Westerbeke 12.6KW EDT, 12.5KW EDT, 7.5KW EDT, 10.4KW EDT, 11.5KW EDT Operator's Manual

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OPERATORS

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DIESEL

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WESTERBEKE

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JOHN

CORPORATION. MYLES STANDISH

HANCOCK

ROAD.

TAUNTON,

MA

02780·7319

INDUSTRIAL

U.S.A.

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,

PROPOSITION

Diesel engine exhaust and some of

its constituents are known the State cancer, birth defects, and other reproductive harm. .

Exhaust colorless unconsciousness exposure

-

-Nausea

-Headache

-

gasses

gas. can

DIzziness

Weakness

and

contain

Carbon

and

Include:

Slfleplness

CALIFORNIA

65

WARNING

of

California to cause

A

WARNING:

Carbon

Monoxide

death.

Monoxide,

Is

poisonous

Symptoms

-

-Inability

of

Throbbing Muscular

Vomiting

an

Carbon

Twitching

to

odorless

and

in

Temples

Think

to

and can,cause MonoxIde

CoheTl/ntly

IF

YOU GET seek until

OR

ANYONE

OUT

INTO

medical

it

has

THE

attention.

been

inspected

ELSE

EXPERIENCE

FRESH

AIR

IMMEDIATELY.

Shut

down

and

repaired.

This

WARNING WESTERBEKE bulkhead

WESTERBEKEalso CARBON living/sleepIng

They

aTl/inexpenslve

obtainable

ANY

OF

THESE

If

symptoms

the.

unit

and

DECAL

and

should

near

your

engine

recommends

MONOXIDE

at

DETECTORS

quarten;

your

local

and

SYMPTOMS,

persist,

do

not

restart

is

provided

be

fixed

or

generator.

of

your

vessel.

easily

marine

stOTl/.

by to

a

installing

in

the

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

to

follow

tions.

Know

when

dangerous necessary and

The

the

PREVENT

A

while

power.

•

PREVENT

•

precautions

your

machinery.

following

American

ELECTRIC

WARNING:

engine

Lethal

Do

not

operate

enclosures

Shut

off electrical

equipment. Use

insulated

equipment. Make

sure

(particularly

Remove

electrical

Do circuits, transfer result

Electrical tor.

wristwatch

not

connect

except

switch.

if

this

Discharge

BURNS -HOT

A

WARNING:

exhanst

very

system

hot!

Always recovery

In before

check

A

WARNING:

case

of

touching

safety

instructions

Boat

and

Do

not

is

runnIng,

voltage

this

and

covers

power

mats

your

clothing

shoes)

equipment.

utility

through

Damage

procedure

shock

results

capacitor

Do

components. A running

the

engine

tank.

an

engine

the

carefully.

fundamental

conditions exist and

to

protect

yo,:,rse/f,

are

Yacht

Council

SHOCK

touch

AC

or

when

is

present

machinery

in

whenever

when

and

shore

without

place.

before

working

and

skin

handling electrical

all

jewelry

power

a ship-to-shore

to

vessel's

is

not

followed.

from

handling a

by

shorting

ENGINE

not

touch

hot

coolant level

Steam

can

overheat,

engine

allow

or

checking

Most

accidents rules

are

and precau·

take

your

personne4

in

compliance

(ABYC)

electrical connected

at

these

accessing

are

when

to

AC

terminals

engine

cause

standards.

connections

to

shore

connections!

electrical

on

electrical

dry,

not

damp

equipment.

working

vessel's

the

AC

double

throw

generator

charged

together.

parts

or

engine

gets

at

the

coolant

inj~~

or

death!

engine

to

the

coolant.

the

with

on

may

capaci-

cool

PREVENT

A

•

Prevent sparks pump,

removing

•

PREVENT

A

injury

•

BURNS -FIRE

WARNING:

flash

to

occur

or

other

vapors.

Use

Do

not

operate

arrester

removed.

death. Do

not

operate

Backiire Do

the engine/generator chances

Be

not

smoke

fuel

aware

can

system.

of

BURNS -EXPLOSION

WARNING:

or

death!

Follow

re-fueling hatches after

closed

fueling.

ning

the

blower.

starting All

when tilated

Do

your

fuel

vapors

handling

area

out

of

the

not

fill

Shut

off

the

fuel

system.

spill.

DO

sources

of

ing.

Ensure

fuel

system.

Do

not

alter

Be

sure

all

Be

certain

free

of

leaks.

Make

sure

properly

Extinguishers for

all

applications

Fire

can

fires.

Do

not

near

the

carburetor,

potential

a suitable

the

fuel

cause

fire.

- diesel

line,

with a

Backfire

with

or

permit

Keep

clean

Wipe

container

carburetor,

Coast

the

air

severe

the

and

up

fuel

will

Explosions

safety

when

fueling.

Check

below

Run

the

engine.

are

highly

and

storing

away

from

spark-producing

reach of

the fuel

NOT

fire

fuel line

maintained.

children. tank(s)

fuel

service

Take

care

allow

any

near

the

fuel

proper

ventilation

or

modify

the

fuel

supplies

fittings

a fire extinguisher

Be

rated

ABC

encountered

cause

injury

or

death!

smoke

or

permit

flames or

fuel

line,

filter,

sources

flames

of

spilled

fuel

to

catch

all

fuel when

or

fuel

filters.

Guard

Approved

can

cause

severe

cleaner/silencer removed.

injury

or

death.

or

sparks

compartment

free

of

debris

all

spilled

fuel

burn.

from

fuel

vapors

instructions.

Open

for

blower

explosive.

fuels.

while

valve

in catching

smoking,

system

fuel

have a positive shutoff

are

familiar

by

Keep

and

fumes/vapor

for

four

Use

Store

the

engine

at

the

engine open

or

engine

exists

when

system.

adequately

is

installed

with

the

NFPA in

this

flame

injury

to

occur near

and

the

to

minintize the

and

engine oil.

can

the vessel's

ventilate cabin

before

ntinutes before

extreme

fuel

in

equipment

is

when

any

fuel that ntight

flames,

when

servicing

tightened and

nearby and

its

proper

are

appropriate

enviroinnent.

fuel

or

fuel

or

cause

run-

care

a well-ven-

and

running.

serviciitg

or

other

servic-

the

valve.

is

use.

.

-.v:

WESTERBEKE

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

Dr

death!

•

Disconnect

generator.

it

last.

• .

Make

starting.

•

Make

installed

BATTERY

A

WARNING:

Dr

death!

•

Do

not

being

highly arcing

equipment

ing

servicing.

•

Never tive

not together.

Ventilate

.

accumulation

disturb is

being

•

Avoid bums wristwatch, the

•

Always

the and

BATTERY

A

WARNING:

severe

•

When

level, tion.

If

it

with

inadvertently

STARTING

Accidental

the

battery

Remove

certain

all

personnel

certain

all

covers,

before

starting

EXPLOSION

Battery

smoke

or

serviced.

explosive or

connect

(+) connection

test the

the

contacting

or

battery.

battery

reconnect it

Lead

by

lit

tobacco

in

the

battery

Sparks

any

compartment

of

battery

charged.

sparks

rings,

tum

the

connections.

gas, vicinity

could explosive

that

battery

last

ACID

SulfuriC

injury

Dr

death!

servicing

wear

BatterIeS

comes

water.

rubber

contain

in

contact

Acid

when

the

cables

the

negative

explosion

allow

an

acid

which

negative

terntinal

condition

ignite

charger

the

terminals

could

and any

when

battery

gloves,

sulfuric

with

may

splash

removing

starting

are

guards,

the

engine.

open

batteries entit hydrogen, a

products.

to

gases.

connections

cause

other

charger Remove

disconnecting

acid

a rubber

your

can

before

servicing

lead

first

clear

of

the

and

hatches

can

cause

flame

near

can

be

ignited

Shut

off

prevent

containing

electrical

(-)

battery

cable

of

the

starter

by

shorting

battery

gases

batteries

To

avoid

with

tools,

an

explosion.

jewelry

off

before

the

negative

In

batteries

or

checking

apron,

acid

which

skin,

wash

on

the

skin

electrolyte caps.

cause

the

and reconnect

engine

are

Injury

the

by

electrical

all

electrical

arcing

to

solenoid.

the

terntinals

or

fuel

sparks,

while the

etc.,

before

disconnecting

the

battery.

can

the

electrolyte and is

destructive.

it

off

or

into the

injury

engine!

before

re-

battery

dur-

the

posi-

Do

vapors.

to

prevent

do

battery

to

prevent

Remove

handling

lead

first

cause

eye

protec-

at

once

eyes

not

TOXIC

•

EXHAUST

A

WARNING:

Ensure

that the exhaust discharged regularly are

securely attention exhaust

•

Be

sure

•

In

addition

install

a carbon

builder

•

For

additional

tional

information

A

WARNING:

odorless nausea

•

Do

not

fumes

can

tems.

Exhaust sulfur

tubing

resulting

•

Do

not through exhaust enter

the

flow

of

•

Although

exhaust

gas

is

present

tOllis

or

are:

Vontiting

Dizziness

Throbbing Muscular

Intense Weakuess

AVOID

•

MOVING

A

WARNING:

Dr

death!

Do

not

tion

arises

operating

ing

moving

GASES

Carbon

from

the

for

leaks

and

attached

to

the

manifold,

pipe

nipple.

the

unit

and

to

routine

monoxide

or

dealer

for

information

on

Carbon

gas.

Inhalation

or

death!

use

copper

tubing

rapidly

destroy

in

exhaust/water

install exhaust

portholes,

discharge

exhaust

exhaust.

diesel

fumes

signs of

twitching

headache

and

from

in

temples

sleepiness

vents,

outlet

discharge

Avoid

engine

diesel

carbon

PARTS

Rotating

service

the

in

which

adjustments,

parts

and

monoxide

system

engine.

make

and

its

surroundings

inspection

installation

Carbon

causes

outlet

is

overloading

exhaust

gasoline

exhaust

monoxide

engine

it

is

use

hot

(CO)

Is a deadly

is

adequate

Check

the exhaust system

sure

the exhaust manifolds

no

warping

water

detector.

refer

monoxide

produces

in

diesel

copper

rapid deterioration of copper

where

or

air

near outlet

parts

while

absolutely

extreme

exhaust

exists.

injection

are

of

the

exhaust

Consult

of

approved

to

ABYC

Monoxide).

(CO)

flu-like

exhaust

tubing

in

leakage.

exhaust

conditioners. If the engine

the

waterline,

and

close

the

craft.

gases

are

engines,

fumes.

inhalation

can

cause

it

is

system

carbon

Some

running.

necessary

care

gas!

to expel gases .

Pay

close

elbow,

and

well

ventilated.

system,

your

boat

detectors.

T-22

(educa-

is

an

invisible

symptoms,

systems.

exhaust

can

or

not

Diesel

sys-

be

drawn

water

could

restrict

the

as

toxic

monoxide

of the symp-

or poisoning

injury

If

a situa-

to

make.

to

avoid

touch-

components.

as

~

WESTERBEKE

Engines & Generators

ii

•

Do

not

wear

loose

equipment;

jackets,

could

•

Make Keep places

•

Do

not

the

engine

•

Stay when be

caught

HAZARDOUS

A

WARNING:

tie

shirts,

,sleeves,

be

caught

sure

all

attaching

protective

at

all

times.

check

fluid

is

operating.

clear of the

the

engine

in

these

NOISE

back

High

loss!

•

Never

•

Do

not

removed.

•

Do

not

open.

A

WARNING:

mentally

operate

an

run

an

engine

run

engines

or

physically

~Iothing

in

moving

shields

levels

drive is

running;

rotating

engine

for

Do

not

long

hair

rings,

hardware and

or

shaft

noise

without

with

long

work

or

jewelry

and

avoid

necklaces

parts.

is

guards

the

drive

and

the

hair

and

parts.

levels

can

its

the

air

intake (silencer)

periods

on

machinery

in

Incapacitated

SAFETY

when

servicing

wearing

or

properly

their

belt's tension

transmission

clothing

cause

muffler

with

by

fatigue!

loose

bracelets

tightened.

respective

can

hearing

installed.

their

enclosures

when

you

INSTRUCTIONS

that

while

coupling

easily

are

ABYC, INSTALLING

Read for

tions

ABYC

"Safety Order

NFPA

"Fire Order

USCG "USCG

Order

NFPA

the

following

safety

codes

when

installing

(American

Standards

from:

ABYC 15

East

26th

New

York,

(National

Protection

from:

National

11 Avon Avon,

U.S. Washingt?n,

Fire Protection

Tracy

Drive

Industrial Park

MA

(United

33CFR183"

from:

Government

AND

USCG

DIESEL

NY

02322

ABYC,

and

standards.

your

Boat

for

Small

Street

10010

Fire

Protection

Standard

States

Printing

D.C.

20404

ENGINES

and

Coast

PUBLICATIONS

NFPA

and

USCG

pUblications

Follow

their

recommenda-

engine.

Yacht

Council)

Craft"

Association)

for

Motor

Craft"

Association

Guard)

Office

FOR

OPERATORS

Many

of the preceding safety

in

your

notes

to

carefully,

procedures.

ENGINE

Preparations

ough

examination of

(ABYC)

·sources Sections of the

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

All

installations

Regulations

MANUAL

Operators

highlight

maintain

Manual critical

INSTALLATIONS

to

instail

standards.

including

the

ABYC

Ventilation

Inboard

DC

Electrical systems

must

(FCR).

your

equipment,

an

the

American

These

USCG

standards

systems

engines

comply

tips

and

along

with

information.

engine

should

Boat

standards

and

the

of particular interest

with

the

warnings

other

Read

and

follow

begin

and

are a

NFPA.

Federal

are

repeated

cautions

your

combination

and

manual

all

safety

with a thor-

Yacht

Council's

Code

of

are:

of

Engines

&

Generators

iii

When

installing

attention

WES1ERBEKE

be

paid

to

the

following

INSTALLATION

engines information:

and

generators

it

is

important

that

strict

CODES

Strict when

AND

federal

installing

REGULATIONS

regulations,

engines

SIPHON-BREAK

For

installations

or

will

be

break

in

the

ntinirnum

the

exhaust manifold

raw

water

If

you

have

to

the

vessel's

siphon-break.

NOTE:

A

siphon-break operation. engine

damage.

EXHAUST

The.exhaust prevent of

the

vessels

A engines

.is

Website:

water

where

below

the

vessel's

raw

water

of

20"

above

injection

damage

any

doubt

waterline

to

the

about

requires

Failure

to

properly

Consult

SYSTEM

hose

must

from

entering

hull.

detailed

also

Marine

and

generatolS

available

www.westerbeke.com

ABYC

and

the

supply

the

under

generators

exhaust

waterline,

hose

vessel's

port

engine

the

guidelines,

manifold/water

to

the

waterline.

is

at

and

possible

position

vessel's

periodic

maintain a siphon-break

the

siphon-break

be

certified

Installation

in

the

pdf

for

exhaust

is

supplied

format

marine

Manual

on

and

safety

in a marine

provisions

exhaust

Failure

or

below

flooding

of

the

water-injected

various

inspection

manufacturer

use.

under

any

covering

with

our

website

codes

must be

environment.

injected exhaust

must

be

made

elbow.

This

to

use a siphon-break

the

load

waterline

of

the

operating

and

The sea

conditions}

cleaning

can

result

for

proper

system

conditions

gasoline

every

unit

sold.

to

download

elbow

to

install a

hose

must

boat.

exhaust

to

ensure

in

catastrophic

maintenance.

must be

and

This

complied

is

close

siphon-

be

looped.a

when

will

result

elbow

relative

install a

proper

designed

at

any

angle

diesel

manual

with

to

in

to

AVAILABLE YOUR

WESTERBEKE

OEALER

FROM

·

"~IWESTERBEKE

. I Enoines & Generators

iv

TABLE

Parts

Identification

Introduction

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

Serial Number Location ........................................ ..4

Fuel,

Engine

Digital

LCD Sequence ...................................................... 6A

Internal Components ............................................... 7

Remote Stop/Start Panel.. ........................................ 8

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

011,

Control

Preparations

Pre-Start Inspection ................................................. 9

Generator Voltage .................................................... 9

Generator Daily Safety

Higb Exhaust Temperature Switch ........................

DC Circuit Breaker .... : ...........................................

Oil Pressure Sensor.. ..............................................

Coolant Temperature Sensor ............................ : ....

Break-In

Operation

Shutdown

Procedure/Daily

Maintenance

Cooling

Air Fuel

Engine Oil

Remote

Engine LCD Engine

Fuel

System

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

Thermostat ............................................................. 15

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

Changing the Raw Water Impeller ........................ 16 Six Stud Voltage Connections .............................. .40

Heat Exchanger ..................................................... 16

Intake/Silencer

System

Fuel LiftlWater Separator ...................................... 18

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

Fuel Lift Pump Filter ............................................. 18

Fuel Filter .............................................................. 18

..........

Lubricating

Engine

Testing

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

Pressure

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

Oil Pressure ...............................................

Oil

Filter

Troubleshooting

Display

Faults

Adjustments

Drive Belt Adjustmen ............................................

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

Valve Clearance .....................................................

Testing Engine Compression ................................. 26

. Fuel

Injecto~s

Injectors

Injector Testing : ..................................................... 28

Spray Pattern .......................................................... 28

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

and

Panel

for

Initial

Engine

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

Procedure

Coolant..

Start-Up

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

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

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

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

Switches

Schedule

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

Operation

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

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

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

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

Oil

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

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

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

(Chart) .............................. .22

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

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

... "-.. "-... ,.,

··

.................. : ................ , .............................

..

" ......................................

l1A

, ........

OF

CONTENTS

2

. 3

5

6

Fuel

Injection

Preparation ............................................................. 28

Inspection ............................................................

Adjustment ............................. : .............................. 28

Glow

Plugs

Starter

Emergency

Service ..................................................................

Alternator

9

10

19 10

11 11 11 11

Voltage Regulator .... : ............................................. 32

Checking the

Battery Care ........................................................... 34

Wiring

Diagrams

#54193 ................................................................... 35

#54655 - 24 #53477 - 24

#54628 ................................................................ 35C

#54680 - 24 V ...................................................... 35D

#52793 .................................................................. .36

Generator

BT

. 12

14

Generator

Six

and

BT

Generator/Single

Internal

15

17 18

18

19

Generator

Twelve

No-Load Voltage Adjustment ............................

Full

Load AVR BT

Generator Single Phase

Shore

Power

BT

Generator Internal Regulator

. 20

20 21

Internal BT

Generator Specifications

8.0/B.OKw -10.0/7

23

24

25

,29

27

11.5/9.2Kw -12.B/1

Specifications

12.5/9.4Kw -15.0/12.0Kw

,Lay-Up

Power

Raw

Water

Metric

Suggested

limingl

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

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

Motor

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

Start ................................................... .31

Testing

Information

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

Service Battery ................................ 34

V ..................................................... .35A

V ...................................................... 35B

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

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

Twelve

Wiring

Stud

lIIustrations

Phase

Diagram

Voltage

Stud Voltage Adjustment ...................... .40A

Voltage Adjustment.. ............................ .41

Six Stud .................................................... ..42

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

Adjustment..

