment will come off.

test.

With a battery connected to the solenoid ter-

and to the starter body, manually pull out the

The

pinion must remain at that position even

released from holding with your hand.

TEST

DISASSEMBLY

two

screws· fastening the solenoid.

two

long through bolts

brush

holder. Remove the

for

the pinion shaft

and

from

the armature,

two

rear

screws

bracket.

Then

and

remove ·the

end

Remove

pull

At

the

play

RETURN

TEST

BATTERY

SERVICE

WES'IERBEKE uses a standard starter motor which can serviced or rebuilt at any starter motor automotive.service center. Starter motors used on marine gasoline units must be ignition protected. Use only a genuine Westerbeke replacement starter.

7. Pull out the reduction gear lever and lever spring from the

front bracket.

8.

On

the pinion side, pry the snap ring out, and pull out the

pinion and pinion shaft.

9.

At

each end a bearing puller. press-fitted in the front bracket. off, replace the front bracket assembly.

of

the armature, remove the ball bearing with

It

is impossible to replace the ball bearing

If

that bearing has worn·

be

INSPECT

FOR

WEAR & CHIPPING

STARTER·

MOTOR

TYPICAL

LEVER

SPRING

PINION

Engines & Generators

23

NOTE:

Inspect,

if

necessary

soleniJid,

following

---

clean

brush,

armature,

pages.

and

replace

conunuter,

etc.

See

the

GLOW

PLUGS

TYPICAL

DESCRIPTION

The

glow

plugs

are When should

PREHEAT

"click;'

on

is

and the

INSPECTION

To

inspect tions, head. soft

oil burn

the

then

unscrew

Thoroughly

brush

and

deposits.

erosion;

plug,

clean

cleaning

While

if it

has

wired

through

pressed

glow

remove

or

unclamp

each

solution

cleaning;

eroded

NOTE:

WESTERB$KE

ments

be

performed

below

is

provided

the

preh~tsolenoid.

at

the

control

plug

should

the electrical

each

plug

plug's

tip

and

to.remove

examine

too

the

much,

ENGINE

recommends

by

a competent

to

assist

panel

this

solenoid

begin

to

get

teri:ninal

from

tip.fOI'

replace the

the

'threads

all

the

connec-

cylinder with

carbon

wear

plug.

ADJUSTMENTS

that

the

hot.

a

and

engine

mechanic.

following

mechanic.

FUEL

In

case injectors injection loss

of

in

injector clean injector

Before

base

of falling out

easily

.the

injector

free

it,

The

injector washer. replaced

installed.

Injector

engine

The

INJECTORS

of.severe

checked

service

positive

faults.

room

enviroment,

as

a

spare

removing

the

injector

down

into

and

is

side-to-side

and

then

seats

This

washer

with a new

to

Cylinder

adjust-

it:tformation

vibrations

and

center.

fuel

pressure

Since

should a problem

the

to

the

held

lift

it

in

Head

and

overhauled

Poor

to

fuel

injectors must

it

is

best

old

injector,

help

prevent

injector hole. If

in

by

carbon build-up

with

out.

the

cylinder

should

be

washer

Tightening

when

detonation

by

fuel

quality,

the

to

clean

the

aid

head

removed

the

Torque·

an

authorized

contaminants

injection

carry

at

occur.

the

any

rust

the

injector

of

the

on a copper

with

new

40

± 4

noise,

pump

be

serviced

least

area

or

debris

or

the

socket

the

injector

ft·lb

(5.5 ± 0.5

have

fuel can

one

extra

around

from

will

like,

wrench

sealing

'injector

is

the

and

result

in

the

not

work

kgl·m)

a

lift

to

and

TESTING

An

accl}rate Touch the

other glow method You

can

(8

to 9 amps

A

to

the

testing

Re-instalJ plugs 25

seconds, short compound

Glow

Plug

A

than

way

one

prod

to

the

plug

will

can

be

also

WARNING:

touch.

the

the plugs

should

If the

circuit.

on

Tightening

WARNING:

30

seconds

to

the

body of

have a 1.0-

used

use

an

per

plug).

These

Be

careful

plugs

get

vety

plugs

When

the

threads.

Torque

Do

test

glow

plug's

the

glow

to

with

the

plug in. orout of

ammeter

glow

not

in

the

engine

hot

(at the

don't heat

reinstalling

7 ·11 lb·ft

not

keep a glow

plugs

is

with

wire

plug,

as

1.5-ohm

to

plugs

to

resistance.

test thepower

Will

burn

your

and

test

tertninal

up

quickly,

the

glow

(1.0

plug

an

ohmmeter.

connection,

shown. A good

This

the

e~gine.

drain

become

fingers

them

again.

end)

within

check

plugs;

use

anti-seize

·1.5

kg·m)

on

for

more

and

very

hot

When

The

20.to

for

a

·

REFER FOR

TESTING

to

YOI.JR

WESTERBEKE

AND

SERVICING

SERVICE

OF

FUEL

INJECTOR

MANUAL

INJECTORS.

24

11011:

WESTERBEKE adjustments infomtiltioo

ENGINE

ADJUSTMENTS

recommends

be

perftmned

be.low

iS

by

a

Provided

to

that the

competent

assist the

engine

mechanic.

following

mechanic.

engine

The .

IBEIIATORFREQUEICY-

(IIR1Z)

Once•lh¢~tg~~~~~ht~.

there

may

be

adjusttnents

during

the

engine's

this

period.

AJlO..Ioad

required

These

llOllllal

Frequency

indicated by

Wben

voltage

When

· voltage frequeaq is

1. Connect

2. Adjust

in

oonj~AllCtion

are

not.

warrantable.

break-in~

is

a

direct

tbe

followU)g:

tbe

~~

freqlleJley

tbe

generator

tbe

AC

accordance

specified

BT

GENERATOR

COJ:teSpooditig

shortening

the solenoid's plunger

solenoid. Failure

result in a failed

To

avoid.failure

plunger

operation

linkage throttle

throttle

withAC \bltage

for yoor

tbe

engine's

to

tbe

Throttle

· · ·

of

the

solenoid

bottoms

at the initial start-up.

joints

between

joints

between

·arm

will

required

break"in

y~adj~t._y

with

adjustments

maintenance. ·

result

of

isnmattSOOf111u.tJJe:4Cw~

is 60herlz. . . . . .

is

nm

SO

laertz. · · · ·

output~

genenuor

sed;i~oflhis

speed toObtaiatbe

tbe

vot.a,e

j\dj~~,

is

to

solenoid.

of

the

solenoid.

in

tbe

SQ)eooid.

llle

the

eliminate

for

e~ne·•spmi·~)

peri<Jd·(mst

tbe

engine~s

SO~).or

speed

as

·~••rdale

····.·•·

·...

engine/generator

· ·

...

. .

.·

•.• · .•..

at

lSOO

rpcn.

tile

to

the:

AC~tlal·b~in

~-.diagmm

sea.

Which

..

~

manual.

~

selected.

com~ly

botto1n

solenoid solenoid

bjnding.

by

~

in

the

~

efis1d

..

~the

Periodiadly

plunger Md

plunger~

•.

~t

'·

.·

speed •

•··

•....

. . . . ·

~C

hl•tlle··

. . .

ex~

the

soienbid

soleooid•s

lUbricated

· · ·

.•

af!er

be

to

.·.

-~t

•

or

.

.sure

the

will

·

the

IOTE:

The solenoid plunger must move smoothly

rapidly energized. Set

'fo

sPeed,.of'the

monitor

method

into

the solenoid

drawing the engines

Speed/RJm

arrive

Position.

~

tbe

engine/generator

!be

frequency

being

the

when

appropriate

with a

more

precise

the solenoid

throttle

frequency,

with

frequency

of

is

electrically

ann into the

ei.ther

monitor

a tachometer or

meter.

The

the

two.

and

the

latter

DRIVE

Belt

1.

2.

BEl.tADJUS'fiVJa!T

A

CAUTION:

tensioned; alternator

alternator~

Drive

bela

out

of

alignment

out

prematurely.

tension adjustmentis

altemator Lcosen the

mounting Pivot

left or right

Drive

belts

Loose

drfrle

charglnga/ld

that

are

too

and/or

on

its

base

~ternator

bolt.

the

alternator

as

required.

on

must

belt$

Will

will

eveniiJ.ally

tight

will pill/

callse.tlle

made

b)'

mounting

adjusting

the

base

b{l

prtJperly

not

alternator

pivoting

bolt.

strap

~ountiDg

providl,prtJ/J(Ir

damage

the

bolt

the

alternator

Ill

wear

th~

and

the

base

bolt

to

the

..

3.

Tighten

strap bolt.

4.

.

Operate the shut

the

down

base

engine

and

recheck

mounting

for about 5

belt

BaT

bolt

and

minutes

tension.

TENSION

the

adjusting

at

idle,

then

ENGINE

ADJUSTMENTS

11.0KW

VALVE

Adjust the valve clearance when the engine is cold.

0.0098 inches (0.25 mm). Tighten the cylinder head bolts to the specified torque and sequence shown below.

1. Pull off the air breather pipe from the rocker cover, and

2. Adjust the valve clearances at

3.

NOTE:

clearance

11.0KW BOLTS

17mm

soiTs

14mm

CLEARANCE

take off the rocker cover bolts.

each cylinder when they are on their compression stroke. Make sure that

timing mark

If

not, the valve will interfere with the piston because

improper cam positioning.

Retighten·the cylinder head bolts before the valve

is

adjusted.

BTD&

12.5KW

5,6,7,8,9,10,11,12,13 & 14 (11.5

-12.5kg-m)

1

,2,3

& 4

(6.5-

8.0kg-m)

ADJUSTMENT

TDC (Top Dead Center)

the

timing mark on the gear case and

on

the. crankshaft pulley are exactly aligned.

BTDA

83.1-86.7

47.0-57.8

ft-lbs

BTD & 12.5KW

for

of

BTD(A)

VALVE

CLEARANCE

i

. I

--=-7·

,

I

0.25MM

(0.00981NCHES)

INTAKE & EXHAUST

12.5KW BOLTS

22mm BOLTS 1 ,2,3

22mm

11.0KW Rocker

14mm

10mm

12.5KW Rocker

14mm 10mm

NOTE:

BTD

5,6,7,8,9,10,11,12,13 & 14 (15

-16kg-m) & 4

(11 -12kg-m)

BTD & 12.5KW

Shaft

Hold

!town (4.0 • 5.5kg-m) (0.8

-1.2kg-m)

BTD

Shaft

Holddown (4.0 -5.5kg-m) (0.8

·1.2kg-m) 5.8-8.7

MM

size shown are sockets size

J

0

108.4-115.7

79.0-

86

ft-lbs

BTDA

Bolts

28.9 • 39.8

5.8-8.7

28.9 -39.8

ft·lbs

Bolts

ft·lbs

0

1

9

0

1

0

ft-lbs

ft·lbs

ft-lbs

0

5

6

0

for

holddown bolts.

0

lO

8

0

2

0

4

Westerbeke recommends .that these engine adjustments

be

made

by

a.

qualified mechanic.