Connections

AVR

(Three Phase) ............................ .43

Wiring

Diagram

Sensing

Three

Diagram

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

Phase

(12 Stud) .......................... .46

Troubleshooting

(3

Cylinder Engine) ........................ .48

.5Kw

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

0.4Kw

(4 Cylinder Engine) ......................... 51

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

(6

Stud) ............... " ...... .39

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

......

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

..

, ................................

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

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

Chart

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

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

and

RecommiSSioning

Take-Off

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

Discharge

Heater

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

Conversion

Spare

Data

Parts

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29 30

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32

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37

..

38 38

39

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42 42

.44 .45

.47

49 50

52 53 55 56

.57

58 59

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EngInes & Generators

1

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PARTS

IDENTIFICATION

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MAIN

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DIESEL

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WESTERBEKE

Engines & Generators

5 '

DIGITAL

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PANEL

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Battery Voltage,

13.5 VDC

0

,.

Engine Hours

3.8

HOURS

,

AC

Phase Voltage

A120V

'B

120V'

AC

Phase Voltage'

AB

:lilO

.'

'BC,378V, ,

CA380,V

SCROLL

To

stop

the continuing sequence, press the SCROLL LOCK button, This enables for

any

length of corner.

Use

functions.

button

again.'

0

vO

"Ii'"

o

LOCK

the

To

resume

.....

time.

up

Oil Pressure . ,

I

30

5.CROLl

SC~OlL

2ml

.~

~D~

SCROLL

3.1

:B1\R'

0,

0 .6,9

0

120V

'

AC

Frequency

60,1Hz

At

LineVoltage

0

"40

PSI-'

,11m

SCROLL

St;RO~~

, Ac Line Voltage

',or

..

SCROLL

the

and

AB380\fr'

600

i

BC378V':

600

I.

CA380V

operator

The

word

to LOCK

down arrows

"'

.......

o

".

,"LOCK

monitor a single function

will

appear

to

find

and observe other

scrolling, press the SCROLL LOCK

'~

I

100

i

2cio

;!

'-'~oo

'

I

m

_

..

'600

i

::r

.,

"

600

in

i

"

,the

1\l'

¢

WESTERBEKE

Eng~nes,

& Generators

Oil Pressure

,

Failure

Light

is

red.

Oil

Pressure

Light

is

or~nge.

When a failure occurs, refer wirlog

diagram,

and

general operating text

Low

Resel

ECU

to

Restart

to

the troubleshooting chart,

in

this

assist in solving the trouble.

There are

displayed but

many

combinations of messages that can be

they

are

all self explanatory and the operator

can easily isolate and correct the problem should Before

r.,.s!artin&,

the generator, the 20

amp

DC

breaker l"ust be r'f.sekWith lhe problem corrected

generator'started, the'sequences will begin cycling

NOTE:

Three

phase voltages will vary

output configuration

, ,

'

of

the

generator.

d,epending.on

Controi

and

are

.

manual

011e

circili~

Box

Frequency

on

the

to

occur.

.

an~'-the

again.

the

AC

Components

Adjustments

following

page.

t

6A

DIGITAL

CONTROL

BOX

FREQUENCY

Frequency

engine The

ECU

signal

from

over

the

signal

as

shouid a

frequency

The

red

frequency

display

NOTE:

If

same fault

frequency LED will BliNK.

WHEN

.

FREQUENCY ON BOARD

...

ON

FAULT

is

displayed

is

running in 'RPMandfrequency

is

receiving a

the

MPU

flywheel

both

RPM

. . ".

this

signal

fault shut

failure

LED

screen

will

the unit shuts down

"overspeed" will show

CHANGING

THE

CONTROL MUST

FOR

50

HZ

which

ring

and

vary

on

will

tum

show

THE

(50160

HZ)

PANEL

BE

SWITCHED:

AND

OFF

on

low

gear

hertz.

approximately

down

the

from

the

GENERATORS

SWITCH

FOR

the

LCD

display

screen

(hertz).

AC

voltage

signal

and

is

positioned

teeth.

The

will

occur,

display

green

fault

for

an underspeed condition, the

#1

ECU

60

HZ.

on

the

ECU

interprets

2%

eit\ler

initiated

panel.

will

illuminate,

to

amber

text

"overspeed".

on

the screen but the

and

while

the

hertz

bellhousing

this

up

or

down,

by

the

ECU.

the

LCD

GENERATOR

CAUTION:

the ECU, box. Tum it back on

NOTE:

If the unit shuts down

same fault

. frequency LED will BliNK.

1.

T\lm

FREQUENCY

When changing the generator frequency setting

tum

off

the 20 amp DC circuit breaker on the control

tifter the setting has been changed

"overspeed" will show on the screen but the

the

DC

breaker

on

position.

2.

Open

the

cover

of

the

(EI.,tronic

3.

Locate .position

See control

4.

Replace

and engine/generator

the

that

the

illustration

box.

the

start the

Control

#1

dipswitch

corresponds

below

control

unit.

Monitor

is

Unit).

box

operating

fn,quency.

ADJUSTMENT

for

an

underspeed condition, the

the

control

panel

control

box

and

view

on

the

ECU

and

to

the

Herl2

operation

showing

cover,

the

ECU

tum

the

DC

frequency

is operating

(HERTZ)

to

the

OFF

the

ECU

move

it

to

desired).

in

the

breaker

that the

at

ON

ihe correct

on

the

CONTROL

INTERNAL

CAUTION

generator:S This normal.seasonal to

NOTE:

BOX

(WESTERLINK

starting

can

be

as

the

generator

Keep

CoM!PoNiENTS

much

use.

with a NMEA-2009

in

mind

or

NMEA-2DDO):

battery

when.th~.unit

as

72

amp-hours

However.

that

the

Westerbeke

if

the

system or

The

electronic components

is

in

a static state.

in a months.

generator

time

set

shut

is

not

off

the

maybe

in

the

This

with

no

g~nerator

to

be

usedfor a number ojmonths,

DC

breaker

the DC

~

Digital Diesels

maybe

as much

use.

qn

the

power

supply for

WESTERBEKE

Engines & Generators

~~~;AMPDC

BREAKER

as

50

It

is

not necessary

generator's

the

draw a very

milli-ampsfor

control

vessel's

to

be

such

as

winter

boxfor a

NMEA-2000

small

amount

the

system

concerned

storage,

WESTERLlNK

network.

ECU

with this slight

NOTE:

DURING

OF

THE CAUSED AND

NO

of

amperage (milli-amps)jrom

and

SO

it

is

best

system. .

OPERATION

LCD

DISPLAY

BY

HEAT.

CAUSE

milli-ampsjor each

to

THIS

FOR

amperage

disconnect

THE

VARY.

IS

NORMAL

the

display.

during

DC power

COLOR

MAY

CONCERN.

draw

the

7

DESCRIPTION

A remote panel stopped connecting harnesses of

these

NOTE:

For

WESTERBEKE

and

started

can

be

additional

3'1/4"

is

availa\>le

from

combined

dealer.

,"'.:)0""1111

that

allows

any

location

come

in

three

for a maximum

injonnation,

REMOTE

AND

EXTENSION

the

generator

on

the boat.

different

contact

lengths

run

your

at 75'

local

STOP/START

HARNESSES

to

be

The

and

two

(22.17M).

PANEL

;6"

(152.4MMI

CONNECTING

CABl.ES

15'

(4.75M)

30'

(9.1M)

60'

(18.2M)

EXTENSION

PN

052959

PN

052789

PN

052960

PN

052560

.

Note:

These

two

dimensions

are

the

measurement

of

the

cut -out

opening.

-...v

WESTERBEKE

Engines & Generators

8

PREPARATIONS

FOR

INITIAL

STARTUP

PRESTART

This preparation,

and

stopping

for

the

generator

life.

Before

prolonged

o

Check the

o

Check bowls

o

Check and battery negative (this

o

Check and

o

Visually parts, threaded

o

Check wiring

o

Examine

o

Be

load

o

Be the system connected 3-phase the

o

Make

o

Make

INSPECTION

section

of the initial

procedures. Follow the

conditions

set

will give reliable performance

starting

your generator set

layoff,

the

engine oilleve!. Add

high

mark

the

fuel

for

contaminant's.

the

DC

battery

cable

(-)

cable

location

the

coolant

at

the

manifold.

examine

disconnected

connections.

load leads diagrams.

air inlet

sure

no

other

lines.

sure

that in

neutral

is

requires,

to

systems

wrong

line-to-neutral voltage

sure the

sure

that the generator is

manual

starting,

indicated

check

the

on

the

dipstick.

supply

and examine

electrical

connections.

is

connected

is

connected

is

tagged).

level

the

unit. Look

wires,

for

correct connection

and

outlet for air

generator

power

systems

properly

and

that generator

the

load

neutral. In single

an

incomplete

mounting

provides the

break-in,

and your

following

system. Inspect

in both the

grounded (or

installation

starting

procedures

WESTERBEKE

for-the

oil

Make

to

the

starter

to

the

for

unattached

or

utility

with a neutral

or

open

on

properly

operator

items:

to

the

certaiil

engine

plastic

loose

flow

power

ungrounded)

neutral

unbalanced is

with

(wann

or

cold)

as

presented

and

long

service

rust

time

or

after

a

maintain

hoses,

the

level

at

fuel

filter/separator

wire

connections

the (+)

solenoid

as

obstructio~s

phase

neutral

secure.

and

ground

recovery

or

missing

and

check

specified

is

connected

line

is

properly

and

can

loads.

grounded.

the

stud

tank

in

.

..

that

as

the

some

supply

the

to

GENERATOR

The however,

60

50

The however adjusted

VOLTAGE

actual load

to authorized

PLASTIC

A

CAUTION:

recommended be

switched

and,

in

cold

will

prevenr'dllmau.B.Caused

of/he

AC

stalling.

When

starting

that

all

AC

OFF

until

the

climlltes,

machliJiJiJt~f1d

;

starts

..

VOLTAGE

speed

of

the

generator

iUs advisable

Hz

speed

it

to

service

to

be

suitable

RECOVERY

The

At

rated

59.5 The

At

rated

49.5

of

fue-generator

is

advisable

optimum

ADJUSTMENT

attest

used

iii

v;a''EluiSesllianRdif~auK.lt~seems

'"

,"M'L_""'"

engine

amperage,

- 60.0

engine

amperage,

- 50.0

values

load

service.

to no-load

Hz.

no-load

Hz.

to

the

loads,

especially

engine

has

to

warm

by

unanticipated

will

prevent a cold

engine

is

verify.

speed

hertz output

speed

hertz output

engine

is

verify.

The voltages

no-load

in

this

manual).

of

the

same power

If

the

voltage

evident,

generator,

come up.

it large up

to

This

precaution

is

motors, speed

operation

engine

from

adjusted

~djusted

and

is

at

set

at

may

set

at

may

full

load

If

factor

cannot

contact

the

factory,

. -

61.0

- 60.5 Hz.

decrease

50.0

- 50.3 Hz.

decrease

at

the

factory,-

are

easily

(refer to

possible,

as

be

adjusted

your

apply

the

eH.''''H.CAP

to

GLOW CONNECTION

SIDE

Engines & Generators

9

OIL

CAP

Oil

CAP

DESCRIPTION

Although your engine

hour

of

test operations assembly operated life of operated

Breaki1)g-in a new piston

and glazed engine during

Your conditioning operation to Perfonn following:

Start section. water

procedures

properly, a break-in

your

engine

and

serviced

rings

to the

smoky

operation

or

scored,

new

engine

maximize

this

the

Run

pump,

the

conditioning

engine

the

oil

is

engine

cylinder

which

the

break-in

requires

perfonnance

according

engine

pressure,

GENERATOR

has

experienced a minimum of

at

the

factory

to

make

were

followed

dependent

during

basically

walls.

indicate

is

caused

period.

approximately

to

break in

carefully,

to

while

battery

and

that

time

is

required.

upon

how

its

initial hours of

involves

Excessive

that the cylinder walls

by

overloading the

50

each

moving

and

service life of the

keeping

the

STARTING

checking

that

charging)

one

sure

accurate

the

engine

The

service

the

engine

is

use.

seating the

oil

consumption

are

hours of initial

part in

engine.

in

mind

the

PROCEDURE

all systems

are

functioning.

BREAK-IN

order

PROCEDURE

After

the

first

can

be

increased

cally

vary

the

Avoid

overload

exhaust

the the

rpm

Hertz), current

NOTE:

with

current

being

generator's

to

produce

control drawn

Be

aware

draw

required

draw

can

be 3 to 5 times

GENERATOR

Once

the

generator has been placed into operation

(commissioned),

(raw

generator:~

no-load

INFORMATION.

10

hours of to

the

generator's operation, llie load

the full-load rated output, then periodi-

load.

at

all

times.

An overload

reduced output

drawn

rating.

60

hertz

of

the generator's break-in

from

the

of

motor

for starting

voltage

from

Since

the

(or

at

generator.

starting

motors.

the

1500

rionnal

INFORMATION

generator operates at 1800

is

and

frequency.

generator

rpm

to

loads

and

This

starting.

running

in

this

manual.

signaled by smoky

and produce 50

is

amperage.

ADJUSTMENTS

there

maybe

the

need to adjust

AC

voltage

output. See

Monitor

keep it within

governed by the

the

high current

amperage

'See

the

GENERATOR

AFTER

Once tion between

CHECK

Follow

•

START-UP

the

generator

and

then

encourage a

20%

and

LIST

this

check list

Check

that all

in

the

off position

Record

the hourrneter

relate

to

the

Any

deficiency

be

corrected before

Visually

Check Check Check

inspect

the

oil level

the coolant

your fuel

60%

generator

maintenance

• Check the starting

• Check drive belts

CHECK

•

WITH

Check

for abnonnal

blow-back

THE

sounds.

• Confinn exhaust When

the engine

When

the engine

When

the engine

has

been

of

each

before

or

problems

start

the

engine

(dipstick).

level

supply.

batteries

for

ENGINE

noise

smoke:

is

cold

is

warm

is

overloaded -

started, check for proper

fast

warm-up.

full-load

day

before

for

starting

Run

the

first

circuit breakers (power

starting.

reading

in your

log

schedule.)

in

the following items must

up.

for

fuel,

oil,

or

in the coolant recovery

(weeldy).

wear

and proper tension

RUNNING.

such

as

knocking,

- White

- almost

Smoke.

Smokeless.

some

Black

opera-

.the

generator

10 hours.

THE

your

generator.

panel)

(engine

hours

water leaks.

tank.

(weeldy).

vibrating

Smoke.

DAILY

ROUTINE

NOTE:

This is

reached

are

A

periods

generator.

STOPPING

Remove the temperatore,

generator safety

CAUTION

Digital Diesels draw a very small

the maybe

and

jor

with

amperage

set

best system

,

WESTERLINK

NOTE:

supply for

Some

unstable

condition

and

CAUTION:

of

time

THE

the

AC

generator

then

is

shutdown,

running

should

abate

loads

are

applied.

Do

not

operate

without a load

GENERATOR

loads from

to

run for

tom

3-5

the

close

key

as

the

minutes to stabilize

precaution.

{WE~;YERLINK

generator's starting battery

as

much

each

display.

no

generator

draw

is

not

to

be

to

disconnect or

shut

Keep

in

the

Dr

NMEA~20IiO}:

as

50

milli-amps for

This

can

be

use.

during

used

the DC power

off the DC breaker

system.

mind

yessel's

as

It is

not

normal seasonal

for a

number

that

the

Westerbeke

NMEA-2000

when

much

necessary

may

occur

in

normal

operating

the

generator

being

placed

generator

to

the off

one

position.

down all circuit

The

amount

of

to

-~ieci~nic

of

amperage (milli-amps)

the

unit

is

the

as

months,

the

on

the

network.

in

system

ECU

72

amp~hours

to

be concerned with this slight

use.

However,

such

generator

generator's

generator

a cold

engine.

temperature

for

long

on

the

at

a time.Allow

the

operating

Once

the

breakers

components

a static

and

as winter storage, it is

with a NMEA-2000

control

maybe

as

a

in

This

months

box/or

DC power

from

time

a

state.

50 milli-amps

in

a

if the generator

the

,..yo

WESTERBEKE

Engines & Generators

-fO

SAFETY

SHUTDOWN

SWITCHES

....

",'

_<lno.

ENGINE

BLOCK

SAFETY

The switches. Should

before

SHUTDOWN

"ENGINE"

correcting

is

shutdown

the

screen.

The

following

switches.

HIGH

EXHAUST

An exhaust

injected exhaust will

open

the

switch

supply of raw water

mixing contact

HIGH

TEMPERATURE

SWITCH

is a

TEMPERATURE

temperature

elbow.

and signal

sense

a high

elbow). resets

at

'V"""

•.

This

approximately

T--

SWITCHES

protected

occur,

cause

as

description

switch

Normally

the

ECU

exhaust

causes

a high

switch

opens

by

four

do

shown

of

these

SWITCH

is

located

closed

(shutting

temperature

exhaust at

19soF

EXHAUST

automatic

not attempt

on

the

LCD

automatic

on

the

contacts,

off the

(an

temperature

270°F

(ISI°C).

(126°C).

ELBOW

shutdown

to

restart

Display

shutdown

water

this

switch

engine)

inadequate

This

should

in

this

OIL

PRESSURE

An

oil

pressure engine. as

screen.

pressure. ECu. down:

this

to

It

The

It

will

Engine

occur.

sensor

is

sends a voltage

Should

this

ECU

will

open

then

display

oil

pressure

mounted

signal

fall

the

K2

the

fault on the

dropping

OIL

PRESSURE

on

the oil manifold for the

to

the

ECU that is interpreted

below a set

run

relay shutting the unit 10 -15

LCD

psi

point in

Display

will cause

the

ENGINE

The generator's DC panel (20

. overload anywhere in

wiring

be

DC

CIRCUIT

mounted

amps

will generator will shut position indicating

off.

The should

occur,

After

repairing the

generator.

manually

DC). Excessive current

cause

DC

circuit

check

BREAKER

the

down. this

fault,

CONTROL

PANEL

CAUTION:

components,

When

tum off

servicing

electrical

breaker

and

circuit

is

protected

resetable

the

control

The breaker

fault

on

the

repair the

reset the breaker aud restart

the

20A

to

trip. In

and

the

uuit

20 CIRCUIT

or

rep/acing

DC

rocker

draw

or

panel

wiring

this

will

LCD

will

be inoperative

source

. 8

AMP

FUSE/CONTROL

.

PANEL

AMPS

DC

BREAKER

DC

circuit

by a control

type

circuit breaker

DC

electrical

or

event

trip

to

Display

of

the

problem

breaker.

engine

the the

off

screen

If

the

this

..

will

AIR

BLeED

PETI:OClI,

ANTIFREEZE

An

antifreeze thermostat housing base., ECU nal reach a condition

ting

the unit play temperature reach

COOLANT

coolant temperature sensor is

that it interprets

set

point

existing.

down

screen.

This

will

TE.MPERATURE

as

where

The

and

happen

approximately

This

sends

temperature.

the

ECU

will

displaying

should

SENSOR

an

electrical

Should

interprets

open the

the fault

the

21O"F

(99°C).

THERMOSTAT ASSEMBLY

located

in the

signal

the

voltage

an

overheat

K2

run

relay

on

the

LCD

antifreeze

coolant

to

sig-

shut-

dis-

the

EngInes & Generators

11

BREAK-IN

PROCEDURE/DAILY

OPERATION

BREAK-IN

After

then

and 20%

A

tor

After

can

be

vary Avoid

smoky Monitor

it

within

NOTE:

drawn can

be

INFORMATION

CHECK

Follow

o

Record relate

o

visually

o . o

o

blowby

o

PRQCEDURE

the

generator

encourage a fast

to

60%

of

CAUTION:

by

running

the

first

10

increased

the

load.

overload

exhaust

the

current

the

generators'

Be

aware

required

forstarling

3to 5

limes

LIST

this

check

the

to

the

inspect

Check

the

oil

Check

your

Check

the

starting

Check

for

abnorrnallloise

sounds. Confirm When When When Make

from

exhaust the the

the

sure

the

engine engine engine

exhaust

has

been

warm-up.

full

load

for

the

00

not

attempt

without a load.

hours

of

the

to

the

full-load

at

all

times.

An

with

reduced

being

drawn

rating.

oj

motor

starti~g

motors.

normal

running

in

this

manual.

list

each

day

hourmeter

maintenance

level

diesel

the

reading

schedule).

the

engine

(dipstick).

fuel

supply.

batteries

smoke:

is

cold -White

is

warm -almost

is

overloaded -some

cooling

water

outlet.

started,

check

Run

first

10

to

generators'

rated

overload

output

voltage

from

loads

This

amperage.

before

starting

in

your

for

fuel,

(weekly).

such

as

knocking,

Smoke.

is

discharging

for

proper

the

generator.

hours.

break-in

output;

the

and

starling

oil

Smokeless.

your

operation,

then

is

signaled

and

generator

the

high amperage

See

your

log

(engine

or

water

vibration

Black

properly,

NOTE:

operation.

between

genera-

maintenance

NOTE:

condition reached

A

long

the

load

periodically.

.

by

a

frequency.

and

keep

cu;.;..~t

drawn

GENERATOR

.

generator.

hours

leaks:

and

Smoke.

outboard

generaW.

STOPPING

Remove generator ahrre,

GENERATOR

onc~'the:generator

governor engine's

ENGINE ADJUSTMENTS. A no-load

required (see

GENERAlVR

*

MANUAL

Should function to

inariti~Ls~\!tdp\vn

above-the.siae,oilfill.

,

until

the

schedule

should

loads

the

AC

to

run

press

- - -

first

20

unstable

abate

are

00

of

time

THE

GENERATOR*

loads for

3-5

the

STOP

After

Some

and

CAUTION:

periods

then

ADJUSTMENTS

has

acljustffients

break-in

in

period

SPEED

(HERTZ)

conjunction

INFORMATION).

eNGINE

the

;to;;

button

stop.

the

lever locatedon

the'engines

coines

hours

of

generator

for

the

20

-hour

running

applied.

from

required

may

occur

as

normal

operating

not

operate

without a load

the

generator

minutes

been

with

to

stabilize

button;

shutdown

placed

for

engine

(first

50

hours)

ADJUSTMENT)

voltage

the

engine's

SHUT-PFF

ori

the

control

engine,

the

engine

Simply

hold

to a complete

operation,

service

check.

in a cold

temperature

the

generator

being

one

the

in

operation,

speed

or

after

under,ENGINE

adjustment

speed

panel fail in its

is equipped

the

erigine

down

the

stop.

engine.

for

placed

at a time.

operating

is

automatic.

there

(bertz)

this

period

may

adjustment

blqckjust

lever

check

the

This

is

on

Allow

temper-

may

be

during

(see

also

be

normal

with

a

toiheleft

the

lhe

.

~anUaIEngij,e

.

...

ShutOff·

Engiries & Generators

..

·113

.

SHUT·DOWNLEVER . SIDE

Olt

FILl.

A

WARNING:

running. use

the

correct

servicing

NOTE:

Many

difficult

and may

MAINTENANCE

Never

Wear

any

of

the

attempt

the

proper

tools

fo;

of

the

engine's

following maintenance jobs

require

the

safety

each

DC

expert

to

perform

eqnipment

job.

Disconnect

electrical

knowledge

SCHEDULE

any

service

such

the

equipment.

are

of

a service

while

the

as

goggles

battery

and

terminals

simple but others

mechanic.

engine

gloves,

are

is

and

when

more

SCHEDULED MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel Starting

(and

Engine

Generator

Heat

Fuel/Water

Exhaust

Engine

Separator

Oil

Level

Belts

Inspection

Fllter~nlel

House

Exchanger

Batteries

Batteries)

Oil

(and

Separator

System

Hoses

Filler

filler)

Zinc

of

Engine

Anode

CHECK

EACH

DAY

0 0

0

weekly

0

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000

NOTE:

Please

keep

engine

surface

clean.

and

oil

will

inhibit

the

engine's

ability

to

remain

cool

0 0

0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0

0

0 0

0

0 0 0

0 0

0 0 0 0 0 0

1250

Dirt

0

Diesel

No.2

Check

for

if

necessary).

011

level

should

dipstick. Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Initial

change

Every

50

and

make

excessive

Initial

engine

change

both

Check

that

with

no

chafing.

for

additional

Inspect

zinc

exchanger

Change

the

Initial

check

for

leaks.

the

exhaust

buildup

on

necessary. Hose

should

spongy.

EXPLANATION

rating

water

indicate

if

needed.

proper

if

needed.

fuel,

oil

connections.

loose

at

operating

sure

connections

corrosion.

oil & filter

every

AC

connections

information.

anode,

end

filter

at

50

Check

elbow

inside

Check

be

Check

OF

MAINTENANCE

of

45

cetane

and

dirt

in

fuel

between

tank;

if

empty,

tension

(3/8"

Check

and

water

belt

tension.

50

hrs,

then

hours

check

change

100

hours.

See

GENERATOR

replace

of

zinc

anode

and/or

drain

hrs.,

then'

anti-siphon

for

carbon passages; that

all

connections

hard & tight.

and

tighten

SCHEDULED

or

higher.

(drain/replace

MAX.

and

check

at

to

1/2"

deflection)

belt

edges

for

leaks.

Inspect

Keep

bolts & nuts

change

every

electrolyte

are

very

tight.

at

50

hrs.,

are

clean

and

SECTION

If

needed,

clear

debris.

water

every

250

hrs.

valve

operation.

and/or

corrosion

clean

and

replace

are

Replace

if

all

hose

clamps.

filter

LOW

manifold.

wear.

wiring

tight.

250

hrs.

levels

Clean

off

then

secure

the

heat

200

hrs.

Inspect

Check

as

tight.

soft

or

on

.

Engines & Generators

12

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

hour

meter

gauge

to

by

running

time.

SCHEDULE

log

your

engine

hours

or

.

record

your

SCHEDULED MAINTENANCE

Raw

Water

Pump

At

750

operating disassenible overhaul.

Raw

Air

Coolant

Electric

DC

;

-Fuel

and

Water

Pump

Inlet

Filter

System

Fuel

Alternator

Injectors

"

,-Starter

Motor

-Preheat

-Engine

Circuit

Cylinder

Compression

-Torque

Cylinder

Hold-down

-

Adjustlhe

-Heat

Exchanger

hours, inspect

Lift

bolls

Valve

Pump

for

Drive

,

Head

Clearances

CHECK

EACH

DAY

HOURS

OF

OPERATION

100

50

250

0

500

750

1000 1250

0 0

0

0 0

0

'0

0

0 0

0

0 0

0 0 0

0 0

0

EXPLANATION

Remove

the impeller, Inspect seal should

Remove slot

housing

or

oil

turn,

for

wear.

Inspect

every

Replace Drain,

flush,

cam,

leaks.

pump

as

needed.

appropriate various

COOling

Periodically inspect

the

Check

DC

charge

bracket;

tighten

Check

and

adjust

spray

condition

Check

solenoid

and

lubricate.

pinion

drive.

Check

operation

clean

glow

Reinstall

Check

At

Adjust

with

compression

(see

Engine

first

50

(see

ENGINE

Valve

(see

ENGINE

Remove, pressure

hours,

have tested.

OF

SCHEDULED

MAINTENANCE

pump

cover

and

impeller.

cover

and

inner

weep

holes

for

Check

shaft

bearings

not

wobble).

and

inspect

pump

100

hours.

Remove

and

refill

cooling

antifreeze

check

fuel

plugs;

mixture

system

the

wiring

line

connections.

from

electrical

injection

(see

ENGINE

and

motor

Clean

and

of

preheat

check

anti

seize

pressure

metals.

alternator.

connections.

opening

for

lubricate

solenoid.

resistance

compound

and

Adjustments).

then

every

ADJUSTMENTS).

Clearances

ADJUSTMENTS).

professionally

Inspect

the

wear

plate

for

wear.

signs

of

shaft

water

(the

shaft

and

drive

and

clean.

system

with

compatible

connections

Check

mounting

pressure

with

and

ADJUSTMENTS).

corrosion.

the

starter

Remove (0.4-0.6 on

threads.

Remove

motor

and

ohms).

timing

500

hours

cleaned

and

-WESTERBEKE

CAUTION

gelterator:S

This

can

normal seasonal

to

the

generator with a NMEA·2000 system or shut

NOTE:

Keep

A

DC

components, turned battery

recommends

(WESTERLINK

starting battery

be

as much

in

CAUTION:

use.

mind

or

as

72

However,

that

the

When

the

off

using

either

switch.

this

service

be

NMEA

..

20DO):

The

when

the

amp·hours

electronic components

unit

is

in

a months time

if the generator set

Westerbeke

generator maybe

servicing/changing

DC

power

must

the

DC,breaker

performed

a static

be

by

an

is

or

not

off