CYLINDER

HEAD

BOLT

liGHTENING

SEQUENCE

26

ENGINE

ADJUSTMENTS

S.OKW & 10.0KW

VALVE

Adjust the valve clearance when the engine is cold.

0.0098 inches (0.25 mm). Tighten the cylinder head bolts to the specified torque and sequence shown below.

1. Pull off the air breather pipe from the rocker cover, and

2.

~

3. Next, the piston

CLEARANCE

take off the rocker cover bolts. Adjust the valve clearances at

TDC

(Top Dead Center) for each cylinder when they

are on their compression stroke. Align the timing marks on the gear case and on the

crankshaft pulley as shown. In this position, the No.1 cylinder is at its Timing Mark while dead center on its compression stroke. Check both the intake and exhaust valve clearances specific clearance, adjust by means Remember to align the timing marks properly, valve may be pushed up by the piston, depending on the position

the crankshaft aligning the timing mark gear case. Then check and adjust the valve clearance.

of

the cam lobe.

ADJUSTMENT

of

the cylinder.

of

the No.3 cylinder comes TDC. Turn

240° clockwise from the above piston,

Of

the

val,ves

of

adjusting screws.

of

the crankshaft with that

have no

if

not the

of

the

N0.2

TOP

BTD

VALVE

CLEARANCE

~

I

0.25MM (0.0098

,

I

INCHES)

INTAKE & EXHAUST

4. To check the No.2 cylinders valve clearance, turn the

crankshaft another timing marks. Check and adjust the valve clearance in a

. similar manner.

NOTE:

Retighten the cylinder head bolts before the valve clearance is adjusted. MM

size shown are sockets size

ROCKER

14mm

8.0KW 17mm

BOlTS#

14mm

SHAFT

(3.4

and

(11

-12.5

1,2

(6.5

kg-m)

10.0KW

& 3

· 8

kg-m)

240° clockwise and then align the

for

holddown bolts.

HOlOOOWN

24.5

BTD

KG-M)

BOlTS

ft-lbs

BOlTS

83.2-

90.4

47.0 · 57.9

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

ft-lbs

&11

0

7

4

0

O-z

li

0

Ot

TIMING

CRANKSHAFT

MARK

PULLEY

~

N0.3

TOP

Westerbeke recommends that these engine

be

adjustments

made

by

a qualified mechanic.

CYLINDER

HEAD

BOLT

TIGHTENING

SEQUENCE

I"W"IWESIERSEKB

l EnglnN & Generators

27

SPECIFICATIONS

WESTERBEKE

8.0

KW

BTD

GENERATOR

Engine

Type

Governor CornbuGtion

Chamber

Bore & Stroke

Piston

Displacement

Firing

Order

Direotion

of

Rotation

Maximum

(at Compression Compression Valve

Valve

Valve (engine

lnjeotion Engine

Engine Dimensions

Weight Fuel

(approximate)

Inclination

General

Operating Fmsh Raw

Raw

at

System

(fresh

Torque

1800

rpm)

liming

Seat

Angle

C!Barance

cold)

Pressure

Speed

Timing

Consumption

Temperature

Water

Pump

Water

Pump

Water

Flow,

1800

rpm

Capacity

water)

Ratio Pressure

SPECIFICATIONS

Diesel,

four-cycle, water-cooled, mechanism, (14

hp

at Mechanical, Swirl

chamber

2.B7 x 3.07

60

cubic

1 •

3-2

Clockwise,

41.50

lb-tt

23:1

455.2

psi

Intake

Opens

Intake

Closes

Exhaust Exhaust

Intake

45°

Exhaust Intake

0.0098

Exhaust 1707

psi

1800

rpm

1500

rpm

19°

BTDC

Height

21.8

Width:

17.00

Length:

450

los

0.9

gph

Continuous Temporary

COOLING

Fresh

water-cooled

controlled

170 • 190°

Centrifugal Positive

belt-driven.

8.5

US

gpm

before

discharging

5.0

Qts

(4.73

three-cylinder,

vertical

in-line

1800

rpm

maximum).

centrifugal

type

inches

(73 x 78

inches

(0.979

when

viewed

(5.73

kg-m)

(32

kg/em')

18°

BTDC

46°

ABDC

Opens

46°

18°

inches

kg/em' + 10

60

Hertz

50

Hertz

inches

kgs)

lph)

15°

20°

(not

BBDC

ATDC

(0.25

(552.72

(431.80

(716.28

at

full

to

Closes

45•

0.0098 (120

28.20 (204.12

(3.40

SYSTEM

block,

with

heat

exchanger.

f (77-

88°

type,

metal

displacement,

(32.2

lpm)

into

liters).

weight

liters)

from

at

280

(0.25

rated

exceed

C). impeller, rubber

(measured

exhaust

fresh

overhead

valve

type

mm)

the

front

rpm

mm)

kg/em' -Okg/cm'

mm)

output

20

min.)

thermostatically-

belt-driven.

impeller,

elbow).

General

Fuel

Injection

Fuel Fuel

Injection Nozzle Injectors Fuel

Pump Fuel

Filter Air

cleaner

Air

Flow

General

Oil

Filter

Sump

Capacity

(not

including Operating

(engine

hot)

Oil

Grade

Starting

Battery

Capacity

DC

Charging Regulator Starter Starting

Aid

DC

No-Load

DC

Cranking

Emission Systems

Pump Timing

(on

engine)

LUBRICATION

filter)

Oil

Pressure

ELECTRICAL

Alternator

Current

EXHAUST

Control

FUEL

SYSTEM

Open

flow,

self

bleeding

# 2

D(cetane

Diesel

Nippon 19° Throttle

Pintle

12

Volt

Canister

Metal 32

cfm

rating

grade

according

Denso

±.5°

BTDC

type

Type

DC,

Electro-Magnetic

type

screen

type -cleanable

(.906

(Bosch M Type)

(static

with

cmm)

SYSTEM

Pressure

type

external

paper

gals

psi

(2.8

10W·30

by

pressure

element,

(3.121iters).

-

or

15W-40.

with

Full

flow,

3.3

U.S.

40 • 80

API

Specification better SAE

SYSTEM

12-Volt,

(·)negative 400 -600 12 Internal

12-Volt, Glow 90 175-200

Volt

DC,

plugs,

Amps

Cold

Cranking

50

Amp

regulator

1.2

~.

sheathed

max.

at

Amps

(engine

EMISSIONS

Smoke

Puff

Limiter

of

45

or

higher)

to

ASTM

D975

timing)

type

replaceable

Trichoid

5.6

CF,

built

reduction,

11.5

pump,

relief

spin-on

kg/em').

CG-4,

ground

Amps

into

type

volts

cold)

element

gear

valve

type.

CH-4,

(CCA)

alternator

solenoid

SYSTEMS

SAE

driven

Cl·4,

CJ-4

mounted

J313

or

L""'IWESIERBEKS

l

Eng!n•

& Generators

28

SPECIFICATIONS

General

Voltage

Regulation Frequency Rating

60

8.0KW

50

6.0KW

Generator Air

(60

NOTE:

Regulation

(Volts

Hertz

(1800

Hertz

(1500

Cooling

Requirements

Hertz)

at

Increase

AC)

rpm)

1800

air

AC

rpm

supply

WESTERBEKE

GENERATOR

Brushless, Pre-lubricated, Reconnectable, regulation (optional

120

220

±5% ±3

120 120/240

220

175-200

15%

or

1201240

Volts

no

Hertz

Volts

tor

50

four-pole,

single-bearing

single-phase

solid

state

Volts

-

50

Hertz.

load

to

full

(5%)

no

66

Volts

66/33

27

cfm

(5.66-

Hertz

operation

revolving

voltage

-

60

load.

load

to

Amps

6.37

transformer

regulator)

Hertz

full

load.

Amps

cmm)

(1500

field.

design.

rpm).

8.0

KW

BTD

Engine Air

(60

Generator Ambient Recommendations

Cooling

GENERATOR

Combustion

Requirements

Hertz

at

1800

RPM)

Compartment

Temperature

Air

32

cfm

104"f

NOTE:

to

mafntafn

tures

100-200

COOliNG

(.906

cmm)

(40"C)

maximum

Forced

ventilanon

gtJneratar

below

104°F

ctm

(2.83-5.66

should

compartment

(40°G).

cmm)

be

provided

temptJra-

SPECIFICATIONS

WESTERBEKE

10.0

KW

BTD

GENERATOR

Engine

Type

Governor Combustion Bore & Stroke Piston Firing Direction Maximum

(at Compression Compression Valve

Valve

Valve (engine

Injection Engine

Engine Dimensions

Weight Fuel

(approximate)

Inclination

General

Operating Fresh Raw

Raw at

1800

System

(fresh

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Ratio Pressure

Timing

Seat

Angle

Clearance

cold)

Pressure

Speed

Timing

Consumption

Temperature

Water

Pump

Water

Pump

Water

Flow,

rpm Capacity

water)

SPECIFICATIONS

Diesel,

four-cycle, water-cooled, mechanism, (16.5

hp Mechanical, Swirl

chamber

3.07 x 3.07 68

cubic

1

-3-2

Clockwise,

47.71b-ft

23:1

483.5

psi

Intake

Opens

Intake

Closes

Exhaust Exhaust

Intake

45°

Exhaust Intake

0.0098

Exhaust 1707

psi 1800

rpm 1500

rpm 19°

Bmc

Height:

22.0

Width:

16.85

Length: 4951bs

1.0

gph

Continuous Temporary

COOLING

Fresh

water-cooled

controlled 170-190° F (77Centrifugal Positive

belt-driven.

7.2

US

gpm

before

discharging

8.0

qts

(7.61iters).

three-cylinder,

vertical

in-line

naturally

at

1800

inches

when

(6.6

(34

Opens Closes

45°

0.0098 (120

60 50

32.56 (224.5 (3.781ph)

20°

aspirated

rpm

centrifugal

type

(78 x 78

(1.12

viewed

kg-m)

kg/em')

18°

BTDC

45°

ABDC

46°

BBDC

18°

ATDC

inches

(0.25

inches

kg/em'

Hertz Hert.z

inches

(558.7

inches

(427.9

inches

(826.02

kgs)

at

full

15°

(not

to

SYSTEM

block,

with

heat

exchanger.

88°

type,

metal

displacement,

(27.25

lpm)

into

maximum).

weight

liters)

from

at

230

(0.25

+ 1 0

rated

exceed

C).

impeller,

rubber

(measured

exhaust

fresh

overhead

valve

type

mm)

the

front

rpm

mm)

kg/em' -Okg/cm'

mm)

output

20

min.)

thermostatically-

belt-driven.

impeller,

elbow).

General Fuel

Fuel

Injection

Fuel

Injection Nozzle Injectors Fuel

Pump

Fuel

Filter

Air

cleaner

Air

Flow

Fuel

Lift

Pump

General

Oil

Filter

Sump

Capacity

(not

including Operating

(engine

hot)

Oil

Grade

Starting

Battery

Capacity

DC

Charging

Regulator

Starter Starting

Aid

DC

No-Load

DC

Cranking

.