the

authorized

state,

This

with

the

maybe

/10 generator

to

be

used

DC·breaker

the

DC power supply for

in

for a number

mechanic.

the

Digital Diesels

as

much

use.

It

on

the generator's control box for a WESTERLINK

/"'fI'ItT/WESTERBEKE

I

Engi~es

& Generators

'13

draw

a very

as

50

milli·ampsfor

is

not

necessary

of

months,

the

vessel's NMEA·2000 network.

small

the

to

be

such as winter storage, it is

amount

of

ECU

amperage

and

50

best

to

system.

milli-ampsfor

system

concerned with this slight

(milli·amps)!rom

amperage

disconnect

each

draw

the

DC power

the

display.

during

DESCRIPTION

Westerbeke for

fresh bustion which water coolant cools parts, and from exchanger,

water fresh ferred

tube exhaust system where

other

coolant

transferred heat overboard through the exhaust

fresh water coolant and

each

allows

harmful deposits.

FRESH

marine diesel

water cooling.

and

friction

circulates throughout the engine. This circulating fresh

the

engine

the

fresh

water coolant

similar

flows

through

water coolant

to

the fresh water coolant

walls

to

the raw

words,

the engine

is

cooled by

other.

Using

the cooling water passages

WATER

CODLING

engines

Heat

is

transferred

the

engine block, its internal moving

oil.

The heat

in

function

the

tubes

flows

around

water

finally

is

cooled

raw

water,

raw

only

fresh

are

designed and equipped

produced

to

raw water by means of a heat

to

of the heat exchanger

which

it

water circttits are independent

water coolant within the engine

in

the engine

to

fresh water coolant

is

transferred externally

an

automotive radiator. Raw

the

tubes; engine heat trans-

is

conducted through

is

then pumped into

is

discharged overboard. In

by

fresh water coolant,

and the raw water carries the

to

stay clean and free from

CIRCUIT

COOLING

by

com-

while

the

this

syste!Jl.

The

SYSTEM

of

When

the engine

vented

by

is

bypassed manifold thermostat gradually coolant to cooling

from overheating).

system.

Coolant

A coolant recovery tank aliows and

contraction during engine operation, without

cant

loss

oJ

ing

system.

engine

manifold level

CHANGING

The

engine's antifreeze coolant must be changed according

to

the

~TENANCE

allowed ability,

cylinder erosion and can cause the

seals

t6

overheating issues can result

to

leak.

is

started cold, external coolant

the

closed thermostat (although some coolant

around

the

thermostat

opens,

flow

unrestricted

Recovery

coolant This tank should be located at or above the

THE

Tank

and

without introducing air into the cool-

and

ANTIFREEZE

SCHEDULE.

become contaminated or loose its protection

to

prevent the exhaust

As

the

engine warms up, the

allowing

to

should be easily accessible.

full

flow

of

the external portion of

for

engine coolant expansion

COOLANT

If

the coolant

as

well

as

external

raw

water pump shaft

flow

is pre-

flow

the engine's

the

any

signifi-

is

.

NOTE:

Refer

to

the

ENGINE

ommended

fresh

Fresh water coolant lating

then heat exchanger where it block via the suction side

antifreeze

water

coolant.

pump,

absorbing heat from the engine.

passes

through the thermostat into the manifold, to the

and

is

pumped through the engine

COOLANT

water

mixture

is

cooled, and returned to the engine

of

the

section

to

circulating

be

used

Th~

pump.

for

by

coolant

the

as

a circu-

the

rec-

A

WARNI~:

Wear

protective

Drain

the engine antifreeze coolant by removing the

drain

plug and opening the drain petcock pIng

side

of the heat exchanger along with removal

cap

on

the water jacketed exhaust

with

fresh

clean

A

CAUTION:

critical; traced

a.slibstantial

back

.l1ewai{i

of

the

hot

gloves.

manifold.

water,

then start the

Proper

cooling

number

fo~ooling

system

refili

system

of

engine

corrosion.

engine

coolant.

on of

the pressure

Flush the system

process.

maintenance

failures

blo~k

the lower

Is

can

be

ENGINE

BLOCK

COOLANT

DRAIN

"Mr

WESTERBEKE

Engines &

14

Generators

COOLING

SYSTEM

Refilling

After exchanger's coolant

NOTE:

Fill the

Monitor

the sure

Remove

coolant the

flow

After Coolant

engine

needed.

the

Coolant

replacing

- .

Open

the

petcock

manifold

cap.

into

checking

cools

TO

coolant

into

the

system

then

the

coolant

to

the

cap

mix

to

Run

the

recovery

should

down.

Clean

the

engine

block

petcock.

manifold

air-bleed petcock

and

close

the

on

halfway

engine

for

draw

up

any

watch

the

in

the

filler

the

tank.

leaks,

back

Add

spilled

and

for

petcock

manifold

neck

"

coolant between

and

stop

into

coolant

drain

Then

pour

when

on

antifreeze

..

and

install

recovery

LOW

observe

the

engine

the

cooling system

to

the

coolant.

the

and

the

plug,

clean,

coolant

the

thermostat

coolant

add

the

tank

and

MAX

coolant

and

recovery

close

the

premixed

is

visable

to

flow

as

needed.

manifold

and

fill and

expansion

allow

as

tank

heat

in

housing.

from

Fill

pres-

with

replace

it

to

cool. the if

Replacing

Remove

ing

as

ket,

apply a thin

before

screws

Run

the

there

GASKET

PN#(1369~i6----

the

cap

screws

shown.

When

coat of sealant

p,~ssing

. .

~e

engine

no

leaks

it

and

THERMOSTAT

ASSEMBLY

Thermostat

and

disassemble

installing

into

place.

check

at

the

on

Do

not

for

normal

thermostat

the

thermostat

new

thennostat

both

sides

over-tighten

temperatures and that

housing.

~---COOLANT

and

of the gasket

the

PETCOCK

hous-

gas-

cap

BLEED

TEMPERATURE SEND

OR

NOTE:

sure good

closes

Periodically

cap.

Ensure

condition

tightly.

check

that

and check

Carry a spare

THERMOSTAT

A

thennos!a!,

engine,

uously engine from

flowing thennostat As

the

thermostat

replaced

controls

flows is

first

to

engine

is

easily.

located

the

through

started, (some prevent

warms

accessible

Carry a

the

upper

near

coolant

the

closed

the

closed

coolant

the

exhaust

up,

the

and

spare

COOLANT

condition

and lower rubber

that

the

vacuum

cap.

---

the

manifold

temperature

cooling

thermostat

is

by-passed

manifold

thermostat

can

be

checked,

thermostat

RETRACTION

of

the

manifold

seals

valve

opens

SEALS

at

the

front

as

the

coolant

circuit.

When

prevents

through a hole

from

overheating).

gradually

and

opens.

~leaned,

gasket.

PR""."""

of

coolant

pres-

are

and

the

contin-

the

in

The

or

CAP

in

the

RAW

WATER

The

raw impeller water

source

water

strainer. through the

heat

ing

fresh

into

the

ing

the

exhaust

water

is

discharge

Raw

Water

The

raw non-ferrous has

flexible

within

the

On

no

account

lubricant

impeller Raw

water

water)

is

are

not

raw

water

NOTE:

Should a failure

(seals

arid

c~ase

a new pump and rebuild

COOLING

water

flow

pump.

This pump draws

(ocean,

The

the

raw

exchanger

water

coolant.

water-injected

gasses.

discharged

pressure.

Pump

water

pump housing vanes

impeller housing,

should

for

the impeller .. There

and

impeller cover gasket

pump

not

present

warrantable,

flow

is

bearings), it

is

created

lake, or

raw

water

pump

tubes)

where

The raw

exhaust

This

overboard

is a self-priming,

and a

which

wipe

this

impeller

during

and

operators

present

occur

may

CIRCUIT

by a positive

water

directly

river)

through

passes

from

the

to'

the

heat

exchanger

it

cools

the engine

water

is

then

elbow,

mixing

mixture

neoprene

producing

pump

failures

engine

at

start-up.

of

exhaust

by

the

engine's exhaust

rotary

impeller.

against

a curved

the

pumping

be

run

dry

should

always

(an

impeller

occur

when

operation.

are

cautioned

with

the

pump's

be more cost efficient

the

original pump as a spare.

displacement

from

the

a hose

to

the

strainer

(through

circulat-

discharged

with

and

cool-

gas

and

gas

pump

with

The

impeller

earn

plate

action.

as

water

acts

be a spare

kit)

aboard.

lubricant

Such

failures

to

make

internal

to

parts

pur-

raw

a

as

(raw

sure

a

En.9ine.E!

15

.&

Generators

CHANGING

. Close

and

gasket pliers. Lightly Install water

THE

the

raw

or

Carefully

coat

the iuside of

the

new

intake

valve.

water

O-riug

impeller

RAW

intake

with

pry/pull

WATER

the

and

PUMP

valve.

Remove

aid

of

impeller out of

pump

cover

with

IMPELLER

the

two

screwdrivers

the

housing

gasket,

RAW

WATER

with

COOLING

pump

cover

or

pump.

SYSTEM

glycerine.

Open

the

raw

PUMP

NOTE:

Also

follow

aground.·

If

the

engine

temperature

nonnal reading, the may

have

been caught

raw

water

through

the

cause

the

above

gauge

may

up

in

cooling

RAW

procedure

ever

shows

be

that

the

strainer,

system.

WATER

after

having

a higher

silt,

leaves or grass

slowing the

STRAINER

rLln

than

flow

hard

of

INSPECTION:

EACH REPLACE ANY

CHECK

BLAOE

BY

THE

CRACKS.

A

impeller,

cool/ng exchanger.

Raw

NOTE:

the

strainer

A

clean

engine's

strainer

in

the

Perfonn

operation:

1. Close the

2. . Remove

3.

Clean

4.

Replace

5.

ReaSsemble

6.

7.

THE

BASE

BENDING

IMPELLER

CAUTION:

circuit.

Water

Always

raw

cooling

when

glass

the

Open

the

Run

the

OF

VIGOROUSLY.

IF I Htlit

If

they

must

They

Intake

install

will

always

water

intake

system.

making

should be

following

raw

water

and

clean

glass.

the

washer

and

seacock.

engine

Alit

BLADES

GLYCERINE

any

of

the

be

found

often

can

Strainer

the

strainer

be

self-priming.

strainer

Include a visual

your

periodic

clear.

maintenance

seacock.

the

strainer

if

necessary.

install

the

and

check

WITH

vanes

to

prevent

be

at

is a -vital

filter.

strainer.

for

leaks.

have

found

or

below

inspection of

engine

after

every

broken

off

blockage

hl

the

heat

the

waterline

component

check.

The

100

hours

in

the

of

the

this

water

so

of

HEAT

EXCHANGER

The

heat number the engine removes

HEAT

of small copper

small

is

EXCHANGER

PETCOCK·

TYPICAL

RAW

(OWNER

exchanger

copper circulated atound

heat from

is a copper

tubes

the

CLEAN DEBRIS

CLEANOUT

DEBRIBAT BOTHENOB

tubes.

and

fresh

WATER

INTAKE

INSTALLED)

cylinder

Raw

the

fresh

the

copper

water

coolant.

HEAT

EXCHANGERS

N..&PAVAILABLE

CUPRO·NlCKEL

STRAINER

which

water

is

pumped through

water

coolant from

tubes.

The raw water

WITH

TUBING

encloses a

ANODE

ARE

the

HEAT

EXCHANGER

Enl!ines & Generators

16

COOLING

SYSTEM

Zinc

Anode·

A zinc

anode,

or

circuit

within

the heat exchanger. The pmpose zinc anode place in the effects of electrolysis on other The condition

and should be carried

NOTE:

installation

is

raw

the

anode

NEW

Electrolysis

and

to

of cleaned or replaced

,

/

pencil,

is

located

sacrifice them

water cooling circuit,

the zinc anode

on

board.

REPLACE

ZINC

ANODES

action

is

the

vessel

location;

in

the

raw

to

electrolysis action

thereby

components

should

as

REPLACE

result

not

of the system.

be checked monthly

required. Spare

CLEAN REUSE

of

each

that

of

the

water cooiing

of

having the

taking

reducing the

anodes

AND

particular

engine.

If

the zinc anodes

..

which

the zinc anode

ening

the anode with

boss

from removing the poor condition, there the exchanger. Remove the

clean

the inside exchanger end gasket aged

when

to

your engine model's heat exchanger end gasket part num-

ber),

O-ring and

NOTE:

The

do

.not

require insulate ing

Heat

After approximately and pressure test the engine's heat exchanger. (Aloca! automotive exchanger.)

NOTE:

the

preventing

Exchanger

radiator shop should be able

Operating that a heat

every

1

DOlt

need

possibly

removing the

threads

Zinc,

of

cover,

tearing

note

are

all

of

sealant.

zinc

from

electrolysis

Service

1000

in

silty

exchanger

hour

•.

replacement, hold the

is

threaded with a wrench while loos-

another

wrench. This prevents the

off the exchanger shell. After

the

condition of it.

probably a lot of zinc flakes within

end

of the heat exchanger and

zinc

debris.

Always

in

case

the present one becomes dam-

end

cover.

Replace the gasket (refer

and

install a

the

zinc

Sealant

the

metal

action

hours

and/or

cleaning

new

anodes

are

should

of

the

on

the

of operation, remove, clean

to

tropical

be

peifonned

not

heat

zinc.

clean

waters

have

zinc

pipe

be

hex

boss into

If

the zinc

a spare heat

anode.

threads

used

as it

exchanger

and

test the heat

may

more

often

require

hex

is

in

and

may

hous-

than

AIR

INTAKE I SILENCER

DESCRIPTION

A marine diesel engine ronning at 1800 rpm will typically

consume only most into the engine must

AIR

The replaceable canister contains a paper element that be inspected

~an

If the element be replaced, cany a spare. .

NOTE:

continuous

and intake.

FILTER

Detach the air inlet hose from the air intake. Unplug the temperature sensor from the engine harness. Then remove the bolts that secure the air and housing the harness

as

much

as 6,000

the

engine

INTAKE

be shaken off or cleaned with compressed

FILTER/SILENCER

every

100

is

greasy or black with

To

operate

efficiently a diesel

volume

black

exhaust

smoke

CARTRIDGE

remove the housing, screen facing

to

the inlet base. Plug

and

reconnect the air inlet hose.

cubic

feet

of

room

be

well

ventilated, the air

be

unrestricted.

operating hours. Dut

engine

of clear ail;

are

Hard

all

symptoms

starting,

INSTALLATION

intiiKe

silencer housing to the inlet base .

in

the

air·

air per

dirt,

the canister

..

must

of a restricted

out.

Reinstall the

temperature sensor

in

.

hour.

the

air,

an

intllke

erratic

Not flow

should

element'

however,

must

a

idle,

air

aii:

to

NOTE: Regular air filter cartridge maintenance is essential

for proper engine operation. Failure to maintain the air filter cartridge will result in air obstruction into the engine, causing poor fuel combustion and resulting in smokey/sooty exhaust discharge a!ong with lube oil consumption deterioration which could result in internal engine damage.

and

possible filter

FILTER

CARTRIDGE

#03970

TURN

OVER

WHEN

INSTALLING

17'

FUEL

SYSTEM

DIESEL

Use not

FUEL

A

installed between the

water

be Most

installation

. contantinant's

A is separator tank will ment. the impurities. maintaining

FUEL WATER

FUEL

No.2

diesel

use

kerosene

WATER

primary

typical the

fuel

and

other

carried

to

installers

package

fuel

Rayeor

type

and

engine-mounted

affect

the

The

owner/operator

fuel

reaching

This

FILTER

SEPERATOR

fuel

or

SEPARATOR

filter

contantinant's

the

fuel

include a

in

the

filter/water separator

Model

filter

fuel

the engine's

process

a

with a cetane

home

heating

of

the

water

fuel

tank

system

filter/water

as

they

are

fuel

can

500

MA.

is

not

installed

fuel

pump,

engine

is

accomplished

rating

fuel

separating

and

the

from

the

on

the

engine.

separator

aware

cause.

is

illustrated

Keep

in

between

system,

filter,

responsible

injection

of

45

type

engine

to

fuel

before

with

of

the

problems

mind

that if a water

the

any

water

and

injection

for

making

equipment

by

installing

system.

or

higher.

must be

remove

they

can

the

that

below.This

fuel

supply

in

the

fuel

equip-

certain

is

free

and

of

Do

FUEL

FILTERS

The

fuel

injection

manufactured

from

water

and

must

pass

thruugh separator clean, schedule

FUEL

To in-line filter

and

in

LIFT

ensure

fuel

shonld·be

and

change

clean

filter

pump

and

they

dirt.

at

the

engine's

these

this

manual.

PUMP

fuel

connected

replaced

and

the

must

receive

To

ensure

least

two spin-on

filters

FILTER

into

the

fuel

to

every

fuel

injectors

clean

this

flow

fuel

filters, a fuel

fuel

according

lift

pump,

the

fuel

200

hours

diesel

of clean

filter.

to

the

lift

pump

of

are

precisely fueL fuel;

filter/water

Visually

maintenance

there

is

a small

elbow.

operation.

free

the fuel

inspec~

This

The fuel the fuel

owner-operator requires injection and

Speed servicing types qualified

FUEL

Periodically

pump

fittings one

secured

operations. When

will flow

inject\on

diesel

engine,requiring

injection

servicing,

pump

repairit.

(hertz)

dealer

of

adjustments

injection

LIFT

and

make

are

tight

of

the

pumps

by

the

energized

purge

air

of

fuel

PUMP

check

as

pump

has been

is

cautioned

remove

service

and

timing

can

service

the

sure

and

mounting

thru

from

the

engine

is

facility.

are

perform

or

repairs

shop.

fuel

that

no

secure.

bolt

the

preheat

fuel

is

the

most

important

the

utmost

thorougbly

not

to

attempt

it

and

take

Do

not

the

only

on

the

injection

must

be

connections

leakage

The

bolts

system

running.

to

is

DC

grouud

should

ensure

circuit,

and

component of

caution

in

bench-tested

to

service it.

it

to

an

authorized

attempt

adjustments

present

proper

to

pump.

performed

to

and

out

and

connection

be

clean

pump

the

fuel

provide

continuous

lift

handling.

and the

If

it

fuel

disassemble

the

Other

by

a

of the

that

the

at

and

well

pump

The

ENGINE

Periodlcally leakage.

after

the

FUEL

Clean first

SCHEDULE

Changing/cleaning

1.

Shut

off

2.

Unscrew housing

housing,

3.

Remove

4.

Replace

the

housing.

to

cross

tighten

1/4 -1/2

run

the

engine

Engines & Generators

FUEL

FILTER

check

the

50

hours

for

cleaning

the

fuel

the

retainer

and

allow

and

replace

the

sealing

Thread

thread.

ASSEMBLY

the

fuel connections

filter

element

then

follow

and

the

filter

supply.

ring

that

the

bowl

the

filter

"0"

ring

tile

retainer

When

retainer

turns

by

hand.

to

inspect

for

and

with

kerosene

the

MAINTENANCE

replacement.

element

holds

the

to

come

away

element

and

reassemble

ring

on

contacts

Open

leaks.

the

filter

from

and

clean

carefully

the

fuel

bowl

for

or

diesel

bowl

the

bOWl

so

"0" ring.

supply

fuel

to

bowl.

as

and

the

to

not

18

ENGINE

LUBRICATING

OIL

LUBRICATION

OIL

PRESSURE

SWITCH

OIL

PRES:SURI:----'

RELIEF

OIL

ENGINE

1.

Draining the Oil

the while replace

securely.

ROTE:

is II4NPT.

BMM

11/16

INCH

SOCKET

Always yellow/gray the

prompt

fied

water exhaust system

of

the

caused

location

OIL

PRESSURE

VALVE

OIL

sump

the engine

the hose

Thread

observe

oil.

Although

attention

mechanic

present in

raw

water

exhaust,

by

DIAGRAM

-->o-::rnlll-'~

DRlllli-----"

CHANGE

Sump.

drain

emulsion

the

or

lack

hose

is

in

size

for

the

tbis

to

should

the

attached

through

filling

absence

of

Discharge

(attached

warm.

Drain

its

bracket,

the

lube

used oil

indicates

condition

prevent

water

oil

can

to

the

raw

the

engine.

of

an

maintenance.

the

to

the

front

the

used

and

replace

oil

drain

DRAIN

HOSE

as

it

is

removed.

the

presence of

is

rare,

serious

damage. Call a

be

present

be

the

result of a

the

engine andlor a

water

cooling

This problem

anti~siphon

used

of

oil

completely,

the end

.hose

it does in

the

valve,

.

OIL

oil

through

the

engine)

capped

A

water

require

oil.

fault

siphoning

circuit

is

often

its

SCREEN

cap

end

in

quali-

Raw

in

the

into

poor

2.

Repkzcing the Oil

ter,

you

may

the

upper

and

oil

from

it

into

to

lessen

spillage. A

shouldbe helpful

NOTE:

Do

not

jilter

to

make

Place

some

ter

when

unscrewing it

(Oil

or

any cooling oil sealing ber bracket,

APPLY

filter

sealing

SEALING

CLEAN

WHEN

INSTALLING

When

gasket'.s

ability.

as

gasket

gently

installing

sealing surface apply a thin on

the

new

filter

nipple

filter

firmly

NOTE:

Generic

ial standards

parts

might

Immediately

engine

to

there

are

3.

Filling the Oil Sump.

cap

on

the

After

refilling, checking around

the

stop

the

engine.

lube

oil

dipstick. Fill

the

dipstick,

Filter.

When

removing

find

it

helpful

and

cleaner

lower

portion

of the old

a container

in

punch

certain it

paper towels

other

fluid

Keep

it is removed to

comes off

gasket

remains

remove

ENGINE

the

coat of

oil

filter.

on

the

by

hand.

jilters

or

diameters

be

entirely

after

make sure the oil pressure is normal

no

oil

leaks

top of the

run

the

oil

pressure.

new

oil filter

Then

before

removing

small

automotive

removing

this

on

your

the

hole

without jirst loosening

can

be

removed.

and

a plastic

to

catch

any

the

engine reduces

engine clean.) Inspect the old

make

sure

with

the

old

sealed

against the

it.

OIL

SPIN

ON

TURN

ON

HAND

new

oil

filter

on

the

bracket free

clean

engine

Screw

the

filter

oil

filter

bracket,

are

not

recommended,

a/important

an

oil jilter

engine

the

different

around

Add

engine

from

change