Emission Systems

FUEL

Pump Timing

(on

engine)

LUBRICATION

filter)

Oil

Pressure

ELECTRICAL

Alternator

Current Current

EXHAUST

Control

SYSTEM

Open

flow,

self

bleeding

# 2

D(cetane

rating

Diesel

grade

Nippon

19°

±

.SO

Throttle Pintle

Type

12

Volt

DC,

Canister

Metal

screen

48

cfm

(1.36

12

Volt

DC

Dense

type

of

according

(Bosch M Type)

BTDC

(static

Electro-Magnetic

with

replaceable

type -cleanable

cmm)

lift

capacity

SYSTEM

Pressure

type

by

paper

gals

psi

(2.8-

Trichoid

pressure

element,

(4.51iters).

5.

kg/em').

CF,

or

15W-40.

with

external

Full

flow,

4.76

U.S.

40 -80

API

Specification better SAE

10W-30

SYSTEM

12-Volt,

(-)

negative

ground 400 -600 12 Internal 12-Volt, Glow 90 175-200

EMISSIONS

Smoke

Volt

plugs,

Amps

Cold

Cranking

DC,

50

Amp

regulator

1.6

i<J/1/,

sheathed

max.

at

Amps

(engine

Puff

Limiter

built

reduction,

11.5

SYSTEMS

45

or

to

ASTM

timing)

5'

(1.5m)

pump,

relief

spin-on

CG-4,

Amps

into

type

volts

cold)

higher)

SAE

D975

type

element

gear

valve

type.

CH-4,

Cl-4,

(CCA)

alternator

solenoid

J313

driven

CJ-4

or

mounted

Single

Phase

Voltage

Regulation Frequency Rating 60

10.0 50

7.51W'/ Generator

Air (60

NOTE:

Regulation

(Volts

Hertz

(1800

IW'I

Hertz

(1500

Cooling

Requirements

Hertz)

at

Increase

AC

GENERATOR

Brushless, Pre-lubricated, Reconnectable, regulation (optional

120 220

±5% ±3

AC)

rpm)

rpm}

1800

air

rpm

supply

120 1201240

220

225 -250

15%

SPECIFICATIONS

WESTERBEKE

or

1201240

Volts • 50

no

load

Hertz

Volts

for

50

SINGLE

four-pole,

solid

(5%)

Volts

cfm

Hertz

PHASE

revolving

single-bearing

single-phase

state

voltage

Volts·

60

load.

load

to

full

83.3

Amps

83.3/41.6

34.1

Amps

6.37

(1500

Hertz

Hertz.

to

full

no

(5.66-

operation

transformer

regulator)

load.

Amps

cmm)

10.0

field.

design.

rpm).

KW

BTD

Three

10.0

IW'I·

7.5

IW'I · 50

Voltage (60

Hertz)

Voltage (50

Hertz)

Amperage (60

Hertz)

Amperage (50

Hertz)

Engine

Air

Requirements

(60

Hertz

Generator Ambient

Recommendations

Cooling

GENERATOR

AC

GENERATOR

Phase

60

Hertz

• 3

Phase

-3

Phase

-3

Phase

-3

Phase

Combustion

at

1800

Compartment

Temperature

Air

RPM)

Brushtess, lubricated reconnectable voltage

Delta.

protection Low

vottage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

vottage

DELTA High

voltage

DELTA

GENERATOR

32

cfm

(.906

104•F

{40°C)

NOTE:

Forced

to

maintain

tures

below

10o-200

THREE

six-pole,

single

circuitry.

bearing

for

Solid

WYE

PHASE

revolving

low

voltage

state

COOLING

cmm)

maximum

ventilation

generator

cfm

t04•F

(4o•c).

(2.83·5.66

compartment

field.

design.

WYE,

voltage

208

·

480 240

380 220

35Amps 15Amps 30Amps

14Amps 24Amps

should

cmm)

Sealed

121ead

high

regulator

volts volts

volts

be

provided

tempera-

with

SPECIFICATIONS

Engine

Type

Governor Combustion Bore & Stroke

Piston Firing Direction Maximum

(at

Compression Compression Valve

Valve

(engine Injection Engine

Engine Dimensions

Weight

Fuel

(approximate) Inclination

General

Operating !=resh Raw

Raw

at

1800

System (fresh

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Ratio

Pressure

Timing

Seat

Angle

Clearance

cold)

Pressure

SpeM

Timing

Consumption

Temperature

Water

Pump

Water

Pump

Water

Flow,

rpm

Capacity

water)

WESTERBEKE

SPECIFICATIONS

Diesel,

four-cycle,

water-cooled, mechanism,

(18.4

hp Mechanical, Swirl

chamber

2.87 x 3.07 80

cubic 1-3·4 Clockwise, 54

lb·ft

(7

23:1 455

psi

(32

Intake

Opens

Intake

Closes

Exhaust Exhaust

Intake

45°

Exhaust Intake

0.0098

Exhaust 1707

psi

1800

rpm

1500

rpm

19°

BTDG

Height:

23.75

Width:

16.85

Length:

34.56

5751bs

(260.8

1.2

gph

Continuous Temporary

COOLING

Fresh

water-cooled

controlled

170c

-190° Centrifugal Positive

belt-driven.

7.2

US

gpm

before

discharging

8

qts

(7.61iters).

three-cylinder,

vertical

in-line

at

1800

rpm

maximum).

centrifugal

type

inches

(73 x 78

Inches

(1.3051iters)

·2

when

viewed

.46

kg-m)

kg/em')

at

280

18°

BTDC

46"

ABOC

Opens

46°

60 50

15•

20"

inches

kg/cm

Hertz Hertz

inches

kgs)

at

(not

BBDC

ATDG

(0.25

2

+

(603.25

(427.99

(877.82

full

to

exceed

Gloses18°

45•

0.0098 (120

{4.541ph)

SYSTEM

block,

with

heat

exchanger.

F (77•-

sa•

type,

metal

displacement.

(27.251pm)

into

·

weight

(0.25

10

impeller, rubber

exhaust

11.0

fresh

overhead

valVe

type

mm)

from

the

front

rpm

mm)

kg/cor-

Okg/cm

mm)

rated

output

20

min.)

thermostatically-

C).

belt-driven.

impeller,

(measured

elbow).

2

KW

General Fuel

Fuel Fuellnjec+Jon Nozzle Injectors Fuel Fuel Air AirFlow

General

Oil Sump

(not Operating

(engine

Oil

Starting Battery DC Regulator Starter Starting DC DC

Emission Systems

BTD

GENERATOR

Injection

Pump Filter

(on

cleaner

Filter

Capacity

Including

Oil

hot)

Grade

Battery

Capacity

Charging

Alternator

Aid

No-Load

Current

Cranking

Current

EXHAUST

Control

FUEL

Open

# 2

Diesel Pump Timing

engine)

Nippon 19• Throttle Pintle 12 Canister Metal

42.

lUBRICATION

Pressure with

Full

filter)

Pressure

4.23

40 • 80

API better SAE

ELECTRICAL

12-Volt, 400 • 600 12 Internal 12-Volt, Glow 90 175·200

EMISSIONS

Smoke

SYSTEM

flow,

self

D(cetane

rating

grade

according

Denso

(Bosch M Type)

±

.s•

BTDC

type

Type

Volt

DC,

Electro-Magnetic

type

with

screen

type -cleanable

cfm

(1.2

cmm)

SYSTEM

type

by

external

pressure

flow,

paper

u.s.

gals

(4.0

psi

(2.8 -5.6

Specification

10W·30

or

SYSTEM

(·)

negative

Cold

Volt

DC,

50

regulator

1.6

KW,

plugs,

sheathed

Amps

max.

Amps

Puff

Limiter

bleeding

of

45

or

higher)

to

ASTM

(static

timing)

replaceable

Trichoid

pump,

relief

valve

element.

spin-on

liters).

kg/em>).

CF,

CG-4,

CH-4,

15W·40.

ground

Cranking

Amps

Amp

built

into

alternator

reduction,

at

{engine

11.5

solenoid

type

volts

cold)

SYSTEMS

0975

type

element

gear

type.

C1·4,

(CCA)

SAE

J313

driven

CJ-4

mounted

or

SPECIFICATIONS

Single

Phase

Voltage

Regulation Frequency Rating

(Volts

60

Hertz

(1800

11.0

KW

50

Hertz

(1500

6.3KW

Generator

Air (50

NOTE;

Cooling

Requirements

Hertz)

at

Increase

Regulation

AC)

rpm)

1

BOO

rpm

air

supply

WESTERBEKE

Brushless, Pre-lubricated, Reconnectable,· regulation (optional

120

220

:t5% ±3

120

120/240

220

200 -225

15%

solid

or

120/240

Volts -50

no

load

Hertz

(5%)

Volts

for

50

Hertz

four-pole,

single-bearing

single-phase

state

voltage

Volts -60

Hertz.

to

full

load.

no

load

91.5Amps·

91.6/45.8

37.7

cfm

(5.66 -6.37

operation

revolving

transformer

regulator)

Hertz

to

full

load.

Amps

cmm)

(1500

design.

field.

rpm).

11.0

.

KW

BTD

Three

11.0

8.3

KW-

Voltage (60

Hertz)

Voltage

(50

Hertz)

Amperage-3 Phase

(60

Hertz)

Amperage

(50

Hertz)

Engine Air

Requirements

(60

Hertz

Generator Ambient Recommendations

Cooling

GENERATOR

AC

GENERATOR

Phase

KW -60

Hertz

50

Hertz

-3

Phase

-3

Phase

-3

Phase

Combustion

at

1800

Compartment

Temperature

Air

RPM)

Brushless, lubricated reconnectable voltage protection

Low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA High

voltage

DELTA.

GENERATOR

32

elm

104°F

NOTE:

to

maintain

tures

100-200

THREE

six-pole,

single

Delta.

circuitry.

bearing

for

Solid

WYE

PHASE

revolving

design.

low

voltage

state

voltage

COOLING

(.906

cmm)

(40°C)

maximum

Forced

ventilation

generator·compartment

below

104°F

cfm

(2.83-5.66

should

(40°C).

cmm)

field.

Sealed

12

lead

WYE,

high

regulator

208

volts

480

volts

240

volts

380

volts

220

volts

38

Amps

16

Amps

33Amps 15

Amps

27

Amps

be

provided

tempera-

with

l"'IIV"IWEBIERBEKE

l EnglnM &

Generators

33

SPECIFICATIONS

WESTERBEKE

12.5

KW

BTD(A}

GENERATOR

Engine

Type

Governor Combustion Bore & Stroke Piston Firing Direction Maximum

(at Compression Compression Valve

Valve

Valve (engine

Injection Engine

Engine Dimensions

Weight Fuel

(approximate)

Inclination

General

Operating Fresh Raw

Raw at

1800

System (fresh

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Ratio Pressure

Timing

Seat

Angle

Clearance

cold)

Pressure

Speed

Timing

Consumption

Temperature

Water

Pump

Water

Pump

Water

Flow,

rpm Capacity

water)

SPECIFICATIONS

Diesel,

four-cycle, water-cooled, mechanism, (23

Mechanical, Swirl

3.07 x 3.07 91

cubic

1·3-4-2

Clockwi.~>e,

671b-ft

23:1 455 Intake

Intake Exhaust

Exhaust Intake

Exhaust 1707 1800

1500 19° Height:

Width: Length:

6381bs

1.4

gph

Continuous Temporary

COOLING

Fresh controlled

170°

.