the

new

oil

or

through

for a few

Make

or

from

check

the quantity

to,

but

not

over

should the engine require

the used oil

to

punch a hole

filter

to drain the

it

filter

wrench

old

oil

filter:

bag

around the

oil

left

in

that

the rubber

oil

filter.

TIGHT

element,

oil

wipe

to

the rubber gasket

onto

the

and

then

items on generic

genuine

and

oil

(lew

oil

jilter.

through

the moments

sure

there

the

oil

drain

of

the

high

additional

the

filter

of

the

side

is

This helps

the

the filter.

engine's

If

this

rub-

the

filter

oil

and

threaded tighten

as

the

lnater-

parts.

jill,

run

and

that

oil

filler

oil

fill.

wbile

no

leakage

system,

oil

with

the

mark

on

oil.

fil-

in

fil-

oil

the

and

~

WESTERBEKE

Engines & Generators

19

DESCRIPTION

The

lubricating

an

oil

pump.

the

oil

pump,

the

oil

filter,

engine.

The

continuous

fied

pressure,

pump

and

within

its

OIL

PRESSURE

The

engine's

by

the

oil

normal

operation,

60

psi

(2.8

NOTE:

A

reading an

oil

pressure

readings

engine

and

The

which

oil

cycle.

the

returns

specified

oil

pressure

and

newly

up

to

60

will

vary

the

system

engine

cooler

then

When

oil

to

range.

pressure,

gauge

the

4.2

kg/cm').

started,

psi

reading

depending

rpm<.

is

a pressure

oil

is

drawn

drives

the

oil,

and

various

returns

to

the

oil

pressure

pushes

open

the

oil

sump,

during

operation,

on

the instrument

oil

pressure

cold

enginli'9,on·

(4.2

kg/cm'). A warmed

as

low

as 35

upon

feeding

from

under

pressure,

lubricating

oil

sump

exceeds

the

relief

keeping

will

range between

have

psi

(2.5

the

temperature

OIL

system

using

the

oil

sump

through

points

in

to

repeat

the

speci-

valve

in

the

oil

pressure

is

indicated' \

panel.

During

an

'oil

pressure

engine

can

kgfcm').

ofthe

PRESSURE

by

the

oil

40

and

have

These

TESTING

lOlL

PRESSURE

'MANIFOLD

QILPRESSUilE

35.0

ENGINE

OIL

Ib/in'

BLOCK

PRESSURE

..

(3.8

KQ/cm')

or

more

al1800

rpm.

LOW

OIL

PRESSURE

The

specified

+

0.1

kg/em'). A gradual

a wombearings. For additional

sure

readings,

OIL

PRESSURE

An

oil

just

below

appoximately

LOCATED UNDER FUEL PUMP ENGINE

safe

see

pressure

the

injection

50

JUST

THE

INJECTION

ON

THE

BLOCK.

minimum

loss

the

ENGINE

RELIEF

relief valve

pump.

psi

[343

oil

VALVE

is

kpa]

pressure

of

oil

information

is

pressure

4.3 + 1.4 usually.

on

low

TROUBLESHOOTING

located

on

the

engine

This

valve

opens

at

and

maintains

that pressure.

psi

(0.3

indicates

oil

pres-

chart.

block

OIL

PRESSURE

An

oil

pressure sensor

engine.

It

as

pressure.

ECu.

The ECU will

down.

It

will

screen.

Engine

this

to

occur.

NOTE:

To

gauge

as

sure

gauge.

or

more

at

SENSOR

sends a

Should

then

oil

test

the

shown.

Oil

1800

is

mounted

voltage

oil Warm

Pressure

signal to

this

signal

fall

open

the

K2

display

the fault

pressure dropping

pressure,

install a mechanical

up

the

should

rpm.

on

the

below

run

on

engine

be

35.0

the

oil

manifold for

ECU

that is interpreted

a set point in the

relay

shutting the unit

the

LCD

Display

10 -15

psi will cause

and

read

the

lb/in'

(3.8

the

pressure

oil

pres-

Kg/cm')

-...v-

WESTERBEKE

Engines

20

_&

Generators

REMOTE

OIL

FILTER

(OPTIONAL)

INSTALLATION

This

popular

ter

from

engine

NOTE:

instructions

APPLY A THIN

INSTALLING TIGHTEN CONTACTS

accessory

the

engine

room

bulkhead.

Refer

to

on

COAT

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

to a more

ENGINE

removing

OF

CLEAN

THREAD

3/4

TURN

is

OIL

THE

used

to

reloc~te

convenient location

OIL

CHANGE

the

oil

jilter.

TO

THE

O-RING

ON,

THEN

THE

O-RING

NOTE

THE

ON

THE

REMOVED

•

WILL

BE

WHEN

HAND

ADAPTER

RECONNECTED

KIT AFTER

PN:040078HEMOTEOILFILTER

To

instal!,

SET

simply remove

WES1ERBEKE'S remote

the

engine's

in

this

"IN"

AND

"OUT"

WHEN

FOR

INSTALLATION

oil

such'

as

fI11lnual

for

MARKINGS

THE

HOSES

SO

THEY

CORRECTLY.

fil-

an

ARE

install

this

kit

Contact your

NOTE:

Westerbeke

incorrect

A

installation

CAUTION:

correctly. by·pass from failure.

valve

reaching

If

immedialety

with

WES1ERBEKE dealer

If

the

there

and

In

the

is

the

is

It

oil

the

.

oil

not

responsible

of

the

Is

vital

flows

filter

engine

no

oil

check

the

engine

oil

filter

facing

Remote

to

Install

in

the assembly causing

pressure

the

hose

oil

filter

and

kit

as

shown.

down

a.

illustrated.

for

more

information.

for

engine

failure

Oil

Filter.

the

oil lines

reverse

direction,

will

prevent

an

internal

reading,

shutdown

connections

thread

Always

due

the

oil

engine

on

to

IN

CONNECTION

MUST

ATTACH

OIL

TO

AT

FILTER.

CONNECTION REMOTE

THE

HOSE

OUT

.

APPLY A THIN TER

GASKET FILTER ADDITIONAL

WHEN

CONTACTS

3/4

COAT

OF

INSTALLING.

THE

TURN.

CLEAN BASE,

OIL

TO

THE

AFTER

TIGHTEN

IT

FIL-

THE

AN

Englnes..~,

~en~,:ators

21

ENGINE

.

Note:

The

engines

rocker

..

--

-

_.

Problem

START

BUTTON

Indications.

START

engagement.

START indications

fuel

solenoid

Generator

start,

fuel

Note:

there

;

If

the

engine

will-terminate

will

display

Battery

Generator

(Fault NOTE:

is

protected

reset

control

Engine

Exhaust

depressed,

BUTTON

depressed,

BUTTON

depressed;

OK;

starter

not

engine

solenoid

is

a 8 -

does

and a Underspeed

on

the

runs

down.

not

charging

engine

display

under

The

engines

by a 20

circuit

breaker

panel.

starts,

runs

smoking

,

functioning.

cranks,

no

panel

solenoid

but

energized.

10'

sec.

not

start.

LCD

display

stops.

speed)

DC

electrical

amp

rocker

on

the

and

shuts

problems

panel

starter

OK

does

crank

The

lront

down.

not

cycle.

cycle

fault

screen.

system

type

of

the

type

Battery'Switch

1. Circuit

2.

3,

Loose

1.

Connection

Faulty

2.

Loose

3.

Low

4.

Kl

5.

Poor

1.

'2.

.

Defective

1.

Faulty

~

,

Preheat

2. High

1.

Low

2.

Poor

3.

DC

4.

DC

1.

Alternator

2.

Switches

1.

or

Fuel

2. 20

3. (LCD

Exhaust

4.

Water

5.

Air

6.

Faulty

1. Water

2.

Blue

1.

White

2.

3.

Black

l"'fIY'IWESTERBEKE

TROUBLESHOOTINO-

DC

electrical

reset

circuit

breaker

Probable

b~ttery

solenoid.

battery

battery.

relay.

connections

fueling

resistance

battery

alternator

charge

disconnected.

staruation.

Amp

intake

smoke.

I,

Engines & Generators

Cause

noton.

breaker

trippedioff:'

connectiQns.

to

solenoid

connections.

to

fuel

solenoid.

system.

solenoid

faulty.

leak

leak.

connections.

not

charging.

circuit

drive.

and/or

wiring

circuit

breaker

display

blank)

system

is

in

fuel.

obstruction.

oil

pressure

temperature

smoke.

"faulty.

fuel

solenoid.

to

ground.

faulty.

loose

tripping.

restricted.

switch.

22

system

mounted

..

is

protected

on

the

....

__

..

_--

1.

2.

4.

1. 2,

3.

4.

5.

1.

2.

1. la. lb, lc. ld,

2. 1,

2.

3.

control

-

Check

Reset circuit

Check engine

Check

Check Check Check Check

Check

Check fuel

run

Cileck

Switch Replace Check Change

Check

lines.

after Check

Check

corrosion.

4.

Check

DC

1,

Pertorm

DC

2,

Check for

loose

are

present

Inspect

1.

Inspect

2,

Check Check

3.

Ensure

cause

4.

Check Pump

5.

bleed

6.

Check

1.

Check

2.

Check

Incorrect

1. la.

Crankcase through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel.burn

Insufficient exhaust

3b.

Improperly

3&.

Lack

ventilation.

by a 20

amp

paneL·

Verilicalion/Remedy

!:\witch

breaker;

and (+ ) connection

ground

connection.

that battery

battery Kl

connections.

that

solenoid.

that

to

batteries.

fuel

inlet solenoid. wiring.

Do

short

ali

table

connections,

ELECTRICAL

drive

at

wiring

switches

fuel for

breaker

tripping.

for water

fuel

air

oil

water

injector

of

- .- .

and/or

battery

if

breaker

check

12

volts connections. charge

relay.

12

fuel

combine

lift

fuel

not

start

Is

located.

wires

connections

D.C.

belt

connections.

the

supply,

high

blockage

from

system. intake pressure

grade

is

the

is

running

grade

incomplete

air

system:

timed

air -check

trips

circuit

for

to

starter

stud.

Check

are

present

state.

volts

are

present

valves

are

house

pump.

filter.

Insert

sensitive

engine.

for

temperature

check

SYSTEM/ALTERNATOR.

voltage

check

SYSTEM/ALTERNATOR.in

tension.

Check

Exc.

terminal.

for

short

circuits

for

proper

fuel

valves,

OC

amperage

is

not

overly

or

collapsed

fuel

tank(s);

filter

cartridge.

switch.

temperature

of

engine

overfilled

cold.

or

Incorrect

of

fuel

for

proper

check

injectors

air

with

or

due

eXhaust).

connections.

again,

check

shorts

to

ground.

solenoid

battery

cable

at

the

at

the

open. and

start

batteries.

(0 -.25

R~move

connections

rise

to

at

battery

for

belt

tension.

of

generator

Alternator

air

intake

should

output

and

operation.

fuel

feed

draw

during

sensitive

muffler.

change

switch.

all.

engine

Injector

timing.

possible

generator

to

high

back

combustion

intake).

or

valves and

air

LCD

preheat

and

(-)

connections.

solenoid

connection.

(+)

connection

amp)

meter

locate

the

loose

connections,

test

alternator.

charging

this

turn

voltmeter,

loose

connections.

strainer.

operation.

to

heat

which

filters

and

oil

(oil

is

blowing

overload.

pressure

(Check

or

poor

compression.

filter.

Check

DISPLAY

solenoid

connection

on

the

in

battery

and

replace

faul!.

See.

circui!.

See

manual. freely.

Check

Ensure

12

would

out

in

exhaust

for

restrictions

for

proper

FAULTS

(continued)

to

volts

or

ih

~

Y'

ENGINE

TROUBLESHOOTING

LCD

DISPLAY

FAULTS

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

PRESSURE

HIGH

COOLANT

HIGH

EXHAUST

BATTERY

GENERATOR Overspeed Underspeed

LED

TURN

WAITING

VOLTAGE

FREQUENCY

(steady

(flashing

OISPLAY

EDGES

PINK

FOR

DOES

TEMPERATURE

LED)

ECU

PROBABLE

1.

Check

2.

20

amp

3.

Loose

4. 1 amp

1.

Oil

level

2.

Lack

of

3.

Ground

4.

Faulty

5.

Faulty

1.

Check

2.

Sea

water

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

Faulty

3.

Gmund

4.

Faulty

5.

Sea

water

6.

Faulty

1.

Check

2.

Check

3.

Check

4.

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank (underspeed

1.

Compartment too

high.

1.

ECU

and

2.

Loose

3.

Panel

4.

Blown 8 amp

5.

Terminating

6.

Battery

CAUSE

battery.

breaker

off.

display

connection.

fuse

blown

low/oil

leak.

oil

pressure

connection.

control

module

oil

pressure

system

coolant

pump,

water

pump

temperature

connection.

control

module

sea

water

flow.

exhaust

temperature

Connection.

control

module

pump.

fire

suppression alternator charge battery

control

engine fuel

cycle

cable

DC

Voltage.

connections. module

speed.

supply.

load.

with

fault)

ambient

LCD

display

connection.

breaker

fuse.

Resistors.

Voltage

drive

no

to

(faulty).

(ECU).

sensor.

level.

drive

belt.

sensor.

(ECU).

system.

belt.

(ECU).

start.

temperature

not

OFF.

ECU.,

switch.

compatible

VERIFICATIONJREMEDY

1.

Battery

on.

2.

Turn

breaker

on.

3.

Check

all

cable

connections.

4.

Check/replace.

1.

Check

2.

Test

oil

filter,

3.

Check

4.

Inspect

5.

Check

1.

Add

coolant.

2.

Inspect

3.

Adjust

4.

Check

5.

Check

6.

Check

1.

Inspect as

needed.

2.

TesVrepl~ce.

3.

Check

4.

Check

5.

Inspect

6.

By-pass

1.

Adjust

2.

Check

3.

Check + and -cables

4.

Check

1.

Check

2.

Inspect

3.

Check + and -cables

4.

Check

1.

Ventilate Note:

display.

1.

Check

2.

Check

3.

Turn

4.

CheCk/replace

5.

Check per

resister

6.

Check unplugged

present,

Determine

oil

level,

add

pressure.

inspect

oil

ground

connection.

all

the

plug

sensor/replace.

Check

impeller/pump/replace,

belt

tenSion,

sensor/replace.

ground

circuit.

plug

connections/replace.

thru

hull

ground

circuit.

plug

connections.

impeller/replace.

system/check. tension/replace excitation.

plug

connections/replace.

speed

setting.

filters/replace

cause

for

compartment.

Heat

will

often

This

will

compatibility all

cable

connections.

ON,

check

fuse.

all

terminating

me'asured

between

from

ECU

is

cause

oil

and

repair

leaks.

If

OK,

test

oil

pressure

pump.

connections/replace.

for

leaks.

,

replace

belt.

fitting,

hose

and

strainer.

if

worn.

Replace/repair

from

filters.

from

no

start.

change

not

effect

with

DC

voltage

Check

resistors

across

pins

P2-24

ECU.

Power

faulty.

alternator

battery

to

Test

fuel

battery

to

the

color

the

operation

Westerlink

across

breaker.

DC

voltage

are

in

#4

and

P2-25.

turned

sendor,

Correct

engine.

pump

engine.

of

an

of

or

NMEA.

across

place.

and

#5.

P2

ON.

If

inspect

operation,

LCD

the

engine.

fuse

holder

120

ohm

ECU

plug

voltage

is

-..v'

WESTERBEKE

Engines &

23

Generators

ENGINE

ADJUSTMENTS

DRIVE

Proper is

Drive

Drive not damage the wear out cause fresh on temperatures.

The

no

(12mm)

point

A spare

BELT

inspection,

important

Belts

belts

provide

the

alternator

prematurely.

rapid

water

the

belt

dtive

less

than

as

between

belt

A

WARNING:

drive

belt's

belt

Adjusting

1.

Loosen mounting

2.

Wilh

Ihe

edges.

3.

Pivot

the

or

right

4.

Tighten

bolt.

5.

Run

the

recheck

ADJUSTMENT

service

and

for

the

efficient

under

MAINTENANCE

must

be

properly

proper

alternator

alternator.

out of

alignment

wear

of the belt

pumps

bearing. A

can

cause

is

properly

3/8

inch

the

belt is

the

two

or

belts

Never

tension

Belt

Tension

the

alternator

bolt.

belt

loose,

alternator

as

required,

tlle

base

engine

for

Ihe

belt

operation

tensioned.

charging

Drive

belts

Excessive

and

belt

slipping,

adjusted

(10mm)

depressed

pulleys

should

always

attempt

while

the

adjusting

inspect

on

Ihe

to

loosen

mounting

about 5 minutes,

tensions.

maintenance

of

SCHEDULE).

Loosedtive

and

that

are

and/or

cause

dtive

belt

reduce

the

slack

belt

or

resulting

if the belt

and

no

more

with

the

on

the

longest

be

carried

to

check

engine

Is

strap bolt

for

wear,

cracks

base

mounting bolt

or

tighten.

bolt

and

the

of

the

your

engine

will

too

tight

the

tension

service

the

presence

in

can

than

thumb

span

on

or

in

operation.

and

adjusting

then

shut

dtive

belts

(see

belts

eventually

will

pull

alternator

can

also

life

of

high

operating

be

deflected

112

inch

at

the

mid-

of

the

board.

adjust

the

base

frayed

to

the

strap

down

will

to the

of

belt.

left

and

oil

ELECTRONIC

The

Electronic sensing flywheel.

the

engines controller engine

to

GOVERNOR

Governor

the

engine's

The

governor's

speed

signals

the

desired

and

Actuator

The

following instructions

the

actuator.

1.' Shut-off

2.

Disconnect

3.

Measure

mounting

4.

Back-off

5.

Apply actuator mounting boss. Maintain

actuator measured (The

6.

Reconnect the actuator

the

DC

the

distance

surface

ACTUATOR

-.J)......

MEASURE REFERENCE

the 1 7/16"

a small

and

screw

and

the

Secnre

standard distance

,

regulates

RPM

with a

controller

if there actuator speed

electronically.

power

actuator

wires

between

as

shown.

___

FOR

jam

amount

of

the

engine

the actuator's

the

engine

speed by

magnetic

is

any

and

the

are

for adjusting or replacing

to

the

from

Inmrrl---l

tJWIlIIw.r~~

-1

nut

and

teflon

actuator

the

same

mounting

is

13116"

wires

pick-up

continuously

discrepancy,

actuator

generator.

Ihe

wiring

the

actuator

ENGINE SURFACE

-JAM

unscrew

sealant

to

into

the

engine's

distance

sUlface

position

and

to

test

with

7/8").

the

at

monitors

the

adjusts the

harness.

and

the

MOUNTING

NUT

the

actuator.

the

replacement

between

as

previously

the

unit.

the

engine

the

jamuut.

/

~

WESTERBEKE

Engines & Generators

24

NOTE:

lithe

down

turn

unit

properly

the

actuator

of a tum

is·

achieved.

shut testing"loosen

and

1/8-114

shutdown

f+-----13/16"

does

not

when

the

jam

nut

in

unlil

proper

TO

STANDARD

.7/8"

NOTE:

WESTERBEKE

ments

be

below

is

ENGINE

peiformed

provided

by

to

ADJUSTMENTS

recommends a competent

assist

the·

that

engine

mechanic:

the

following

mechanic.

engine

The

informaiion

adjust-

VALVE

Make

1.

2.

FRONT

3:',Find

(a)

CLEARANCE

the

following

Remove

Slightly to

below.

the

specified

loosen

010

Os

top

piston

by

Thmthe crankshaft until IDC

pulley

is

adjustments

the

cylinder

the

torque

Tightening

04

06

(M

dead

center

using

the

aligned

with

cylinder

ADJUSTMENT

when

the

engine

head

cover.

head

bolts,

and

in

the

TDrque

01

012

FOUR

CYLINDER

THREE

compression

procedure

the

mark

number

55:!:

CYLINDER

4lb·n

'011

that

mark

on

sequence

(BB±"S'Nm)

05

03

position follows:

on

the

timing

is

cold.

retighten

shown

for

No.1

crankshaft

gear

them

case.

(b)

With No.1 piston

stroke;

the rocker

crankshaft

(c)

I{therockerarmsmove,No.l piston cehteron the

,

turri

the

crankShaft rotation thetompn;ssion

4.'

again.

Loosen

adjust

the

ga).lge

inserteq b,etweentherocker the

.

I '

.

is

turned

iniake

N~.l

stroke.'

lock nut

valve

clearance

.

, >

~"

::.,

~;!

.....

'1~~

:":1

at

top

dead

lU1IlS

will

approximately

or

exhauststroke,

360' in the

piston

is

for

the

by

{"''';,

~

,'"

n'

- -

--

~.,

not

adjusting

center

be

moved

direction

now

turning

on

th~compression

When

the

20'

in

both

directions.

is

at

top

dead

In

such

a case,

of

~ngine

'.

at

top

dead

center

on

·screW.

With a

ann

and valve

the

adjusting

O.25mm, (O.,009BINCHES)

INTAKE & EXHAUST

fe~ler

cap,

screw.

.

TDC

(TOP MARK AND

NO.4

DEAD

FOR

CENTER)

1

TDC

MARK

'NO.2

AND

NO.3

PISTONS

S.

After

tbe valve clearance on

,

bave,

been

adjuste!!.

below

for eit\lerthe t\lIee tbecraDksh/lft adjus(the Repeat

FlRlNG,QR!)ER

Three

Cylhidetl-

Four

cYIlndeI 1

6.

After

allyalves

tnre;e.

cOfflplew'revolutions

steps #3. -

7..

Install the rocker

ROCKERCOVER BOLT TORQUE: 2 - 3 It-Ib (0.3 -

iI!,

the

valves

fQr'th~next

nntil aIr cylinder valves

3 - 2 240

~

3 -

bave

#5.

cover.

the

valves

for

No.1

cylinder

Follow

the

firing

order

seq~ence

OI

four cylil!derl!\odel.

directiol!

4-2

l1e,n adjusted,turn the crook shaft

of

l!orinalIQtatiOI!

cylindel

are

adjnsted.

degrees

180

degrees

and

recheck

il1tbe

of

of crank sjlaft rotation

valve

Ro/jlte

and

firing order.

crank shaft rotation

'Clearances'

two

followi'ng

0.45

m-kg)

to

1;-'1.f!irre~

,~J~e.~erator$

2'5

TESTING

Make the must

1.

2.

certain

air

intake

also Warm Move

fuel.

ENGINE

be

in

the

(Disconnect

used).

3.

Remove the der on

TESTING

all

compression

which

ENGINE

COMPRESSION

the

oil

level

(dipstick)

filter

is

clean.

The

good

condition.

engine

to

normal

control

lever

to a

the

wires

the

glow

plugs

gauge/adapter

the

compression

NOTE:

ments below

is

battery

operating position

if a

fuel

from

the

combination

is

to

be is

ENGINE

WESTERBEKE

performed

provided

at

the

and

temperature.

for

shutdown

engine

be

measured.

PRESSURE GAUGE

by

to

assist

correct

starter

motor

shutting off

solenoid

and

to

tbe

ADJUSTMENTS

recommends

a competent

the

level

and

the

is

install

cylin-

that

engine

mechanic.

FUEL

In

injectors

injection

loss of

in

clean

injector

Before base falling out the free

The

washer.

replaced

installed.

Injeclor

the

following

mechanic.

INJECTORS

case

of

severe

checked

service

positive

injector

faults.

room

as a spare

removing

of

the

injector

down

easily

and

injector

it,

and

then

injector

This

with a new

to

Cylinder

engine

The

[n/ormation

vibrations

and

overhauled

center.

fuel

pressure

Since

enviroment,

should

the

old

to

help

into

the

injector

is

held

in

side-to-side

lift it

out.

seats

in

the

washer

should washer

Head

Tightening

adjust-

and

Poor

fuel

to

fuel

injectors

it

is

best

a problem

injector,

prevent

hole.

by

carbon

with

the

cylinder

be

when

Torque

detonation

by

quality,

the

injection

to

an

authorized

contaminants

must

carry

at

noise,

be

oCCur.

clean

the

area

any

r)lst If the injector will build-up

aid

of

the

socket wrench

head

on

a copper sealing

removed

the

new

40

with

± 4

injector

ft-Ib

have

the

fuel

and

pump can result

serviced

least one

or

debris

or

the like,

the

extra

around

from

injector

in

not

work

a

the

lift

and

is

(5.5 ± 0.5

kgf-m)

to

4.

Close

the

raw

water

seacock

5.

Crank

the

engine

and

maximum

6.

Repeat

Compression

Maximum

(3

kgf/cm2)

NOTE:

If

repair

7.

Re-install the

8.

Open the raw water seacock (thru-hull).

LOW

COMPRESSION

When

applying a

plug

hole.

Install

reading,

this

process

pressure

permissible

the

readings

threads)

low coinpression

small

Allow

the

pressure

the

and

are

glow

reset

amount the

oil

gauge

then

for

427

difference

plugs

is

to

compression reading rises

rings.

If

the

valves.

A slight

both

the

compression

rise

rings

valve

in

compression

and

the

valves.

(thru-hull).

allow

the

gauge

record

that

each

cylinder.

psi

(30

kgf/cm2)

between

below

the

limit,

(use anti-seize

the

fuel

shut-off

found,

detennine

of

oil

in

the

settle.

and

repeat

dramatically,

does

not

rise,

would indicate a

to

reach a

reading.

af

290

rpm.

cylinders

the

is

42.7

engine

compound

to

the

cause

cylinder thru

the

above

test.

the fault

the

problem

run

is

the

with

psi

needs

on

position.

by

glow

If the

the

is

with

FUEL

INJECTOR

~

WESTERBEKE

~1?1J9~fJ~~_&.

Generators

26

FUEL

INJECTORS

REMOVING

NOTE:

1.

Disconnect the loosen

and

bending

2.

Using a 17mm its lose the

NOTE:

prior

any hole. by side

it

and

3.

The ing injector and replaced with tor

INJECTION

1.

Using

tion

limit, tester,

THE

INJECTORS

Injector

must

be

high

the

lines at

move

them

out

the

lines.

long

entirety

carbon

the

two

fuel

return line

Clean

to

lifting

rust

or

If

the

with

the

then

injector

washer.

is

reinstalled.

from

sealing

the

it

debris

injector

build

aid

lift

it

seats

This

TESTING

the

nozzle

starting pressure of nozzle

adjust or replace

take the

following

serviced

pressure

their

of

socket,

the

top

washers

to

area out

of

from

will

up

or

of

the

out.

in

the

washer

tester,

in a "clean

attachment

the

way

remove

of

the

each

injector.

around

the

cylinder

falling

not

lift

the

like,

J7mm

cylinder

should

a

new

check

the

nozzle.

precautions:

lines

from

of

the

injectors.

and

banjo

the

base

down

out

work

deep

head

be

removed

washer

the

spray

and,

When

room"

the injectors

to

the

injection pump

injectors.

the

fuel

Take

bolt that

of

the

head

to

into

the

easily

and

the

injector

socket

wrench

on

a copper seal-

when

pattern

if

it

exceeds

using nozzle

environment.

and

Avoid

retum line

care not

to

attaches

injector

help

prevent

injector

is

held

in

side

to

free

with the

the

injec-

and

injec-

the

in

Inspecting

1,

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

Spray

the hand lever of

stroke

per

in

its

axial

fuel

in

Also, a spray

These defects

with

dust

ones

cause

infection.)

.

'"i

NORMAL

~

I

111

'11

lull'

ml;\

2.

Apply

the

pressure of

by operating the hand

tip.

nozzle

on the

repl~ced.

remain

indicate a

If

bottom,

A very

on

the tip of

defect.

[I

Pattern

the

nozzle tester

second

to

check

if

the

fuel

direction.

an

oblique direction or

and,

reassembly.

skin

to

CHATTERING

it drips

it is

small

A nozzle

in

the

form

may

sometimes

therefore,

(Care should'be taken not

this

spray

l1IJ

I~;

'~I

FAULTY

,~

..

,

.\',

'"

I~"

1635

lb/in' (115 kg/em') to nozzle

lever,

and check

or

has

a large accumulation 'of fuel

considered

amount

the

nozzle;

is

defective

in

several

of particles indicates a

be

caused by clog-

all

parts

should

as

it

may

penetrate the skin

U]J]I

TEST

the

defective

of

however,

fuel

and

may

at

intervals

is

injected cor-

if

separate

be carefully

~:,

~\

,FAULTY

I.

','

I"

,.

~i"1

drips

from the

should be

sometimes

this

does not

of

it

to

A

CAUTION:

such

of

skin

enters

a.

b.

c.

d.

e.

velocity

of

fingers

the

If

the

diesel

replace

it.

Set

the

nozzle tester

dust

or dirt.

Mount

the nozzle

tester. Use

the

fuel

68' F (20' C)

of Operate

bleed

the air

lever

at

intervals of one stroke per.second

ing

the injection starting pressure.

The

that

and

hands,

bloodstream,

fuel

of

At

the

same

and

at

the

hand

lever

in

the

spray

injected

it

may

ppnetrate

destroying

it

may

the

nozzle tester

time, clean

in

a clean place

nozzle holder on·the nozzle

approximate temperature

of

nozzle

line,

INJECTION

1920

cause

tester

then

PRESSURE

PSI

from

deeply

tissue.

blood

is

discolored,

or

replace

where

several

move

the

while

nozzle

is

into

the

If

it

poisoning.

the

filter.

there

is

no

times

the

hand

read-

to

DRIP

TEST

The injection starting pressure increasing

The shim (0.05 With each increased approximately 71.1lb/in' (5.0 kg/em'). replacing remove the specified

or

has

mm)~

between

0.0020in

the

body

decreasing

10

different

0.0049in

(0.05mm)

shim,

grip

with a

torque:

for

the

injectors

the

thickness

thicknesses

(1.25mm).to

the

retaining nut

wrench.

of

the

for

every

0.0669in

increase, injection pressure

in a vise

Tighten the

is

adjusting shim.

retruning

~

ADJUSTING SHIM

adjusted

0.0020 in (1.7mm)

When

and

nut to

!

SHIM

THICKNESS

i

by

is

"'IIY'

WESTERBEKE

Engines

27

& .Generators

FUEL

INJECTION

TIMING

PREPARATION

a. Close the h. Disconnect

cylinder head

c. Remove

pump. holder.

injection d.Connect the fuel injection e.

Hold (Generator)

INSPECTION

a.

Open the ON

NOTE:

Fuel

pressure

if the

engine

fuel flow

h.

Slowly open end of coming out

NOTE:

Tum

do

step

c.

The fuel injection timing crankshaft pulley is aligned gear case when

FUEL

INJECTION

fuel

shut-off

the

No.1

and

No.1

delivery

Remove

Restore

the

pump.

speed

control lever in

remove

[Fuel

fuel

shut-off

position and press

will

come

when

the

starter switch

is equipped with

into

the

container.

tum

the

is

the

crankshaft

b again

to

verify

TIMING:

valve.

fuel

injection

valve

the

delivery

the

fuel

Flow

Method]

valve.

preheat.

from

the

injection

an

crankshaft injection

fuel injection

in

reverse

the

injection

fuel

stops

BlDC

17'

injection pipe from

pump.

holder from the injection

valve

and

valve

holder

pipe

to

the

low

shut-off solenoid.

Turn

the hey switch

pipe with

key

is turned

electric

fuel

clockwise,

pipe.

The

instant

timing.

direction.iust a

timing.

is

correct if the IT mark

with

the mark

from

the

injection

(STANDARD)

the

spring

only

injection

speed

high

to

ON

pump.

looking at

fuel

on

from

the

to

the

pump.

position.

to

position

Direct

the

stops

little

on

the

timing

pipe.

the

and

the

ADJUSTMENT

a.

If

the

fuel

injection

it

RANGE:

(0.0079

in) and

to

prevent

the

timing

fuel

injection

shims

to

advance

STANDARD ± 1.5

shims

in),

0.8mm

Apply

oil

has

filter

pipe

thickness of increase or decrease of

will vary the timing by

h. Increase the thickness of the

or decrease

ADJUSTMENT

Four kinds of

0.2mm

(0.0157

no

identification, measure the

with calipers before using

A

CAUTION:

shim

c.

After

correct.

d.Close the

and

timing

is

under the

the

10.

the

are

available

0.3mm (0.0315

it.

sealant

leaks.

been

adjusted,

valve

and

to

the

original

TDC

MARK

incorrect,

fuel

shims

timing.

(0.0118

restore

change the

injection pump. An

by

O.1mm

to

0

in

thicknesses

in),

in).

These

thickness

to

both

make

state.

17' 19'

f

,

(0.004 in)

.

retard the timing

O.4mm

shims have

of

each shim

faces

of

sure it is

the

delivery valve

20'

each

"""~~:":23'

~~,

~I

~

\...-;.;\

.

.--....I..h>...,IJj

(?)

---

fo~:-r->

~~.{i'i:

rtt.,,,

~~

»~.::::

1

@Q~""

AlTERNATE

In

the

fuel flowinethod,

As

a result,

. inside the

however, it

a. Disconnect

injection nozzle (cylinder

b.

Prime

c. Slowly

swells at the

instan~

to approximately into account when

T'l-I~-

~

::FJ~

.",.,

X.

t!">

'"

- . .

,,-,

2,0

~~

~

4~

I

/

METHOD

there

fuel

injection

is

not necessary to

the

fuel

tum

check the position of

the

mark on the gear

D_.1"l

U

FUELFLOWS

the

delivery

is a good chance

pump.

In

this

remove

No.1

fuel

injection pipe at the fuel

head).

system.

the crankshaft clockwise nntil

free

end of

the

case.

I'

retarded.

Take

making a shim

t

~

/'?-..~

r

AA

I;::~""r'

4l:

1ft'

FUEL

S:~S

valve has

for

dirt particles to get

alternate

the delivery valve.

injection pipe

the

IT mark with respect

This timing is

this

adjustment.

I·~'

0<

l'

~'f1c...'=-

'/'I-I

~ r-1l~1~

\

-N

,

- r

'

/'

/1~

to

be

removed.

method,

fuel

just

and,

at that

retardation

p...

1:::S<f

""

•

k!...

••

~

0

'~.,,£;

(/1

.

~

~.

\

•

'f

ANGLE

BY

WHICH

ANGLE

BY

WHICH

INJECTION

TIMING

FUEL.

1<

INJECTION

IS

ADVANCED

FUEL

TIMING

.mG5

~~-~1L.d=l.

,

I

ADVANCED

Engin~$1f<

Generators

28

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are When .should

PREHEAT

"click"

on

is

and

INSPECTION

To

inspect

the

plug,

tions,

then

unscrew head. soft oil

deposits.

bum

Thoroughly

brush

erosion;

and

While-

clean

cleaning

cleaning,

if

it

has

TESTING

An

accurate Touch other plug

used

an

ammeter

A

to

the

testing

way

to

one

prod

to

the

to

the

body

of

will

have a 0.4 -0.6

with

the

plug

in

to

test

the

WARNING:

touch.

the

These

Be

careful

plugs.

wired

pressed

the

remove

or

unclarnp

each

solution

eroded

test

glow

the

glow

or

out of the

power

glow

through

glow

ohm

not

the

preheat

at

the

control

panel

plug

should

the electrical teoninal

each

plug

from

plug's

tip

and

to

examine

too

much,

plugs

plug's

plug,

resistance.

drain

plugs

to

burn

remove

wire

as

engine.

(5

all

the

tip

replace

is

with

an

connection,

shown. A good

This

You

- 6

amps

lvill

become

your

solenoid.

this

begin

to

connec-

the

threads

the

carbon

for

wear

the

ohmmeter.

method

can

per

plug).

very

fingers

solenoid get

hot.

cylinder

with

a

and

plug.

and

the

glow

can

also

use_

hot

when

be

Re-install

plugs

should

seconds.

circuit

When

pound

on

A

WARNING:

than

30

Glow

Plug

the

plugs

get

very

If

the

plugs

reinstalling

the

threads.

seconds.

Tightening

Torque

in

the

engine

~nd

hot

(at

the

teonina!

don't

heat

up

the

glow

Do

not

keep a glow

7

-11

ff-Ib

TESTING A GLOW WITH

AN

DHMMETER

test

quickly,

plugs,

plug

(1.D

-1.5

PLUG

them

end)

check

use

on

m-kg)

anti-seize

again.

The

within 7 to

for a short

com-

for

more

TERMINAL

END

TIP

15

TESTING A GLOW USING A TEST

c

"

PLUG

LIGHT

'""'"

WESTERBEKE

Engines &' Generators

29

DESCRIPTION

STARTER

MOTOR

The starter high-speed internal-reduction separate from the pinion shaft. A shaft exposed outside smoothly without becoming motor shaft lever mechanism,

. are identical

is a new

and

a pinion

is

'TERMINALS--~

MOTOR

type,

motor

reduction

shaft.

the

starter

supported

switch

to

conventional

small,

shaft;

gear

The

so

at both

and

.....

pinion

fouled

ones.

0.""-.

TYPICAL

STARTER

REFER DIAGRAM

MOTOR

TO

THE IN

WIRING

THIS

MANUAL

.

TROUBLESHOOTING

A

WARNING:

procedures

Sparks

could

must

cause

The

not

an

be

following

used

explosion

light-weight and is called a

starter.

The pinion shaft

the

pinion

slides only

is

installed between the motor

sliding part is not

that

the

pinion may slide

with

dust and grease. The

ends

on

baJl

bearings. The

overrunning

clutch inner circuit

SOLENOID

emergency

with

gasoline

and

fire.

on

starting

engines.

is

the

SOLENOIO

/",,,,-,·"~)(jmr5~;:-----'(M)

'IGNITION

TERMINAL

To

test the ignition

is

one of the circuit). Use a from

that ignition

terminal

If

circuit.

If

motor

on

the starter cranks, the fault

the solenoid clicks but nothing happens, the starter

is probably faulty.

SOLENOID

circuit,

small

tenninal stnds

screwdriver;

terminal

the

solenoid.

~

locate the ignition(s) tenninal (it

and

is

wired

to

don't touch the

to the positive battery connection

lies

blade,

with the ignltion

TERMINAL

the ignition

to jump

Prior to testing,

charge and that (terminals) are clean the ground wire connections on

1b

check the seconds, never hand along the that indicate

Using a multimeter, test the voltage between the positive tenninal stnd on (ground).

If

you

read

make

the

starting

and

wiring,

try cranking

more

than

wires

resistance.

the

start solenoid

12

volts,

certain

the

ships

batteries are at full

system

wiring connections

tight.

Pay

particular attention to

the

engine block.

the

starter

for"a

10

seconds

and

terminals

Repair or replace any trouble

the

starter is faulty.

at a time, then run your

looking for warm spots

and

the engine block

few

spots.

C:~~~IJI{.}--_(+)

IGNITION TERMINAL

If

nothing happens

the

of

and

that

stored

potentially

battery isolation

There

terminals.

nearby.

current.. Check wiring connections. it defective.

A

WARNING:

fly

when

jumping

space

is

free gasoline, materials

at

all,

the solenoid

is

also possible that

will

be

Be

explosive

there

are

NO

r""'--J(M)

is

switch

the

'arching

and

certain

fumes,

flammable

POSITIVE

TERMINAL

~

not getting

and

inspect the

solenoid

sparks

the

engine

especially

solvents

is

will

or

, I

Engines &

30

Gen~rators

STARTER

MOTOR

A

WARNING:

When

perfonning

position-yourself-safely-away-from

the

engine

in

case

the

engine

starts-up.

other

crllw

members

IGNITION TERMINAL

Test

again

by jumping

screwdriver screwdriver blade would cause a short

blade finnly between

to

of

the

touch

the

danger.

two

large tenninal

the

solenoid

the

these

procedures,

themoving-jlarfs

Also

warn

POSITIVE

studs.

Hold

studs.

Do not

allow

or starter

casing,

of

the the

this

EMERGENCY

Corrosion cancauseilie sporadic-problemoLilieenginestarting_one time

but

will

need.

It is

however,

starter

lightly

Wiili

ilie

starter/solenoid

to

the

not

anoilier.

to

be

sometimes

wiili a small

battery

START

starter

brushes

If

corrosion

rebuilt.

switch

off

casing

as

andlor

possible

hammer.

and

no

shown,

ilie

is

ilie

to

get

ignition,.

ilien

try

solenoid

problem,

started

tap

to start the

contacts

ilie starter

by

taping

lightly

engine.

on

__

ilie

_

AWARNING:

starting

the

.

If

the

If

the

If

no

solenoid.

NOTE:

In

the that using a screwdriver will

starter switch it will though

current

screwdriver.

starter starter

arching occurred,

Stalter "wtors

pre-engaged

engages

run

create

spins, the solenoid is faulty.

fails to spin, the motor is probably faulty.

the

stalter motor

the

nwtor without engaging

on

enough

the

contacts inside

There

will

should

be

flowing

there

are

either inertia

nwdel,

the

to

bypass

to

provide pow.,.

magnetic field for

the

be

arching

is no juice reaching

sole/wid

to

the

solenoid

sole/wid

thru

type

also

flywheel the

flywheel.

to

the

the are

as

the

blade

or

pre-engaged.

nwves

of

on

such a starter

solelwid.

ann

to

bad.

full

of

the

an

the

engine.

ThI7l

Hopefully

move

ann

the

even

If

that

fails,

turn member wiili contact the starter

tum

ilie

hammer.,

to

start will

the

need

SERVICE

WESTERBEKE

serviced

center,

If

certified USCG dealer.

TO

1.

2.

3.

4.

5.

or

rebuilt at

replacing

the

for

marine

standards.

REMOVE

Disconnect

If

necessary,

to

ti,e

starter

Label

and

disconnect

allow

wires Remove Remove

starter

obstructions,

tile starter the

will

have

1he

ilie

battery

ignition

the

uses a standard

starter

FOR

remove

motor.

to

starter

on

'This

may

engine.

When

to

be

repaired

any

starter

motor,

use.

Automotive

If

in

doub~

SERVICE

negative

any

the

touch,

tape mounting from

to

be

turned

switch

on

and

off

rapidly

loosen

ilie

you

reach a reparr

.

starter

motor

make

certain

starters

contact

your

battery

cable.

components

wiring

from

over

ilie

bolts.

the

engine.

to a different

and

have a crew

as

you

brushes

automotive

terminals).

and

motor

which

ilie

new

do

not

WESTERBEKE

to

gain

full

the

starter.

In

some

cases

angle

tap

again allow facility,

can

service

motor

meet

access

(Do

tile

to

clear

"

be

is

not

Engines & Generators

-'-,

31

ALTERNATORS

50

AMP

MITSUBISHI

TESTING/TROUBLESHDOTING

ALTERNATOR

VOLTAGE

The integral voltage regulator device which senses

~ ~ thecvoltage~appliedt()~thefie\d

system voltage. The regulator desigu

thick-film adjusted encapsulated possible

REGULATOR

is

an

electronic switching

the

system

voltage level and switches

in

order to'maintain a proper

utilizes

all-silicon

assembly'

to

the

damage

techniques.

proper

regulating

to

protect the circuit and the components from

due

to

handliug

semi

After the voltage has been

valve,

the entire circuit

or

vibration.

conductors and

is

REFER

TO

THE DIAGRAM MANUAL

WIRING

IN

THIS

FOR

ALL

CONNECTIONS

DESCRIPTION

The following mfonnation applies that are supplied with WESTERBEKE'S Engines and GeneratorS.

ELECTRICAL

The charging system consists regulator, circuit breaker and a batteIy with connecting cables. Because of

the

use regulator back

of

It

is

desirable

voltage regulator) using the wiring barness and electrical

loads that are a pennanent part

provide the technician with an operational test

charging system electrical system.

ALTERNATOR

The stator is connected to a three-phase, full-wave bridge rectifier package which contains six diodes. converts the ba!teIy charging and accessories,

Power

to

altematoris provided by the field diode (or diode trio)

paCkage These alternators produce a rated output of 50 or

rated output

rpm at

alternators are desigued to operate

range nf<40'to'2i2"F-(<41l'-to i1l0'C).

CHARGING

an engine

of

is

veIy compact and is mounted internally or

the alternator.

DC

wiring hamess, a mounted DC

integrated circuits

to

test the charging system (alternator and

as

well

as

DESCRIPTION

AC

generated in the stator

the regulator and the field

contained in the alternator.

is

achieved at approximately 6000 alternator

an

ambient temperature

to

the standard alternators

CIRCUIT

of

an altemator with a voltage

O(::'s),

the electronic voltage

of

the system and will then

of

the major components

The

to a DC

of

the integral regulator

of

75'P

(23.8'C). The

in

an ambient temperature

on

the

of

the

bridge

output for

51

amps.

the

ALTERNATOR

Use

this

exists with

determined have a qualified technician

A

WARNING:

alternator alternator

LOW

BATTERY/fAULTY

If

the starter

of

spinning faulty connection problem.

PRELIMINARY

Before starting the

testing the following

L Make certsin your

2.

Check the drive belts for

if

it is

3.

Check that all terminals, connectors and

and tight. Loose or resistance and undercharging or corroded battery cables reaching a fully charged condition.

4.

Check the condition A low or discharged battery readings in the

NOTE:

An selector the

batteries

with

the starting OK

ond

TROUBLESHOOTING

troubleshooting

the

charging circuit

that

the

can

become

until

alternator

A

working

if

bas

section

to

or

with the alternator.

or voltage regulator

check

it.

alternator

very

bot.

cooled.

CIRCUIT

only

moans

or

makes

a clicking sound instead

the

engine

to

life

it

is

likely a

in.

the starting circuit and not

INSPECTION

actual

alternator

checks

are

recommended.

worn

isolator

switch

so

nouse

battery

the

problem

alternator

or

glazed.

corrO<jed

this

could

damage

tests.

with a diode, a solenoid,

is

usually

the

starting

batteries.

but

not

is

securely

proper

corulections

cause

overcharging,

to

the

could

prevent the battery from

of

the

batteIy and charge

may

mounted

battery

if

the

isolator

the

house

battery,

ill

the

battery

determine

Do

and voltage

tension. Replace the belt

charging

cause false

ill

is not

if

runs

hot. A failed

not

touch

low

battery or a

mounted.

plugs

cause

systern.

or a

the circuit

discharged

is

charging

the

altemator is

charging

a problern

If

it is

is

faulty,

the

an

alternator

regulator,

are

clean

high

Badly

if

necessary.

or

misleading

battelY

to

isolate

along

the

circuit.

Englnes~

G.enerators

32

TESTING

THE

ALTERNATORS

ALTERNATOR

TESTING/TROUBLESHOOTING

MEASURING BATTERY

ENGINE

VOLTAGE

OFF)

ACAUTIDN:

-------_.-

certain

that

away

from

1.

~tart

the Engine.

2.

After

the stuting multimeter

a.

If

the

alternator

b.

If

tl1e exists continue

Belor~

starling

-

everyone

sheaves

engine

battery

set

voltage

is

voltage

with

is

clear

and

belts

has

run

for a

voltage

on

working.

either

at

DC

volts.

is

increasing

remains

Steps 3 1hrough

around

the

a1termitor

the

MEASURING BATTERY

(ENGINE

3. 'furn off the engine. Inspect all

Ensure

connections

4.

If

a battery

!\lat

5.

Check condition

VOLTAGE

RUNNING)

iliat

selector

it

is

on

the

battery

the

ilie

battery

are

the

correct

reading