Centrifugal Positive

belt-driven.

7.2

US

before 8

qts

vertical

hp

at

1800

centrifugal

chamber

type

inches

when

(9.26

kg·m)

psi

(32

kg/em')

Opens

20°

Closes

44o

Opens Closes

45°

0.0098

inches

0.0098

psi

(120

kg/em'+

rpm

60

Hertz

rpm

50

Hertz

BTDC

25.34

inches

18.17

inches

37.25

inches

(289.4

(5.29

lph)

15°

20°

SYSTEM

water-cooled

with

-190"

F (77"-

type,

displacement,

gpm

(27.251pm)

discharging

(7.61iters).

rpm

(1.491iters)

viewed

44° 20•

inches

kgs)

(notto

heat

metal

three-cylinder,

in-line

overhead

maximum).

weight

type

(78 x 78

mm)

from

the

at

280

rpm

BTDC ABDC

BBDC ATDC

(0.25

mm)

(0.25

mm)

10

kg/em'-

(643.60

mm)

(461.50

mm)

(946.10

mm)

at

full

rated

output

exceed

20

block,

thermostatically-

exchanger.

sa·

C).

impeller,

belt-driven.

rubber

impeller,

(measured

into

exhaust

elbow).

fresh

front

Okg/cm

min.)

valve

FUEL

SYSTEM

General Fuel

Fuel

Injection

Pump

Fuel

Injection

Timing

Nozzle

Injectors

Fuel

Pump

Fuel

Filter

(on

engine)

Air

cleaner

AirFlow

General

Oil

Filter

Sump

Capacity

(not

including

filter)

Operating (engine

Oil

2

Starting

Battery DC

Regulator Starter Starting

DC

Oil

hot)

Grade

Battery

Capacity

Charging

Aid No-Load Crankinq

Pressure

Alternator

Current

EXHAUST

Emission

Control

Systems

Open

flow,

self

bleeding

# 2

D(cetane

Diesel Nippon 19• ± .5° Throttie Pintle 12

Volt Canister Metal 48

cfm

LUBRICATION

Pressure

with Full

4.76

. 40-

API

better SAE

ELECTRICAL

12-Volt. 400 • 600 12

Volt

Internal 12-Volt, Glow 90

Amps

175·200

rating

grade

according

Denso

(Bosch M Type)

BTDC

(static

type

Type

DC,

Electro-Magnetic

type

with

screen

type -cleanable

(1.2

cmm)

SYSTEM

type

by

elrternal

pressure

flow.

paper

element.

u.s.

gals

(4.51iters).

80

psi

(2.8-

Specification

10W•30

or

15W•40.

SYSTEM

(-)

negative

Cold

Cranking

DC,

50

Amp

regulator

1.6

KW,

plugs,

sheathed

max.

at

Amps

(engine

EMISSIONS

Smoke

Putt

Limiter

of

45

or

higher)

to

ASTM

timing)

type

replaceable

Trichoid

5.6

CF.

built

reduction,

11.5

pump,

relief

spin·on

kg/cmz).

CG-4,

CH-4,

ground

Amps

into

alternator

solenoid

type

volts

cold)

element

valve

(CCA)

SYSTEMS

SAE

0975

gear

type.

Cl-4,

mounted

J313

dt:iven

GJ-4

or

Single

Phase

Voltage

Regulation Frequency Rating

(Volts

60

Hertz

(1800

12.51<W 50

Hertz

(1500

9.310N Generator

Air

(60

NOTE:

Cooling

Requirements

Hertz)

Increase

AC

GENERATOR

Regulation

AC)

rpm)

at

1800

rpm

air

supply

15%

SPECIFICATIONS

WESTERBEKE

SINGLE

Brushless,

Pre-lubricated, Reconnectable, regulation {optional

120 220

±5% ±3

120 120/240

220

200-

or

120/240

Volts -50

no

load

Hertz

Volts

255

for

50

four-pole,

solid

{5%)

cfm

Hertz

PHASE

revolving

single-bearing

single-phase

state

voltage

Volts -60

Hertz.

to

full

load.

no

load

to

full

1

04

Amps

104/52

Amps

42.3

Amps

{6.37-

7.08

operation

(1500

12.5

field.

design.

transformer

regulator)

Hertz

load.

cmm)

rpm).

KW

BTD(A}

GENERATOR

AC

GENERATOR

Three

Phase

12.5

I<W

-

60

KW -50

Hertz

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Combustion

Hertz

at

1800

Compartment

Temperature

Air

Hertz

Phase

RPM)

9.3

Voltage

{60

Voltage (50

Amperage (60

Amperage (50

Engine Air

Requirements

(60 Generator

Ambient Recommendations

Cooling

THREE

Brushless, lubricated reconnectable voltage protection

Low High DELTA

High DELTA

Low High DELTA

High DELTA

GENERATOR

32

104•F

NOTE:

to

tures

100-200

six-pole,

single

Delta.

circuitry.

voltage

cfm

(.906

(40•C)

Forced

maintain

below

cfm

for

Solid

WYE

WVE

WYE

COOLING

cmm)

maximum

ventilation

generator

104"f (

(2.83-5.66

PHASE

revolving

bearing

design.

low

voltage

state

voltage

l.ihould

compartmtmt

40°C).

cmm)

field.

Sealed

121ead

WYE,

high

regulator

208

volts

480

volts

240

volts

380

volts

220

volts

43Amps 18

Amps

37

Amps

17

Amps

3D

Amps

be

providcd

tempera-

with

/,y-#WESI!f!lEKE

f

Engines

&

GeneflltonJ

35

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The power required

than

is

more Some motors require

- others. Split-phase under similar circumstances, monly used machines; or where started, such 7 times avoided, whenever ven

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

In

general,

to

medium

MOTOR

*NOTE:

more for

for

this is that the

made-in

Because the motors be damaged if it seconds. off

all

on the electric

Required

Run the generator generator's capacity, indicted on the generator's should be checked periodically the generating plant voltmeter or and load, check it

NOTE:

contains AC equipment that

the

vide

panel.

generator.

required

on

as

much current to start

a small

to

which

the

current

starting

SIZE

(HP)

1/6 114 113 1/2 314

1

In

the

some

~er

fieavy

is

required.f6r.only

If

difficulty

other electrical

Operating

ampere

When

the

generator's AC tenninal block

one

120 volt AC hot

This

will

MOTORS

to

start

to

keep

much

(AC)

motors

easy-starting

loads

small

power

possible,

generator.

to 4 times

required

it

An electric motor connected

example, no

load

is

required

loads

will

AMPS

(AMPERES

above

table

small

motors

hardest

sizes.

surge

can

bring is

experienced

loads

motor.

Speed

first

with

and

the

meter

with

a portable meter and

vessel

in

of

ensure

good motor starting

an

electric motor

it running

more current

require more current to start,

than

other

loads,

such

are applied after

tools.

Because

as

to

run,

if

the

electric motor is

Capacitor and repulsion-induction

as

much current

to

start

any

will require more current

connected.

to

start

115-

be

approximately

FOR

RUNNIN~)

3.2

4.6

5.2

7.2

10.2 13

the

maximum

than

for larger

starting types (split-phase)

of current needed

an

instant, the generator will not

the

motor

in

and,

if possible,

no

load applied,

finally

loaded

data

plate. The output voltage

to

ensure proper operation of

appliances it

is

not installed

which

the

generator

120

volts

only,

leg

for

the

vessel's distribution

is

considerably

~r

it

is

started

to

start

them

than

types.

They

are

as

washing

the

motor is

they

require 5

their

use

should

to

be

to

start

motor

varies

with

to

an

than

Volt

motors

connected

as

follows:

AMPS

FOR.

(~TARTIN~)

AMPERES

6.4

to

22.4*

9.2

to

32.2*

10.4

to

72.8*

14.4

to

29.2*

20.4

to

40.8*

26to

52

Amps

for Starting

ones.

The

reason

are

for

starting

up

to speed

starting motors, turn

to

be

in a few

reduce

the load

then

at half the

its full .capacity

supplies.

to

it

configured

If

an

monitor voltage

amp

probe.

is

installed

is

recommended

to

response

from

com-

dri-

as

air

a

AC

pro-

to

be

the

not

as

the

is

Generator

Frequency is a direct result of engine/generator speed, indicated

• When the generator output

• When output

Therefore, to tor's drive engine's speed must of the AC output connections at

sary.

Generator

• Maintaining reasonable cleanliness is important. Connections of terminal boards and rectifiers may become ducting

allowed to build cause excessive heating

• For unusually severe conditions, thin rust-inhibiting leum-base coatings, should be sprayed or brushed surfaces suggested 410" and Ashland ''Tectyle 506"

• In addition

inspected for

of overheated terminals

• The drive checked periodically and for

. should not

accelerate cracking. The bolts which fasten the drive to

8, ners of

• The rear annature bearing is lubricated and sealed; maintenance noisy or rough-sounding,

• Examine bearing at periodic intervals. of shaft should be detected motion shaft of bearing socket outside bearing Repair rub

The and

decal

~

generatpr

These

Frequency

by

the

following:

frequency

the

generator

frequency

change

Adjustment

is

run

at

1800

is

60

Hertz.

is

run

at

1500

is

50

Hertz.

the generator's

be

the

RPM,

the AC

RPM, the AC

frequency,

changed. A reconfiguration

generator is also

the

genera-

Maintenance

corroded,

if

salts,

to

are

discs

any

the generator shaft must be hardened steel SAE identified

the

is detectable, bearings

n:rust

an~

cause major damage to generator.

generator's frequency

is

on

end

voltage

and

insulation surfaces may start

dust, engine exhaust, carbon, etc.

up.

Clogged ventilation openings

and

reduced life of windings.

reduce rusting

Daubert Chemical Co. "Non-Rust

to

periodic cleaning, the generator should

(a)

tightness of

on

evidence of incipient cracking failure.

be

allowed

by

6 radial marks,

head.

is

required.

be

made quickly or major components

data

rating

the

inside

that

diagrams

and

corrosion. Typical

or

equivalent.

all

connections, (b)

and

(c)

loose or damaged

single bearing generators should

if

possible for tightness of

to

become rusty because rust

one

at each of the 6

However,

have

when

plate

gives

of

the

generator.

of

the

includes

ate

if

the bearing

it replaced.

No

force

are

wearing or wear

the

voltage,current,

An

louvered

the

also

cover

AC

voltage

shown

side

is

applied. if side

has

occurred.

AC

wiring

at connections.

on

these

screws

movement

the

voltage

neces-

materials

AC-

evidence

as

con-

are

may

petro-

over

all

be

wires.

be

Discs

may

disc

grade

cor-

no

becomes

on

will

pages.