~~~

tight

switch

voltage.

tenninals

and

clean

is

setting.

If

should

the

of

moving

during

few

battery

toward

12

or

6,

wiring

and

in

the

your be

12

fJ/Igine

make

parts!

test

procedures.

minutes,

volts,

battery

measure

tenninals

14

volts,

a problem

ilie charging

and

the engine

charging

is

to

13

volts.·

..

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Keep

the

using

a

the

circuit;

connections.

ground

circuit,ensure

.

in

good

TESTING

1.

2.

3.

4.

5.

THE

Connect the positive probe connect

Wiggle

voltmeter.

battery voltage,

obtained, or output circuit for loose or dirty connections damaged wiring.

Start

Repeat ilie same measurement, the negative probe ground; The voltage reading should volts. it

If

terminal terminal. inspect Jump battery)

the

negative probe

ilie

engine

wiring

The meter should indicate the approximate

and

if

ilie reading varies,

the engine.

the positive probe

If

your alternator

repaired at a reliable service

the previous test

B,

If

the

wiring for breaks

12

volts

and

is

13-14

volts,

use

the

12

volts

from

operate

..

reads

then

to

the output terrinal

to

ground.

harness

should not

is

only battery voltage

meter

to

is

not

a

12

volt source (such

tl1e

alternator. If the

tl1e

alternatoris

while

observing

vary.

If

no

check

the alternator

to

B with the

be

between

over or under-charging, have

shop.

measure the

pre&ent

and

13.5

at

exciter terminal R,

poor

connections.

OK.

reading

or

engine

and

DC

excitation

as

voltage

Band

ilie

is

to

running.

14.5

at

ilie

output

E/!f1ines&

'33

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Generators

THE

OUTPUT

ENGINE

RUNNING

#10

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#16

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ALTERNATORS

TESTING/TROUBLESHOOTING

---

TESTING

1.

--·-e*eitation-terminal-R-on-Ihe-altemat<lr-and-lhe-negative---hllve-a-voltage-between-l.~-and-t4,,0Its-when1he"n)linds

2.

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(ENGINE RUNNING)

3. 'If the reading is between

4.

5.

THE

EXCITATION

Connect (-)

Thrn the battery switch to the on position

the

2.5

rotor

If

field

If

alternator-excitation lead or in the excitation circuit of the Connect lead

If

voltage, replaced. excitation circuit damaged

the positive

lead

to

ground.

multimeter

volts

reading.

(see illustration).

THE

field

circuit

probably

the reading is between

circuit probably

no reading is obtained, an open

regulator. Disconnect the lead

the positive multimeter probe

and

the negative multimeter probe

the multimeter

the voltage regulator is defective

If

wiring.

now

no voltage is indicated, check the

for

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(+)

multimeter

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.75

is shorted or grounded.

6.0

is

open.

inilicates

loose or dirty connections or

probe

to

the

and

should

be

EXCITER

TERMINAL

and

1.1

volts, the

and

7.0

volts, the rotor

exists

in the

from

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terminal R.

to

the excitation

to

ground.

an

approximate battery

and

1.3

must be

hote

to

CHECKING

Check running.

cbarging circuit isolator,

When

is

back

'tenuinal

wiring

ALTERNATOR

If

tests sembled do

the

NOTE:

illstructiolls staruJard

BATTERY

The

the

engine's

Cranking

Review establish' a engine's

•

Mouitor engine

•

Check

hydrometer. .

•

Use, level.

•

Make tight

THE

SERVICE

the

voltage

offue

If

not,

fuere

circuit.

Troubleshoot

by

checking

battery

the

problem

in

operation,

studs.

harness.

fue

switch,

bas

Also

REPAIR

indicate a failed

and

repaired.

job.

WESTERBEKE'S

for

the

disassembly

altenwtors.

CARE

minimum

recommended

i2

volt

Amps

(CCA).

fue

manufacturer's

systematic

starting

batteries

your

operation. fue

electrolyte

only

distilled

certain

to

fue

battery

voltmeter

fuat

BATTERY

service

is a problem

fue

wiring

and

fue

been

solved

take

fue

time

clean

fue

connecting

alternator,

Any

good

Service

capacity

DC

control

recommendations

maintenance

and

for

ie,!e!

water

to

battery

cable

posts

(and

battery.

in

fue

service

connections,

battery

and

to

tighten

it

will

alternator

Manual

alld

repair

circuit

schedule

house

batteries.

proper

and

specific

bring

electrolytes

connections

to

your

this battery service

itself.

before

of the battery

is

charging

battery

the

fue

and

terminals

need

to

service

has

detailed

of

their

600 -

900

and

for

gravity

engine).

battery

charging

clean

be

fuen

your

during

to

are

should

solenoid,

alternator

fue

from

the

disas-

shop

can

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in

Cold

with

a

a proper

clean

and

TESTING

THE

EXCITATION CIRCUIT

ENGINE RUNNING

':'

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OUTPUT

TERMINAL

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EXCITER TERMINAL

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GENERATOR

INFORMATION

USE

OF

The

ELECTRIC

power

required

MOTORS

to

start riioretl1aii-isreqiiireatoKeep Some

motors

require

much

others.

Split-phase

under

similar

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such

7

times

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require

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circumstances,

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loads

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MOTOR

SIZE

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1/6 1/4 1/3 1/2 3/4

1

-NOTE:

more

for

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Because motors

In

the

above

for

some

this

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larger sizes.

the

heavy

is

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be

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all

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REQUIRED

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generator's indicted should the

generating

voltmeter

load,

NOTE:

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pan.el.

gel1eratol:

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other

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This will ensure

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the

it

motor,

generator's data

plant

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AMPS

lrUNNIN~l

AMPERES

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hardest starting types (split-phase)

surge

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good

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Because

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and

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start

any

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FOR

maximum

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is

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them

more

current

types.

They

such

as

washing

the

motor

they

require 5

their

use

motor

is

repulsion-intluction

current

motor

varies

current

115-

Volt

motors

approximately

AMPS

STARTING

(AMPERES)

.

6.4

to

.

9.2

to

10.4

to

14.4

to

20.4

to

26

to

Amps

for

ones.

fOf_starting

the

generator

to

speed

starting

motors,

reduce

SPEED

no

load

applied,

loaded

plate.

to

ensure

appliances

not

installed meter

and

which

the

generator

120 volts

leg

only,

for the vessel's distribution

motor

starting response from the

then

to

its

full

The

output

proper

it

supplies.

to

monitor voltage

atnprobe.

is

it

is

recommended

be

configured

than

to

start,

are

is

should

to

be

dri-

to

start

with

to

an

air

than

a

con-

as

FOR

.

22.4"

32.2"

72.8"

29.2"

40.8"

52 Starting

The

reason

are

will

in a few

tum

the

load

at half

capacity

voltage

operation

If

an

installed

to

be

as

the

not

the

AC

pro-

is

as

of

and

GENERATOR

Frequency

-Illilicatea-6y

•

When

output

•

When output

Therefore,

. generator's

dipswitch generator sensing

GENERATOR

•

Maintaining

FREQUENCY

is

a direct result

thefollowing:

the

generator

frequency

Ibe

generator is

frequency

to

change

drive

on

the

changed

PC

board

MAINTENANCE

reasonable

Connections corroded,

salts,

build

sive

•

For

and

dust,

engine exhaust,

up.

Clogged

heating

and

unusually

petroleum-base

over

all

surfaces

• In

addition

inspected

overheated

• The checked and should

accelerate to

the

8,

identified

ners

• The

maintenance

noisy

• Examine bearing

of motion

wear.

will

Carbon

to

for

terminals

drive

discs

periodically if

for

any

evidence of

not

be

cracking.

generator shaft

of

the

head.

rear

annature

or

rough-sounding,

shaft

should

is

detectable,

Repair

rub

and

Monoxide

WES1ERBEKE

monoxide detector

monoxide,

The

presence

leak

from

the

elbow/exhaust hose,

are

enteting your

If

carbon

monoxide

clean air

and

is

60

is

50

the

engine's

ECU.

The

and

the

changed.

of

terminal

insulation

ventilation

reduced

severe

coatings

to

reduce

periodic

tightness

on

single

allowed

by

6 radial

bearing

is

required.

at

be

detected

must

cause

Detector

recommends

even

in

of

carbon

engine

boat.

correct

ADJUSTMENT

of

engine/generator

..

-------.--

lUn

at

1800

rpm,

HeItz.

lUn

at

1500

111m,

Hertz.

generator's frequency/voltage;

speed

must

be

AC

output configuration of

connections

cleanliness

boards surfaces

carbon,

on

is

and

may

etc.

openings

life

of

windings.

conditions,

cleaning,

of

and

possible

incipient

to

The

must

marks,

periodic

inspect

be

made

major

thin

should

be

rusting

the

all

connections,

loose

or

beming

for

become

bolts

which

be

hardened

one

is

lubticated and

However,

have

it

intervals.

when

the

quickly

damage

sprayed

and

damaged

generators

cracking

rusty

replaced.

force

bearing

to

mounting a carbon

in

the

vessels living

small amounts, is deadly.

monoxide indicates

or

generator

or.that

is

present,

the

problem

or

fumes

ventilate

immediately!

speed,

..

-.--.-

the

AC

voltage

the

AC

voltage

changed using

the

voltage

important.

rectifiers

may

start conducting if

are

allowed

may

cause

rust-inhibiting

or

brushed

corrosion,

generator

should

evidence of

wires.

should

tightness

of

failure.

because

fasten

the

steel

SAE

at

each

of

the 6 cor-

sealed;

if

the

beruing

No side movement

is

applied.

and

shaft

or

major

components

generator.

quarters.

an

from

the

from a nearby

the

area

as

.....

.

the

become

to

exces-

be

screws

Discs

rust

may

drive

grade

no

becomes

If

side

for

Catbon

exhaust

vessel

with

'.

be

disc

"'Io'Y"

WESTERBEKE

Engines

37

l!c

Generators

This which duce

-

-~

stator erator.

be

induced tion. DC

and creates windings supplied parallel

produced

main tifier. the

exciter

a

rated

available

produce a more

generalDr

requires

AC

are

The

Diodes

is a four-pole,

only

output.

The

responsilllefonl1e

magneti.c into

the

located

supply

it

an

electromagnetic

of

the

main

to a load. A step

to

the

AC

in

the

auxiliary

stator

and

is,

The

rectifier

stator

windings,

AC

output.

to

work

stable

brushless,

the

driving

copper

and self-eJrcttln-g-fll"ature-ofthis-gen'

field

produced

in

the

exciter rotor

to

the

windings

field

stator,

inducing

down

output

of

the main

windings

in

tum,

supplied

produces a DC

enabling

An

optional

in

tandem

with the transformer

AC

output.

self-excited

force of

the

laminated

causes

rotor

windings

rectify

of

the

rotating

which

rotates

an

transformer

stator.

of

the

to a full-wave

voltage

the

solid-state

BT-

engine

iron

in

an

AC

this

field.

through

AC

voltage

is

connected

An

AC

transformer

to further

generator

voltage

GENERATOR

generator

to

pro-

the

exciter

voltage

during

rota-

voltage

This

the

which

voltage

and

bridge

excite

to

produce

regulator

to

is

in

is

the

rec-

is

to

A

circuit tors.This circuit breaker ator

power

-

-breaker-can-bemanually-shutoff-when-sefVioing-the-generator

to

.

NOTE:

add-on WESTERB,EKE

CIRCUIT PART

-

breaker

ensure

This

kit

is

in

case

no

power.is

circuit

for earlier model

dealer.

BREAKER

NUMBERS

installed

will

-of

an

electrical

conting

breaker

is

-

8.0KW -42707

10.0KW -42698

11.5KW·42709

on

all

WESTERBEKE

automatically

overload.

into

the

available

as a WESTERBEKE

generations;

1

•

427D9

genera-

disconnect gener-

The

circuit

boat.

contact

your

AVR

AC

TERMINAL

BOARD

OPTIONAL

AVR

••

o,orT"·SWITCH

VOLTAGE

ADJUSTMENT

(FINE)

/ADJUSlrINGSHIMS

,COMPOIUNDTRANSFORMER

BT

GENERATOR

SINGLE

PHASE

(6

STUDI

COMPOUND

TRANSFORMER

AC TERMINAL BOARD

(12

STUD)

BRIDGE RECTIFIER

-...v:

WESTERBEICE

En.gines

& Generators

38

BTGENERATOR SINGLE (12

PHASE

STUDI

BREAKER

BT

GENERATOR

I

SINGLE

PHAS~

[SIX

STUD]

C D

A

r-----.~-::-:-::-:~B~-:-~·:-:~-::-·:-::-:-:~-:ll--li~~~~~1=~~=t~~~~A:\r:;-=:96PHZTERI'ii,NAL

+:

II

i b

~

: 2 3

RED

GR!!EH

'00

:

-{)I-

_________________

l-yllilm

\

'IEllOW

I

SLACK

- .. "

YELLON

______

4

BRIDGE

-t----7

r G

RECTIFIER)

~~~

YELLOW

IWHITE

(TO

SELECTOR

SWITCH)

60cYc.

50

eye:

J

~Ai·v~.R~.I--------=~

PLUG

REDI

WHITE

(I'OHERTlNOLTSBAR)

Bt,ACK/wt/rrE

(TO

BLUE/WHITE

(fO

BLUE/WHITE

(TO

HEMINOLTS

AVR

PLUG

,aTERM.

BAR)

INTERNAL

A.

EXCITER A-I (Selector

B.

EXCITER ROTOR

1.

Auxiliary

2.

Diodes

3.

Rotating Field

4.

Suppressor

C. MAIN STATOR

1.

Main Stator

2.

Main Stator

3.

Main Stator

STATOR

and

A - 2 Exciter Stator

in

COMP position)

Windings

(6)

Windings

Windings Windings Auxiliary

WINDINGS

Windings

and

FIELD

(A

- B -

C)

Windings

1&

WIRING

W/OPTIONAL

2

-...v-

SCHEMATIC

VOLTAGE

WESTERBEKE

Engines & Generators

(SIX

STUD)

REGULATOR

COMPOUND TRANSFORMER

D.

1.

Compound

2.

Compound

3.

Compound

Resistance readings and voltage checks

easily

for

D-3

by locating

points

shown

winding resistance values

component's

G.

BRIDGE

A.V.R.

Optional

Transformer Windings Transformer Windings

Transformer Auxiliary

the

components

the

color coded wires at

on the

above

electrical

RECTIFmR

Automatic

connections.

in

be

Voltage

39

Windings

can

the exciter circuit

the

schematic.

sure

When

to

lift

both

Regulator

.

REFER

TO

AC

TERMINAL

be

accessed

A,

G, C-3

connection

checking

of

the

Plug

(6

THE

FOLLOWING

BLOCK

and

Prong).

PAGE

FOR"

CONNECTIONS

...

.,

,

GENERATORVOLTAGEADJUSTIVIENT

illiTE:

WItSTERBEKE

adjustments

be

recommends

pe/formed

that

by a quailified

the

/ollowinggenerator

technician.

Generator

1~~FrequeilcyiScirurrectresult0ftlngme/generatorspeed:--

, ,

'1800

1500'nfijJ=50 hertz

2.,'

To

"

Frequency

rpriJ."·6b

change generator

a. Reconfigure the

, stud tenfiinal block followi,ni the-Illustrations

Install selected.

b.

Properiyconnect board theneutrallground

,in the breaker

• tie'off the

c.

NOTE:

optional lead voliageihertz connection

hertZ

uer1c

freq

AC

the

torrectlyratedAC brOakerfor the Hertz

to

the line connections cinthe

box.

Unused

On six stud

AVR

is

to

,correspond

y,

follow

the

steps below: .

output

conn~~ons

the

leads from

,the

voltage sensing AC

to

the brass neutrallgroulld stud

When only one lin" is present,

line sense connection.

AC

models,

only,

when

installed, reposition'the blue/white

to

the hertz selected

bar.

'SlxsrUD

AC'·"OLTAGE

Oh

breaker

On

the

an

the

six

below.

and

d. Shut offlhe

---,

_.

,

--~:e

~~:~~~~~~e

20

amp

DC

panel

~~~:~~h~rti:b~;~~~~

hem. Then tum the DC breaker back on.

e.

Shut

off

the ACbreaker and startthe urtit. Monitor

the

no'ioad

needed,

lamin~ted

60

hertz No-Load

50

hertz No"Load

f.

Close the ACbreaker and load the generator

AC

voltage. If,a voltage adjystment is '

add or.temove shim material from under the

steel bar of the compound transformer.

Voltage Voltage

moliltor operation.

CONFIGORATIONS

,.1~9!?~oy,

2

60H

N

breaker

121-124volts

232-235 volts

,

SIX

STUD

and move the '

for

and

AC

VOLTAGE

CONFIGURATIONS

•

'.®

II

..