.

. ·

.

Enpintis~.Gene,._o.rs

36

BT

GENERATOR

This

generator

which

requires

duce

AC

output.

stator

are

responsible

erator.

The

magnetic

be

induced

tion. DC creates

windings supplied parallel

produced main

tifier.

the a

rated available produce a more

into

Diodes

and

supply

an

electromagnetic

of

the

to a load. A step

to

the'

in

the

stator

and

The

rectifier

exciter

stator

AC

output.

to

work

located

is a four-pole;

only

the

driving

The

copper

for

field

the

it

to

the

windingS

main

stator,

AC

output

of

auxiliary

is,

in

turn, supplied to a

produces

windings,

An

optional

in

tandem

stable

AC

brushless,

force of the

and

the

self-exciting

produced

exciter rotor

exciter rotor rectify

field

inducing

down

transformer

the

main

windings

a DC

enabling

solid-state

with

output.

laminated

causes

of

the

which

rotates

an

stator.

of

the

voltage

the

transformer

self-excited

windings rotating

AC

full-wave

generator

engine

to

iron

in

the

feature

of

an

AC

voltage

during

this

voltage

field.

through

voltage

is

connected

An

AC

voltage

transformer

bridge

to

further

excite

to

voltage

regulator

generator

pro-

exciter

this

gen-

to

rota-

to

This

the

which

is

in

is

and

the

rec-

produce

is

to

A circuit

to,rs.

ator breaker tor

NOTE:

add-on

This

power

to

ensure

This

breaker

circuit

in

can

be

circuit

kit for

case

no

earlier

WESTERBEKE

SHIMS

is

installed

breaker

of

an

manually

power

is

brea~r

model

dealer.

on

all

will

automatically

electrical

shut

off

coming

is

available

gerterations;

.

WES1ERBEKE

disconnect

overload. when into the

The

servicing

boat.

as a WESTERBEKE

contact

genera-

circuit

the

genera·

your

gener·

AC

TERMINAL

BOARD

BT

GENERATOR

SINGLE

PHASE

(6

STUD}

COMPOUND

TRANSFORMER

Engines & Generatqrs

37

BT

GENERATOR

SINGLE

PHASE

OPTIONAL

BT 6 STUD

An

optional solid-state voltage regulator (board

ig

nvail!tble

installed, position, pound age

output. excitation fanner provides excitation to the group 2 exciter

AUTOMATIC

MODELS

for

us~

with

and

the regulation switch is moved to

the regulator works together with the

transfonner regulator to regulate

In the ELEC mode, the regulator provides

to

the

groupl

VOLTAGE

REGULATOR

ONLY

the

BT series generators.

the

exciter windings,

and

generator's volt-

Installation

l.

The

regulator

the

generator's

each

15mm

tor

board.

2.

Connect

the regulator

NOTE:

The

one

direction.

~.

Before moving the selector switch to the

the

NO-Load

the

COMP

Load

voltage

volts

(60Hz)

procedures

4.

With

the

move

the

regulator

at

120-

51.5-

allel

with

voltage

FULL-Load.

NOTE:

Do

dawn.

Use

the

regulator

exciter

circuit

for

loadEd

is

mounted using existing tapped

case.

Use

two

long,

with lock washers

the

6·prong

plug

is

Check

position

as

generators.

selection

122

volts

52~0

Hertz). The regulator board

the

output within

not

uuc

the

compound

to

perform

power.

generator

board.

keyed

to

engage

this

and insert it

voltage

produced

will

have

should

be

adjusted

or

224 -228

explained

earlier

no

load voltage properly adjusted,·

switch

board

potentiometer to set

at

61.5- 62.0 Hertz

compound

the

transformer and

;t5

per cent from NO-Load

regulator

transformer for

this causes

This

leaves

volts

into the

conditions.

(2)

M4;

0

to

mount

plug

to

the

regulator

correctly.

by the generator

to

be adjusted.

down

between

(50Hz)

following

in

tllis

manual.

ELEC

NQ..Load

(230-

is

to

force NO-wad

this

the

regulatorto

less

exciter

7mm

receptacle

ELEC

position.

operating in

should

circuit

#34410)

When

the

ELEC

standard

the

trans-

windings.

holes

screws,

the

regula-

.receptacle

position,

when

The

NO·

114-

the

Adjust

voltage

234 volts at

maintain

to

voltage

jUnction.

use

power

(AVR)

com-

in

on

in

118

par-

Using

more

BT

GENERATOR

NOTE:

WESTERBEKE

and

adjustments

LOW VOLTAGE

COMPONENT

F

SELECTOR

B

ROTOR

COMPONENTS

82.

EXCITER

B3.

ROTOR

81.

EXCITER

A ·1·1+2 ExCITER

NO

AC

VOLTAGE

MAIN

STATOR,

COMPONENT

C 1+2

MAIN

B 4

POSI

RESISTOR

· B 2

DIQDES

D

1+2

COMPOUND

B. 3

ROTOR

RESiDUAL

COMPONENT CHECKS:

A 1-1+2

G

D 3

C 3

F.

CIRCUIT CONNECTIONS connections

EXCITER

BRIDGE

SELECTOR

RECTIFIER·

TRANSFORMER

MAIN

STATOR

on

the

TROUBLESHOOTING

recommends

be

performed

60~

CHECKS:

SWITCH

STATOR

(4-6

FIELD

SWITCH

(6

ROTOR

FIELD

WINDING

ROTOR

STATOR

ROTOR

CHECKS:

WINDING

OPEN/SHORTED)

TRANSFORMER

WINDING

VOLTAGE

STATORWINDING(S)

AUX.

(from

Bridge

Rectifier)

that

the

by

a

100

Stud

DIODES

WINDING(S)

WINDING(S).

following

qualified

VOLTS

.

Mpdels).

OUTPUT

COMPONENTS,

WINDING

EXCITER

· WINDING

WINDING

the

Translorrner

tecfmician.

AC

a,b,c.

CIRCUIT

Aux.

winding

CHART

ge11erator

.

tests

TRANSFORMER

FAULTY

to

the

SwitGhing

A

before

vice-versa

ing

may

the

Shore

CAUTION:

with

cause

generator.

Heavy

switching

because

heavy

AC

ctamage

Power

motor

shore

voltage

loads

to

the

to

leads

power

surges

on

the

exciter

Generator

should

to

generator

vessel

circuit

Power

be

induced

being

components

shut

off

power

or

by

switch-

operated

in

engines

& Generators

38

INTERNAL

WIRING

SCHEMATIC

(t2-STOQ}

BT

GENERATOR

D.

COMPOUND

·

WINDINGS

·r-

----·=-.;..

J D .

I · . I . 6 ·

TRANSFORMER

. -. - .

- - -

..,

1,12

STUD

TE.NALBLOCI

A

EXCITER

1 ....

1o.o n ·..

.B.

AUXIUARY

1 o b c

Auxiliary

a-b .... 1.3

2

Diodes

3

Ho~ting

4

Thermister

C

MAIN

STATOR

1

aRd 2 ..••.

3

Main

Stator

STATOR

ROTOR

(6)

Reid Windings •••.

..0.6

WINDINGS

W!NDINGS

Windings

n.

k

....

1.3

.... 0/i.nflnite

••.

.infinite

WINDINGS

Q..

Auxiliary

Windings ....

G·

BRIDGE

RECTIFIEI

COMPONENT

·

are

measured

n.

o-a

....

1.a

n

8.1

n

.

:1

.8 a

in

.pairs:

RESISTANCE

D

G

Nota:

accesser; easily

A.

the When

I)Qth

{II

COMPOUND

1 . .aod.J;

3

8RID~E

..

connection points

....

Compound

RECTIFIEFl

Resistaqce reaqings and

04 and84 byloeating

·checking

ofJhe.

component's electrical

f I

,-.;til

i :

t . . . l

~:

2

....

1·3~~.

I . . . . . 'BLK

l ·

I .

OHMS).

TRANSFORMER

o.z.o

Transformer

for~·

winding

comporn3nts

shOWn

resistarJt::,e · V,alues

Aux.

the

on

voltage

calor

the

wttmn.tt:s

.

Windings ...

in the

caded

abpve

connections.

checks

.exciter

wires

schematic.

be

si.Ire

:::

~,~

3

..

~

4.3

n

can

I:Jfi.

circuit

at,

: .

to 'lift

·

AC.,lntoBridge Rectifier:

DG.out

af

B~iclge

NOTE: A illustrated booklet for the 6 & generators Troubleshooting) off our website www.westerbeke.com

EXCITER

CIRCUIT

Rectifier:

(AC

·loW"lWEBTER1!11iKE

VOLTAGES

No

Load

16

VAC

No

Load 7 VDC ~ Full Load 20

Electrical Testing,

is

available in

fEngines

pdf

& Generators

39

(NOMINAL)

• Fuli,Load 45

12

Stud

Adjustments

form

to

download

.

VAG

VDC

BT

and

GENERATOR

NOTE:

WESTERBEKE

tests

and

adjustments

VOLTAGE

recommends

be

performed

ADJUSTMENT

that

the

following

by a quailified

generator

technician.

NO-LOAD

Voltage being

1.

2.

To The output

hertz)..

NOTE:

produced load remqved. momentary

3.

To (non-conductive under transformer. soften small times laminated shims

VOLTAGE

adjustment

governed

The

selector

position.

confirm

a

momentary

voltage

tary

load

from The

volts

at

61.5-62

The

no-load

by

should

be

The

load

raise

or

the

at

temperatures

reduction

be

accomplished

and

is

the

voltage produced

lower

steel

the

ADJUSTMENT

is

made

with

by

the

compound

switch,

if

installed, must

no-load

removed no-load

applied

voltage,

(moderate)

produced the

generators

voltage

hertz

voltage

generator

to

is

removed

the

material)

laminated

The

material

in

no-load

bar

to

transformer

load

by

the

is

no-load

120

(232- 236

should

once

excite

is

no•

voltage, shims of

are

bar

used

in

the

voltage

by

gently

reduce

core.

the

generator

transformer.

start

the

to

excite

generator

voltage.

volt

leg(s)

should be

volts

be

adjusted to the

staned

and

the

transformer

~Y

the

generator

load

voltage.

placed

on

top

of

for

shimming

176° F (80°

(1

tapping

the

gap

regulation

be

in

the

COMP

generator

between

at

varying

or

removed

the

.to

between

and

the·transformer.

after

the

momen-

Note

the

(230

volt

121·124

51.5-52

a

momentary

and

after

thickness

compound

should

C) range. A

3

volts)

can

the

top

the

apply

voltage·

50

hertz).

voltage then

this

from

.

not

·some

of

the

existing

FULL·LOAD

The

voltage

from

60Hz

the

generators·

Fine

voltage

wires

progressively

have

to

Should (210

volts-50Hz),

·

VOLTAGE

hertz

to

50Hz

full~load

adjustments

A to

leads

#1, #2,

in

that

be

made

as

full~load

output

A

TWORED

WIRES

ADJUSTMENT

connection

can

also

output.

and

order.

well.

fall

the

voltage

6

AND

12

CONNECTION

bar

be

used

can

be performed

#3

increasing

A no-load

below

should

STUD

BARS

that

is

used

to

increase

by

the

voltage

108

volts-60Hz

be

adjusted.

12

VOLTAGE

HERTZ

when

changing

or

decrease

repositioning

loaded

voltage

adjustment

STUD

will

NOTE:

No-load

with

the

·

adjustments placed

on

Less

of

generator

cause a drop

Shim voltage material material

voltage

compound

to

compensate

the

generator/engine

herk/speed, the

in

voltage

thickness

ofO.OOl

by

approximately

raises

the

lowers

no-load

may

be

transfonner.

for overload

output.

inch

4 ~ 6

no-load

voltage.

effected needing

Do

notuse

.these

corulitions

(inductive-motor

result

of

overload,

will

change

the

volts.

Adding

Removing

readjustment

being

type

loads}.

will

no-load

shim

NOTE:

When

and

if the

to

correspond regulator to

produce

the

.optional

Blue/White

to

the

will

sense

abnormally

voltage

(Blue)

lead

Hertz

the

inc_orrect

high

output

regulator is

not

correctly

unit

is

operating

voltage and

voltage.

is

installed

cause

positioned

at,

the

generatQr

En_gines

40

& Generators

NOTE:.

tests

Generator

I.

Frequency

1800

1500

2.

To

a.

b.

If

installed, do not change the wiring Voltage/Hertz Connection AC

c.

Frequency

is

a

direct

result of

rpm =

60

hertz

rpm

=

50

hertz.

change

generator

Connect following

If

lead

Voltage/Hertz

there

Start

no-load between

throttle lever

60 hertz!

50 hem!

the

an

AVR

to

correspond

is

no automatic voltage regulator

terminal for the hertz change.

the

engine,

speed.

the

AC

output

the

illustrations

is

installed,

Connection

monitor

Adjust

throttle

on

the

no-load no-load

frequency

leads

on

reposition

to

the

hertz

Bar.

Ba&

voltage

diesel

arm

and

injection

speed, speed,

GENERATOR

WESTERBEKE

and

adjustments

engine/generator

follow

the

sfeps

to

the

AC

tel111ina1

this

page.

the blue or

selected

Simply reconfigure the

units

fuel

pump

61.5 - 62.0

51.5 - 52.0

on

the

and

adjust

by

the

solenoid

..

linkage

VOLTAG~

recommends

be

performed

speed:

below.

block,

blue/white

the

(AVR

engine

or

the

hertz. hertz.

ADJUSTMENT

that

the

by

a

quailijied

d.

e.

following

After the

voltage generator the changed In

the

ness

60

hertz:

50

hertz:

Load corresponding Rated

60

hertz:

50

hertz:

The

(amps)

60

hertz:

50

hertz:

technician.

no-load

may

was

event

under

the

generator

Loaded

loaded loaded

lowest

generator

hertz

need

to

producing

hertz

setting, it

setting.

it

needs

the

laminated no-load no-load

to

the

Speed

speed, speed,

acceptable

108 -110

205-210

adjustment

be

readjusted:

the correct

would

adjustment,

steel voltage), voltage,

the

rated

hertz

speed

58.5-

59.0

·48.5

- 49.0

voltage

volts volts

is

made,

the

In

most

cases,

no-load

be

adjust

bar of

121-124

232~236

amperage

of the

hertz

at

full

correct

the

shim

the

transformer. volt$. volt$.

output

generator.

rated

output

voltage

at

no-load

if

the

at

tli.e

thick-

The

frame

lie

moved

from

volts

50

hertt;

nections

block,

1!41nch

accept

wire

sized rating necl!on. wire

is

·

green

between

and

the

115V50Hz

~

ground

wire

when

volts

hertz

From

to

use

terminal

studs

changing

and

to

making

the

AC;

that

230

lermlnal

115

50

muiH·strand

for

the

hot

The

frame

whfte

or

white

It

connects

the

neutml

genemtor

amperage

fmme.

from

strip.

@

must

110/220

volts

con-

ends

for

will

copper

lead

con-

ground

with

a

stud

SIX

STUD

AC

230V50Hz

·®

VOLTAGE

®

CONNECTIONS

120V

60HZ

•

TWELVE

115V50Hz

o=:D

o·

6 g

.

N

l!;!~•dJ

CIRCUIT

BREAKER

STUD

AC

VOLTAGE

230V50Hz

o=:D

.o

5

0

6 g

~

N

L1

f!Cl

Engines &

CONNECTIONS

120Y

60Hz.

0 a;::::o

••I

Generator~;

120J240V/60Hz

l2

l1

)tJUMPERIS

R_EQUIRED

.41

INTERNAL

WIRING

SCHEMADC

(6

STUD)

BT

GENERATOR

W/OPTJONAL

VOLTAGE

REGULATOR

RED

YELLOW

BLACK

SELECTOR

SwtTcu

A

B

I

.f

EXCITER

1

and 2 •.•.

EXCITER

1 a b c

· ._b .. :1.5

2 blodes

3

Rotor

4 Thermister ... .Infinite

EXCITER

Voltages measured across

AC

into

Bridge Recitifier: No Load 20 VAC • Full Load 55

DC

out

of Bridge Recitifler: No Load 8 VDC - Full Load 18

("

\·YELlOW

\.

I

~--------y~=-~OW--.

BLACK

STATOR

11.5

1 .... 49.4 0

2 ....

12.90

ROTOR

~~D.CJ!l.f!.ry

(6).:

Field Windlngs .... 9.7 0

CIRCUIT

the

WINDINGS

0

AND FIELD

Wil1cting_s_

o;:b-1:

....

..

ollnfinite · .

VOLTAGES

AC

and DC

BLACK

__

~+~-~~~~----~------~BL:~~~

COMPONENT.

WINDINGS

ar.ft,.m~$U.rec:tJn

1.5 n,

c-a

..

~.1.5

~(AVR)

PLUG

E;

RESISTANCE

pairs:

o .

iirriliviATIC

:VOLTAGE

'R~GOlATOR

···

(NOMINAL)

connections

on

the Bridge Rectifier

VAC

VOC

GREEN

BLAGK

Bll/E

·

(IN

OHMS)

C

MAIN

STATOR

1

and2

....

3 Main Stator Aux. Windings ... :1.3 0

D

COMPOUND

1'

afld 2 .... 0.4 0 ·

Compound E

Voltage.

F Selector

G Bridge Rectifier

Note:

Resistance readings and

accessed easily for

A,

a,

c-3 and

the

connection points shown

When

checking

both

of

the

WINDINGS.

0.40

TRANSFORMER WINDINGS

Transformer

Rl)lgulator

.Switch

0·3

by

winding

component's electrical

(optional) '

the

components

locating·

.50Hz

AI;JX.:

the

on

resistanee

W:!ndings

voltage

color coded

the

above

values be

connections.

3 ... .:4.3 0

checks

in the exciter circuit

schematic.

can

wires

sure

at

to

be

lift

I~WESTERBEKE

~

Engines & Generators

42

BT

GENERATOR

3

PHASE

r-

-----------..,

I l

I A

I I

1 1 I

I

I 1 . l I

l

I I B ' !

I I

L -

c.

EXCITER

STATOR

r----

·t

EXCITER

+ [

·-

- ---- - - - - .I

ROTOR

1 a I 1

·I

: c

I I

l

L-----~----------J

-I--

b

TWELVE

I

-

-------

I C I

I

l I 6 5

.I

ROTOR

* I

(6)

DIODES.

INTERNAL

WIRE

FIELD

RECONNECTABLE

-.,

I ----.,..---+------+----"--·

18

: 4

I

WIRING

12.----+-1-----+-----'11 10

2----L------t----1

tl:!

~------,

DsTATOR

YELLOW

!

9

7

3.

GREEN

ELECTRONIC

REGULATOR

BT

GENERATOR

THREE

PHASE

u

..........

GREEN

AUX.

AC

VOLTAGES

NIL

183

·184

FIL

189

•190

EXCITER

DC

RED

..,

NIL FIL

VOLTAGES

6.5-9.0 15-16

/

Enginss & Generators

43

GENERATOR

AC

VOLTAGE

BE

THREE

CONN~CTIONS

PHASE

. .

VOLTAGE THREE

.

The'regulator (0

to

shown

figuration between connection

NOTE:

a

jumper

REGULATORS

PHASE

6)

and

connection

of

#2

Either

Of!

CONNECTIONS

is

equipped

their

generator.

#1

and

Series

the

regulator

170-27UV

---.

__

j60

with

brass

points

and

jUlllJ?ers

The

#2.

on

the

#0

on

the

voltage

configuration

board

Hz

jumpers.

seven

sensing

AC

regulator

requires

between

numbered

The

illustrations

for

the 3 phase

leads

connect

terminal

block

board.

the

installation

temzinal B and

terminals

con-

arid

of

0.

L-N-120VAC

l·

N

-115

AC

TERMINAL

THREE

10

VAC

10

CONNECTIONS

PHAsE

12

PARALLEL

60HZ 50

HZ

WIRE

wYE

(STAR)

L·l-208VAC l·

L-190

VAC

30 30

60HZ

50

HZ

L-l-480

L-N-,2nVAC 10

US~

JUMPER

L·N-240VAC L2,l3 • N-120

#10

VAC

AWG

FOR

WIRES

VAC

30

10

60HZ

6D

HZ

$ERIES

WYE

SERIES

{STAR)

1-

L-400

VAC

30

L-

N-230

VAC

30

DELTA

L·

N-230

VAC

30

L2,L3-N-115VAC 1050HZ

50 50

50

HZ HZ

HZ

44

SHORE

POWER

TRANSFER

SWITCH

c

z:

:> 0

II!

C)

w

!::

:r

;=

' HOTI::: OiaQrt'.lm

.

wire.

1.~0-Vott

"'

with

threo-wlro,

~

GENERATORfSHORE

_. SWITCH

.,

shows

system

1ZO-Vcll

connoeocilons

from

the

9eneratot1

boat

system.

for

IP

two-

~~---+(®

SHORE

If

the installer connects· shore power

.,.---..."

' \

. \...,..__.,,/

POWER

CONNECTIONS

\

::J;..j-1

---<:---.

(60

HERn)

to

the vessel's

Skip.\o.ShMft

PN

32006

\40Amps/P.ote) PN

32009

(80Amps/Pole)

PN

32010

(125

Amps/

PN

32133

(200

AmptJ/ Poie).

AC

cir-

cuit, this must be done by means of the Shore Power Transfer

'Switch.

OFF position. of shore power

Set the transfer switch shown

'This

switch prevents simultaneous connection

to

generator output.

A

CAUTION:

utility

shore

at

the

same

covered

bility

to

make

under

Damage

power

time.

the

sure

and

This

warranty;

all

to

the

generator

type

of

generator

it

AC

connections

in

the diagrams

generator

output

is

the

Installer's

are

can

result

are

connected

damage

responsi-

correct

' ".·

is

to

if

not

the

Switeh

Pole)

(3

Pol•)

230

SWitching

A

CAUTION:

before

switching

vi~e-versa

With

heavy

cause

damage

generator.