}.1Sy

. 50Hz'

@ @

VOLTAGE

BIJARO

2~QY5.0!:fz_

:@

,@

'~<M

'Ii}

SENSE

50Hz

RESISTOR

UNit

FOR

.

TilE

GROUND

TERMINAL

TilE

GENERATOR

'

SHOWN

BLOCK

ON

IS nISID[

BOX

THE

,

L.:::~+--~

LOAD

-CONNECTIO~

HEN

,WIRING

A

JUMPER

LOAD

CONNECTIONS,

120V/60Hz,

IS

REOUIRED

LOAD

C.ON.HEeT

BETWEEN

'TO

CIRCUIT

ilREAK~R·

101'

1\

BlK·

,.rBLK

VOLTAGE

FOR

"",-1;::;;:=';:1

:liNT

IJ

VOLTAGE

SENSE··

RES'I

STOR

ilOARD

SENSE

60Hz

RESISTOR

UNIT

BOARD

Engines & Generators

40

GENERATOR

NOTE:

WESTERBEKE

adjustments

Generator

~ ~

1~-

-["requencyts-a-rtirecrresult-of-enginelgeneratonpeed:~-

1800

1500

2.

To

Frequency

'fpm = 60

nnp =

change

generator

a.

Reconfigure

twelve below. Hertz

b.

Properly

board

the

neutral/ground

in

the

tie

<1ff

hertz

50

hertz

frequency,

the

AC

stud

terminal

Install

the

correctly

selected.

connect

to

the

breaker

the.

the

line

connections

to

box.

When

Ui1US~

line

output

block

leads

the

brass

sense

ouly

be

follow

the

connections

following

rated

AC

from

the

voll'!ge

on

the

AC

neutral/ground

one line

connection.

performed

steps

the

breaker

VOLTAGE

recommends

by

below:

on

the

illustrations

for

the

sensing

breaker

and

stud

is

present,

~

..

~_

that

a

quailified

~~~

ADJUSTMENT

the

technician.

~

~~~

__

following

c,

Shut

---'..ltl

the

.

·.hertz,

d.

Shut off

.

the

needed, laminated 60 50

e.

:Close

off

dipswitch

hertz

Then

no-load

hertz hertz

the

monitor

generator

the

20

amp

on

the

sglected -ON

tum

the

AC

breaker

AC

voltage.

add

or

remove

steel

bar of the

No-Load

AC

breaker

operation.

ECU DC'breaker

DC

panel

for

"and

If

shim

Voltage Voltage

and

breaker

to

the

nroner

50

hertz,

back

start

the

a

voltage

material

compound

121-124

232-235

load

the

generator

and

move

p_o~iti!m

OFF

for

60

on.

unit.

Monitor

adjystment

from

under

transfonner.

volts volts

and

the

for

is

~

the

TWELVf

THE

GROUND

TERMINAL

THE-

SHOWN

BLOCK

GENERATOR

c:roo

STUD-Iic'

IS

BOX

.'If--\;[

ON

INSIDE

THE

. ,

51

V/HEN

WIRING

A

JUMPER

LOAD

~ONN[CTIONS,

VOLTAGE

.

CIRCUli'

BR~AKER

120V/60Hz,

IS

REQUIRED

CONFIGURATIONS

.'

BETwEE,N

<.]Do

J2.!l!~4.Qlf

__

!!9H.~:

OaD

S

'7

9

N'"

2:@

,I.

®

VOLTAGE

FOR.

~

60Hz

SENSE

UNIT

RESISTOR

BOARD

®CD

THE

GROUND

SHOWN

ON

TERNINAl

THE

BLOCH

GENERATOR

IS INSIDE

BOX

THE

'U<I'

~.1

;;:.:!:

~g:.

U

••

®.

8

:""

~·

I

.'

@CD®

CD

(]Wj

Engines

~

4oA'

G~nerators

VOLTAGE BOARD

FOR

SENSE

50Hz

RESISTOR

UNIT

NO·LOAO

Voltage being

1. .

2.

NOTE:.The

produced

load removed. momentary

3. (non-conductive

under

VOLTAGE

adjustment

governed

The

selector

position. .To

confirm

a

momentary

Tlie

voltage

tary

load

is

output

from

hertz).

The

volts

at

60.0 -60.5

Ito-load

by

the

should

be

The

voltage

load

To

rliise

or

the

steel transformer. soften

at

temperatures

smliil

reduction

times

be

accomplished laminated shims

and

steel

the

----

is

by

the

switch,

no-load

(moderate)

produced

removed

the

generators

no-load

voltage

generator

applied

is

removed

lower

the

material)

laminated

The

material

in

bar

transformer

GENERATOR

NOTE:

WESTERBEKE

tests

and

adjustments

--------_

ADJUSTMENT

made

with

compound

if

installed,

voltage,

load

by

the

is

no-load

voltage

hertz

(232

should

once

to

excite

produced

is

voltage,

are

bar

used

in

the

no-load

to

reduce

by

voltage

gently core.

...

the

generator

transformer.

must

start

the

to

excite

generator

voltage.

120

volt leg(s)

should

be

-

23~

be

adjusted

started

the

transformer

by

the

no-load

shims placed or

on

iop

for

shimming

1760 F

(I

tapping

the

gap

be

generator

the after

between

volts at

and a momentary

generator

voltage.

of

varying

removed

of

the

(8pO

to 3 volts)

between

regulation

in

the

COMP

and

transformer.

the

momen-

Note

the

(230

volt

121 -124

50.0 -50.5

to

the

and

after

thickness

compound

should

C)

range.

can

the

top

the

VOLTAGE

recommends

be

peifonned

apply

voltage

50

hertz).

voltage

then

this

from

not

A

some

of

the

existing

that

by a quailified

.

-FUL[·[lrAD

The from

the

generators

Fine wires A to progressively have

Should (210

BLUE

WIRE:

ADJUSTMENT

the

following

voltage

60Hz

voltage

to

be

full-load

volts-50Hz),

g~niirator

technician.

VOLTAGE

hertz

to

50Hz

full-load

adjustments

leads

#1,

in

that

made

as

output

A

TWO WIRES

ADJUSTMENT

connection

can

#2,

order. A no-load

well.

the

RED.

also

output.

can

and

fall

voltage

bar

be

#3

below

should

STUD

ABLUE

6

AND

12

STUD

CONNECTION

that

is

used

to

performed

increasing

108

be

.

WIRE

VOLTAGE

BARS

used

when

increase

.

by

the

loaded

voltage

adjustment

volts-60Hz

adjusted.

12

STUD

HERTZ

changing

or

decrease

repositioning

voltage

will

NOTE:

No-load

with

the

compound adjustments placed

on

the

Loss

of

generator

cause a drop

Shim

thickness

voltage

by material material

voltage

may

transformer.

to

compensate

generator/engine

hertz/speed,

in

voltage

output.

of

0.001

approximately

raises

the

no-load

lowers

no-load

be

effected

Do

not

for

overload

(inductive-motor

the

result

inch

will

change

4 - 6

volts.

voltage.

needing

use

these

conditions

of

overload,

the

Adding

Removing

readjustment

being

type

loads).

will

no-load

shim

.

NOTE:

and

if

to

correspond regulator to

produce

When

the

BlueiWhite will

abnormally

.optional

to

the

sense

voltage

(Blue)

Hem

the

incorrect

high

regulator

lead

unit

voltage

output

is

not

is

operating

and

voltage.

is

installed

correctly

cause

positioned

at,.

the

generator

Engines & Generators

41

OPTIONAL

An

optional

~

is

available

instailed, position, compound voltage

excitation

former

AUTOMATIC

solid-state

for

and

the

regulator

transformer

output.

to

the

provides

Installation

1.

The

regulator

the

generator's

each

15mm

regulator

2.

Cormect the

NOTE:

one

direction.

3.

Before the the voltage

(60Hz)

procedures

4.

With move the regulator

to 50-50.5 with voltage output

NOTE:

dnwn.

the

regulator

exciter circuitpower.

for loaded

NOTE:

WESTERBEKE

A

off or switching operated components

board.

the

regulator

The

plug

Check

moving NO-Load COMP

position

should

or

224

the

generators

the

selector

120. -122 hertz).

the

compound

Do not

Use

the

to

conditions.

Ship

to

CAUTION:

before

switching

vice-versa

with

may

voltage

use

with

the

regulation

works

regulator

In

the

ELEC group 1 exciter excitation

is

mounted

case.

Use

long,

with

6-prong

as

use

compound

shore

generator plug to

board.

is

keyed

to

this

and insert it

the

selector

voltage

produced

will

be

adjusted

-228

volts

explained

no

switch

board

potentiometer

volts

at

60-60.5

The

regulator board is

transformer

within + or

the

regulator

perform

dealer.

This

switches

Heavy

this

motor

shore

because

cause

in

voltage

heavy

AC

danage

the

generator.

BT

GENERATOR

VOLTAGE

regulator

BT

switch

together

mode,

to

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using

two

lock washers

engage

switch

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down

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load voltage properly

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transformer for

causes

leaves

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power

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(board

se~generators.

is

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the

staodard

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group 2 exciter

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by the generator

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from

to

force NO-Load

less

available at your

surges

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mount

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regulator

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to

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between

this

manual.

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position.

to

set

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should

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the

regulator

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vessel

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maintain

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circuit

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circuit

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holes

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on

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VOLTAGE

REGULATOR

ADJUSTMENTS

[THREE

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Description

The

voltage

optimum

~-~ --complete-protection-circuitry-to-guard-against-~perating--

conditions

regulator

AC

that

generator

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design

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generator.

circuits

overload

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have

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correct

regulator

LED-lights;

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potentiometer.

an

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generator

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operation

conjunction

threshold~

surge

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driver)

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trimmers

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speed,

adjust

power

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output

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speed

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VOLTAGE

generator load

the regulator

adjust

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output

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Prior

hit

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with

voltage

the

voltage

green

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voltage

REGULATOR

to a full

1.0 -0.8 to

starting the engine,

(using

clockwise

their

stops.

clockwise

generator

VOLT

adjust

will

The

voltage

to

LED

will

variation

changes

minimum

the

output

slowly

clockwise until

point

is

DIAGRAM'

output

voltage.

voltage should

rated

with

engine

a mini phillips

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Thm

the (Maximum)

running at

at

minimum,

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recovery

stability

rotate

stable within 1

output

desired

stay

of

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the

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regulator's

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to

time

the

generator

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monitored.

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be

generator

drive

speed turn

screw-

direction

AMP

and

no-load,

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rotate

will

increase

value.

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limit

overcom-

to

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voltage

adjust

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held

in

at

is

this

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proper

at

output

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the

and

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be

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of

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must

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2.

3.

4.

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remove

Setting

NOTE:

jumper strap

two

setting,

1.

2.

3. Increase the

With

tion

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order

to

set

be

loaded

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the

engine

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on

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the

its

stop.

put

of

the

should

come

Slowly

rotate the

output

voltage

age-

output

yellow

LED

Return

to

and

the

generator

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this

When

the

If

the

60

Hertz

the

Th

adjust the

lower

the

(54

hertz

Rotate

the

generator's

the

same

The

red "LED" light

put

will

the

above

normally.

Overload

the

AMP

overload

to

its

full

generator

by

50

AMP

Wait

generator

at

nominal

changing

60

to

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hertz

units).

adjustment

about

15-20

should

on.

AMP

increases

the

start

light

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speed,

voltage

not

happen,

from

hertz jumper bar

Underspeed

unit

is

operating

is

in

place

on

terminals.

generator

engine

on

60

Hertz

time

engine

return

In order

should

underspeed

speed

hertz

units,

adjustment

AC

output

the

red

speed

to

normal.

adjustments

Protection

protection,

output

rating.

rating,

then

(54

Hertz

on

counterclockwise until it

seconds

drop

and

adjustment

to

approximately

of the

adjustment.

come

on:

the

yellow

will

rise

repeat

the

60

hertz

from

Protection

at

60

Hertz

the

regulator

to

be

running at

(low

frequency)

at

90%

of

45

hertz

counterclockwise

voltage

"LED" light

to

its

normal

will

go

out

made,

with the

that

are indicated

LED).

which can be

Each of the

reduction

during

glows

60

after

clockwise until the

to adjustment.

to

the

adjust

its

on

starts

comes

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tile

in

excitor

and

prevent their

which pennits

times such

demands. The

during

of the regulator

the -generator

decrease the speed

hertz units,

which the

the

yellow LED light

97% of the

At

this

point

LED

will tum off

its

normal·value.

50

hertz

operation,

regulator

ensure

board

the

normal

50

speed

the

regulator

that

between

underspeed

no-load.

protection

running

hertz

units.

slowly

to

decrease

on.

(frequency)

AC

voltage

should

board.

two

as

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genera-

45

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the

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speed

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44

REGULATOR

Description

The

regulator

(0

to

6)

- ·snowifconfiectifii1poifi!S uration pin

#1

112

and

NOTE:

the

regulator board between terminal

is

equipped

and

their related brass

of

the

generator.

and

112

#0

on

the

Series Delta

170·270 V

on

theAC tenninal

voltage

requires

SENSING 3 PHASE

NOTE:

WESTERBEKE

and adjustments

with

seven

numbered

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ana

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sensing

regulator board

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installation

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technician.

CONFIGURATIONS

SERIES

WYE

l-L

L-N L-L L-N

WYE

(STAR)

480.

VAG

277

VAG

400

VAG

230

VAG

(STAR)

30

10

30 10

60

60 50 50

N

HZ HZ

HZ

- "'!!"-.

60

3

PHASE

VOLTAGE

PARALLEL

- .

PARALLEL L-L

L-N

L

-L

L-N

WYE

Hz

WYE

(STAR)

240

138

200 115

o

REGULATOR

(STAR)

VAG VAG

3050HZ

10

30 10

60 50 60

--1"60

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N

HZ

HZ HZ

3

Hz

SERIES

DELTA

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l3-11

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L2,

L3-11

DELTA

W'~

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270

VAG

138.

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230

VAG

115

VAG

5

30 10 30 10

60

HZ 60HZ 50HZ 50HZ

1

L2

3

N

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WESTERBEKE

Engines &

45

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4.

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C. MAIN

D.

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STATOR

1.

Main

2.

Main

3.

Main

COMPOUND TRANSFORMER

1.

Compound

2.

Compound

3.

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BRIDGE RECTIFIER

+

AC

-Kl-

AC

WIRING

STATOR

Value

Windings

(6)

Field

Stator Stator Stator Auxiliary

WINDINGS

10.0

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46

BT

The

following insight BT

bmshIess regulation. controls, relationship between potential

Keep

in electricity remember therefore,

a

generator.

Only a few

NOTE:

Troubleshoot the components

1.

LOW

Component Checks

F Selector

8

A

troubleshooting

into

problems

generators

Owing

troubleshooting problems

mind

is

required

that

extreme

basic

Refer

to

VOLTAGE

Rotor

Components

82

Exciter

B3

Rotor

B1

Exciter

1-1+2

which

operating

to

the

cause

are

covered

that a

basic

for

lethal

voltages

cautin

tools

are

the

INTERNAL

60·100

Switch

Rotor

Field

Winding

Rotor

Exciter StatorWinding(s)

simplicity

is

fundamental

this

is

necessary

VOLTS

Diodes Winding(s)

GENERATOR

NOTE:

WESTERBEKE recommends

and adjustments

chart

is

desigoed

may

be

encountered

on

compound

of

the

relatively

and

troubleshoting,

essential

easy,

effect

is

understood.

in the

text

knowledge

are

present

when

for

WIRING DIAGRAMS

in

the

following

AC

a,b,c

to

give

with

traosfonner

equipment

once

the

of

this

manual.

of

and

always

in

the

circuitry:

troubleshooting

diagoosis

and

order.

TROUBLESHOOTING

that

the

be

the

and

Most

repaiJ:

when

peiformed

peiforming

by

a qualified technician.

These

are

haod

meter

capable

of reading

preciSion Before

problem, problem.

which equipment iIiitial bridge one remedied

required

attempting

preferably in

is

rectifier,

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these

early

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following

some

fault.

yo

he problem

easily

CHART

following

tools:

cases,

to

Bring basic repair

so

and

gen.erator

an

amprobe

less

in

reading

any

repairs,

from

an

this

the

method

equipment,

that if

theproblem

replaceable

efficiently.

tests.

component

individual may

tests

and a quality

than

one

ohm

get a clear explanation of the

witnessing

bring

to

of operation rather

tools

such

should

parts, the problem

volt ohm

due

to

the

winding resistances.

the

light a problem

than

'an

with

you

on

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as

giodes

and a

be

found in

cab

be

2.

NO

AC

VOLTAGE

Main

Stator,

Component

C

1+2

Main

B 4 Posi Resistor

8 2 Diodes

o

1+2

compound

8 3 Rotor

3.

RESIDUAL

Exciter

Circuit

Component

A

1-1+2

G Bridge

D 3 Transfonner

C 3 Main

F Selector

Circuit

Connections

(from

the Transformer

connections

NOTE:

Reference

additional information. www.WESTERBEKE.COM.

OUTPUT

Rotor

Components,

Checks

Stator

Winding

(4-6

open/shorted)

Transfonner

Field

Wmding

VOLTAGE

Faulty

Checks

Exciter

Stator

Rectifier

Aux.

Stator

Aux.

Switch

on

the

Bridge Rectifier)

the

BTTroubleshooting guides on WESTERBEKE'S

Winding(s)

Winding

Wmding

Aux.

winding

Transformer

Winding

to

the

website

under "TECHANICAL" for

~

WESTERBEKE

Engine~

47

& Generators

SPECIFICATIONS·

.ENGINE

8.0/6.0

Engine

Type

Displacement

Aspiration

Combustion Bore & Stroke Firing

Direction Compression

Weight

Inclination

Compression

Minimum

Spilled Valve

Engine

Injector

Valve

(engine Engine

General Oil Sump

(not

Operating

(engine Oil

Order

of

liming

Seat

Angle

liming

Pressure

Seat

Angle

Clearance

cold)

Speed

Filter

Capacity

including

Oil

hot)

Grade

Chamber

Rotation

Ratio

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filter)

Pressure

KW

EDT,

GENERAL

Diesel.

cooled, mechanism.

80.4

cubic Naturally Swirl

3.07 x 3.62

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Clockwise,

22:1

8.0

EDT

10.0

EDT

11.5

EDT

12.6

EDT

Continuous

Temporary

TUNE-UP

(Stalic)

SPECIFICATIONS

427

psi

384

psi

17'

(spill)

45'

17'

BTDC

1991 + 71

Intake

Exhaust

0.25mm

1800 1600

LUBRICATION

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flow,

3.9

U.S.

50 -60

API

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10.0n.5

four-cycle.

type.

45'

rpm rpm

30,

vertical

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inches

aspirated.

inches

when

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25'

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kg/cm')

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kg/cm')

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psi

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Hz)

(50

Hz)

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fed

system.

paper

element,

qts

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three-cylinder,

(1.318

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viewed

4771bs 520 520 520

to

at

(140

inches)

liters)

CF

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KW

overhead

liter)

mm)

from

the

(216

kilos)

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(236

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(236

kilos)

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(236

kilos)

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30

280

rpm

+ 5 -0

spin-on

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or

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fresh

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valve

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kgflcm').

type.

CH-4