VOLT/50

Shore

HZ

Power

Heavy

shore

because

AC

loads

to

the

voltage

on

exciter

SHORE

GROUND

TWO

WIRE

to

Generator

motor

loads

power

to

generator

surges

the

~esse/

circuit

· · ·

SlltP1S

Ll!.lO

.,.

SHIP'S

GROUND.

CONFIGURATION

Power

should

be

shut

off

power

or

induced

being·

by

switching

operated

components

in

may

the

.

120

VOLT

/60

HZ

THREE

Notice the repositioning terminal block

Generator

~

.

Shorl!

to

PoWer

the generator

NOTE:

Dl01gram

wire~

12.0

with

three-wlrtJ.120-Volt

WIRE

of

the

white wire ground load

case.

shows eonne.ctions

..

Volt system from the

CONFIGURATION

on

the

for a two-

gen~rator,

boat

system,

fiSfJ':!s;I;~~!'!

45

Till

WIRING DIAGRAM

(8

+I~

VDC

BA.TTEftY

SEE

I

,I

NOTEt!

J

STAftT

.

-6-----~~--~--~.

S:>L.

J

~-T··-----------~

L ____ j

I

L--

I

I I

I

sEE

INOTE-3

I

L

I I

l

I

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I

I I

I

L.-------

STARiE.R

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BTD)

BATTERY~

RETURN

1

6ND

GLOWPWGS

#3465'1

TO

stOCK

STANDARD

INSTRUME:NT

PANEL

(REAR

VIEW)

GENERATOR OPERATION

PRE-HEAT:

DEPRESS PRE-HEAT SWITCH

---

SECOMDS

m!U:.:DEPR£55

~:DEPRESS

BtiTN

(pRE-HEAT

ALSO

SHUTDOWN

ClRtuiT).

WitEN

GENERATOR

SWITCH

ONLY

SWITCH

FOR A FEW

.

PRESSURE

REACHES

STOP

STOPS C0!-1PLETELY

ASREQUIREb.

PRE•HEAT

AND

OVERIDES

LOW

STARTS RELEASE

..

CONTINUE tlOLDfNG

SECONDS

20

Pst).

SWITCH

UNTtl

..

FOR

START

OIL

(UNTIL

TKE

GENERATOR

l$

TO

SWITCHES

PRESSURE

START

PRE"tiEAT

OIL

.

6U

Engines & Generators

46

8A TTiRY

SWITCH

..

~i}

----------

1 '

~-~'

WIRING DIAGRAM #36412

(NO

RELAYS)

GROUMD

TO

ENGINE

BLOCK

112 YEL/RED

110

TAN

3

ID

...

:;;

l~~

sh!Juld

be.installed

circuit

to

di$c:onnect

$ll».1er

from

an

emirgency

leaving

the

volt

diesel

engine.sta:rters··

typically

tUlip$

swilcn

ratillgof17S

.vnc

tAis

must

whim

Will.

jimction,

never·be·

"11ffl&

draw

With

tiOmlldly

..

(he

in

tlds

the

battery

and

when

boat

Twelve

200

to

300

cranking.

a

A

CO'fl.tinutJus

amps

at

.serve

but a

switch

used

to

starter

circuit.

in

12

·

114

PUR/11111"

:ll

...

..

;

L------~-:---------~---------------------------------------------__j

HCIUR

lill!'r&R

..

=

•-•

.-..

~

I

/-.~V'IWESIERBEICE

·~Engines

& Generators

47

WIRING SCHEMATIC #36412

(NO

RELAYS)

~!,12VOC

' '

1 lt:MER,SW,

~

..

"-------------fS::j!.A_I!!

~L..

PR~~~.i!T..,

SOL

..

Gt.CWPI..UGS

:

~------4---------~-----4----~B

'

..,

:

:c.

a.

~

J

20A

1

if

EMERGENCY

: :

57'\~P

SW.

L "

r i r

:

t--:

STOP

SW.

1 J L J

STARTING

START:

I.

ALWAYS

2.WHILE CONTINUING 3,WHEN.

4.WHEN

SWITCH

CIRCUIT).

STOP:

PUSH

START

SW.

r---,

~_.

___

.,

-:

I \

PREHE:AT

$W.

AND

STOPPING INSTRUCTIONS

PUSH

PREHEAT $WITCH FIRST.

TO

GENERATOR

OIL

(THE PREHEI\T

AND

STARTS1RELEASE START SWITCH ONLY.

PRESSURE REACHES APPROXIMATELY

HOLD

THE

SWITCH

STOP

' '

iC

1..

PUSH PREHEAT

OVERRIDES

SWITCH UNTIL THE

Gr---------~

:c.a.

.!

lOA

HOLD

FOR

SWITCH

,PUSH START SWITCH,

20

THE

LOW

GENERATOR

fUEt.

PUMP

IS

TO

GO

SECONDS

AS

PSI,RELEASE PREHEAT

OIL PRESSURE

STOPS

SHUT-DOWN

COMPLETELY.

REQ'D.

NOTES:

!.THIS

PRODUCT

NEAR EXCESSIVE ENGINE WILL CAUSE THE BREAKER WILL

SUPPLY.

l'ANEL,WIRING

ELECTRICAL DEVICES

2.AN

ON-OFF STARTER TWEl.VE

WHEN EXCEED 12VOC USEr.,

IS PROTECTED

THE

STARTER

CURRENT

SHUT

DOWJI.

BECAUSE 'rHE

'THEREFORE

AND

SWITCH

FRO..,

THE

VOLT

DIESEL ENGINE S'rARTERS TYPICALLY

CRANKING. THE DURATION

30

SECO~DS.

WILL

NORMALLY

TO"M~KE"THE

BY

AND AS

CLOSE

DRAW

ANYWHEf!E IN

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56

..

(OPTIONAL)

REMOTE

Olt

PN.040078

INSTALLATION

This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as an engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE in this manual

instructions

APPLY A THIN INSTALLING TIGHTEN CONTACTS

on

COAT

OF

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

removing the oil filter.

CLEAN

OIL

TO

THE

THREAD

3/4

TURN

THE

KIT

ON,

AFTER

O·RING

THEN

THE

O·RING

WHEN

HAND

for

FILTER

{OPTIONAL)

To install, simply remove the engine oil filter and thread on WESTERBEKE'S remote oil filter kit as shown. Always

install this kit

Contact your WESTERBEKE dealer for more information.

NOTE:

Westerbeke is not responsible

incorrect installation

A

CAUTION:

correctly. by-pass from

reaching failure. immed/alety

with the oil filter facing down as illustrated.

for

engine failure due

of

the Remote Oil Filter.

It

is

vital

to

install

the

oil

lines

If

the

oil

flows

in

the

valve

If

there

in

the

and

the

engine

Is

no

check

filter

oil

pressure

the

reverse

assembly

causing

hose

direction,

will

prevent

an

internal

reading,

shutdown

connections

the

engine

oil

I

,,

to

NOTE ON

THE

REMOVED

,

WILL

THE

OUT

CONNECTION

MUST

ATTACH

OIL

TO

AT

FILTER.

CONNECTION

REMOTE

THE

"IN"

AND

ADAPTER

WHEN

FOR

INSTALLATION

BE

RECONNECTED

HOSE

THE

IN

THE

"OUT"

MARKINGS

THE

HOSES

SO

CORRECTLY.

THE MUST CONNECTION REMOTE

ARE

THEY

IN

CONNECTION

ATTACH

TO

AT

OIL

FILTER.

THE

HOSE

OUT

APPLY A THIN TER FILTER ADDITIONAL

GASKET

WHEN

CONTACTS

3/4

COAT

OF

CLEAN

INSTALLING.

THE

BASE,

TURN.

OIL

TO

THE

AFTER

TIGHTEN

IT

Fll·

THE

AN

Engines & Generators

57

POWER

TAKE

Off·

SYSTEM

POWER

A power take off adapter backend. engine for a variety of hydraulic

The

output

TAKE

This

adapter

hoursepowet

or

to

operate

OFF

ADAPTER

allows

can

be

the

power

can

be

access

utiliied

attached

and

eitfier

take·

to

the full power of

electrical accessories.

for

AC

off.

the

generator

amperage

the

STUDS

AND

HOLD

ACCESSORY

'ADAPTER

@@

POWER KIT

TAKE

#34786

HARDWARE

TO

OFF

THE

Contact your WESTERBEKE DISTRIBUTOR

infonnation.

for

additional

8QLTS

FASTEN

TO

GENERATOR

@~'-

ADAP~

HOUSING

l""''Y'/WESTERBEKE

l Engines & Generators

58

LAY·UP & RECOMMISSIONING

GENERAL

Many

owners

rely

on

their boatyards

including engines

off-season or

to

accomplish lay-up preparation

The

procedures which

own

lay-up

you

if

have

local

check list These procedures should afford your engine protection

during a lay-up maintenance

If your provide assistance.

Propeller

The transmission and propeller half couplings be

opened

out

of

the

water or

storage

in

the

strain

severe the

boat

is

shaft

has

actual!y

apply

to

small boats

not

in

use,

period of

Fresh

A recommended for This solution antifreeze, depending solution

Should amount mixture. and cooling

time.

Water

50-50

solution of antifreeze

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine wann, drain

sump.

Remove

with

new

oil.

ENGINE

oil

A

chemicals internal

LUBRICATING

changing procedure. pressure and

CAUTION:

in

the

sump

combustion

parts.

and

generators,

for

long periods

follow

and

recommissioning, or

others

do

the

procedures.

and

also

help

familiarize

needs

of your engine.

any

questions regarding

servicing dealer;

Shaft

Coupling

up

and

the

moved

cradle. The flexibility of

on

the propeller shaft or coupling

taken

out

been

unless they have

Cooling

use

may

require a higher concentration of

make sure

antifreeze

t~e

engine

the

of the

antifreeze

Now

he

bolts

removed

from

or

put

in

the

bent

by

that

are

hauled

been

Circuit

in

the

coolant

on

the

area's winter

the

antifreeze protection

be

needed,

block

and

engine

to

concentration

recheck

the

System

all

and

replace

the

Use

the

correct grade of

OIL

Run

the

make

sure there

Do

not

leave

over

the

Jay-up

deposits

which

combine

can

reduce

to

prepare

for

lay-up

during

of

inactivity.

themselves.

will

allow

will

[Propulsion

land

water.

these

dry

you

may

you

lay-up

be

more

when

to

water,

the

boat

In

strains.

out

of

the

for

a considerable

Others

to

with

procedures, call

than

Engine]

the

some

This

[Propulsion

and

distilled

drain add a more

ensure a complete

antifreeze

the

oil

filter

pages

engine

are

the

period.

to

prQduce

the

life

water

system

at

climate.

an

appropriate

concentrated

throughout

solution's

engine

oil

and

fill

oil.

Refer

in

this

manual

and

check

no

leaks.

engine's

old

Lubricating

harmful

of

your

____j

their craft,

prefer

perform

use

them

the

willing

should boat

is

and

during

often

or

both,

cases,

does

water

Engine]

is

all

times.

Check

is

adequate.

circulation

from

the

sump

to

the

for

engine

oil

engine's

the

your

as

to

always

hauled

puts

while the

not

when

the

strength.

the

oil

for

the

proper

oil

and

a

the

Fuel

System

Top

off

or

higher. stabilizer should gasoline/water separator and

make

a

fuel.

Fuel

System

Top

off

such

as

BioBor

added

at Care should with

the

tern,

Change

separator, if the

sediment

Change the fuel

system,

for

5 -

10 system. the

fuel needed. allow

movement of the

equipment

Raw

Water

Close the through-hull hose

from gallon bucket of clean check

the

.::ngine

any

zinc

~mode

Start

the fresh

water

stop

the solution slightly stronger protection

Start the engine through

the

engine. water circuit from as

providing corrosion protection.

Remove antifreeze mixture Examine a cover

gasket.

until

recommissioning, but replace the cover

Intake

Place a clean cloth, lightly soaked opening of shove

the

recommissioning,

you

may

note

tdretnove the

exhaust

port

[Gasoline}

your

fuel

tanks

with

A

fuel

conditioner such be

certain

there

added.

and

are

unleaded

Change

clean

no

leaks. Clean

gasoline of

as

Sta-Bil gasoline

the

element

the

metal

[Diesel}

your

fuel

tanks

with

No.

2 diesel

and

Diesel

Kleen + Cetcme

this

time

to

control

algae

be

taken

that

the

additives

primary

Check system

Operating the engine

debris

engine

the

Manifold

need

fuel

filter/water separator used

the

element

fuel

bowL

fuel

filter

as

needed.

minutes

for

during

on

the

Cooling

the

seacock.

zinc

anode

and

clean or replace it

from

is

located.

and

through

and

in

your

and

raw

water

This antifreeze mixture should protect

impeller

impeller. Acquire a replacement, if

Do

the

intake

cloth

out of

assisrance

can

be

system

elements

Start

to

make

any

leaks

this

treated

engine.

Circuit

seacock.

Place

fresh

found

inside

Clean

allow

the system.

refill

the

area.

allow

system.

freezing

from

will

accompany

not

replace

and

manifold

sight.

and

an

of

cloth

prior

blocked

in

your primary has

one,

on

the

engine and

sure

no

that

may

servicing, correcting

for

5 -

fuel

Remove

the

end

water.

in

the

as

the

heat exchanger

the

raw

th'e

raw

When

bucket

than

needed

all

of

this

Once

during

your

raw

the

Thru·Hull

to

(If

it

is

attempt

is

the

servicing

to

start-up. The

in

the

fuel.

and condition

used

and

clean

the

engine

air

is

left

have

10

minutes

through the injection

the

of

this

Before starting

primary heat exchanger

required,

water strainer.

water pump

the bucket

with

an

for winter

mixture the

bucket

the winter

water

it,

so

catch

impeller

Exhaust

in

lubricating

block

the

not

'lisible

made

to

dealer.

same

manner.

bowl.

up

any

Fuel

Boost

are

fuel

filter/Water

the

and

allow

in

been

raw

hose

and

where

to

antifreeze

to

lay-up,

pump

it

(into

and

opening.

at

stmt

thru-hull

89

octane

in

your

Re-install

spilled

additives

should

the

fuel. compatible in

the

sys-.

separator

bleed

the

it

to

tun

the

fuel

created

in

them

as

wil1

help

water

intake

into a five

the

engine,

also

clean

the

draw

the

is

empty,

freeze

be

drawn

is

empty,

the

raw

as

well

(some

in a bucket).

needed,

oil,

Make

the

pump)

gasket.

in

Do

the

engine,

and

the

not

a

be

on

stop

59

LAY·UP & RECOMMISSIONING

Starter

Lubrication if battery the

connections

Cylinder

If

WESTERBEKE

access

the

revolutions If

to the

Intake

Clean

cloth

block through-hull to

Cylinder

After small crankshaft spark

NOTE:

the

tighten

each

Motor

and

cleaning

access

to

the

starter

connections

starter.

Take

care

removed

Lubrication

you

anticipate a

recommends

to

the

cylinders.

cylinder

your

be

injectors

walls.

and

engine

removed.

and

re-install

does

Be

return

Manifold

the

filter

screen

lightly

soaked

any

opening.

exhaust

start-up!

Lubrication

engine

shutdown,

amount plugs

crankshaft two full

spark

of

manually

loosely

At spring

properly

plug.

fogging

commissioning,

and

Batteries

If

batteries make to

prevent batteries subjected batteries

environment.

A

hll/hly.;exp/osive

arcing smoke $erviced.

to

Transmission

Check off the coati..ng. additional

are

to

be

sure

that

they

them

from

will

not

remain

to

severe

and

store

thern.in a warmer,

WARNING:

or a light8d

or

allow

an

Shllf

off

prevent

grime

coupling

e/ectilcal

or change

and

grease

and

Check

infonnation;

[Propulsion

the

that

of

the

pennits

its

are

shut

off

in

properly

from

the

starter.

[Diesel]

long

lay-up

period

removal

Squirt

some

Rotate

the

engine

the

glow

not

have

glow

sure

to

have

replacement

fuel

line

[Gasoline]

in

the

flame

in

lube

oil

around

Also

place

an

port,

Make a note

[Gasoline

remove

oil

into

two

complete

for

winter

lay-up

revolutions.

connect.

left

are

enVironmental

Lead

gas~

the

on

board

fully

charged,

freezing.

fully

If

charged,

··.:

acldlJaltiiles

which

can cigarene, open

1/ame

all

electrical

arcing

during

Engine]

fluid

in

the

and

touch

up

output

flange

the.

transmission

refer

to

the

starter

drive

pinion

easy

removal.

before

attempting

replacing

as

oil-soaked

(12

of

Marvel

crankshaft

plugs. plugs,

the

needed.

arrester,

the

to

any

months

the

Mystery

injectors

sealing

and

flame

cloth

remove

1

the

spark

plugs

each

cylinder.

revolutions.

remove

theplugs

Re-install

high

tension

during

the

lay-up

and

will

there

is

any

or

that

conditions,

more

compatible

iiilliiil'yilrogen,

m·ignlted

cigar,

or

pl(ie.

near

the

battery

equipment

servicing.

transmission

any

unpainted

with

an

anti-corrosion

vent is

open.

TRANSMISSION

is

'advisable,

Make

sure

to

remove

electrical

or

more)

glow

plugs

Oill into

by

hand

will

washers

place a clean

arrester

in

the

cloths

and

spray

Rotate

the

Re-install

and

rotate

the

spark

plugs,

leads

fully

·

period,

remain

that

doubt

that

tbey

will

remove

the

by

electrical

~D.o

:n~t

being

in

the

vicinity

as

required

areas.

For

SECTION.

the

for

two

have

for

to

prior

a

the

onto

way,

the

be

a

Wipe

Protect

Spare

Parts

Lay-up

time

provides a good

.

Westerbeke or

coolant

kit

and

during

SPARE

engine

hoses

order

the

lay-up,

PAI?TS

need

items

section

to

see

replacement.

not

on

such

as

of

Recommissioning

·The

recommissioning seasonal those section However, counteracted

1.

2.

3.

4.

5.

6.

lay-up

described

regarding

some

before

Remove

discard removed Install

Reinstall lay-up,

tennlnals

Check

A

and batteries can

cigarene~

flamf,1

electrical arcing

Remove

proper

Check

circuit

· that it solution

engine

short advisable, service, heat

·area. Start

in manual.

the

t):le

the

during

the

and

are

to

make

CAUTION:

eye

protection

emit

be

ignited

cigar,

near

the

equipment

during

the

tightness the

and

is

not from

is

put

period

to inspect

exchanger

the

engine

the

PREPARATIONS

of

your generally in

the

PREPARATJONSFOR.STARTING

preparation

of

the

lay-up

starting oil-soaked raw

water

old

gasket.

lay-up

raw

water

pump

batteries

reconnect

clean

and

sure

that

Wear

rubber

when

hydrogen, a highly

by

electrical

or

pipe.

baftery

in

servicing.

spark

plugs,

[gasoline].

condition

clean

necessary

of

as

or

the

into

time

either

and

in

of

replace

raw

operation,

with

an

the

clear

accordance

opportunity

if

external

hand,

filters

this

follows

the

cloths

pump

Install

{or a replacement,

that the

that

items

Check

or

replace

and

zinc

manual.

Westerbeke

the

same

for

starting

procedures

engine.

from

cover

the

raw

cover

with

were

removed

battery

cables,

the

connections

the

batteries

the

and

gloves, a rttbber

servicing

batteries.

explosive

arcing

or a lighted

Do

not

smoke

being

serviced.

the

Vicinity

to

wipe

clean,

the

zinc

anode

the

anode

to

flush

the

antifreeze/fresh

water

coolant

system.

the

system

no

adverse

end

of

season

area

where

the

any and

FOR

all

with

procedures

STARTING

to

inspect your

such

as

drive

your

basic

spares

those

items

anodes. Refer

engine after a

procedures

and

nonnal

starts.

will

need

to

be

intake

manifold.

gasket

and

water

pump

impeller

if

required).

a

new

cover

during

the

making

are

fully

sure

are

tight

charged.

apron,

Lead

gas,

which

or

allow

an

Shut

off

all

prevent

re-gap,

affects. or

zinc

electrical

and

install

in

the

raw

water

as

needed.

will

recommissioning

zinc

When self-flush

It

is

located

debris

section

Note

from

described

of

belts

used

to

the

as

gasket.

the

acid

open

water

the

in

that

this

'

to

a

the

60

CONTACT

.

WATERPUMP

.

IMPELLER

KIT

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

DIESEL

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

INFORMATION

DRIVE

FUEL F.ILTER

BELTS

HARDWARE

KIT

WESTERBEKE each Kit Kit

packaged

"A"

"B"

in includes is

for

more extensive off-shore cruising.

A

Kit

Impeller Heat

Exchanger Gasket

Fuel

Filter with Gasket

Oil

Filter

Drive

Belt

Zinc

Anodes

also offers

a rugged hinged toolbox.

the

Kit

two

basic spares.

Spare Parts Kits,

WESTERBEKE ENGINE AND A GALLON

RECOMMENDS

OIL

(YOUR

BRAND)

OF

PREMIXED

61

CARRYING

FOR

AN

OIL

COOLANT.

-

ENOUGH

CHANGE

SPARE'

(5

OTS.)

8

Kit

Inipellei.Water Thermostat Kit Zinc Anodes Complete Gasket Heat Exchanger Injector

Fuel Filter Oil

Drive Belt

Pump

Filter

Kit

Repair Kit

with

Kit

Gaskc>.t

Gaskc1

7-2018 .... 1248

Westerbeke 8.0 BTD, 6.0 BTD, 8.8 BTD, 12.5 BTD, 9.4 BTD Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual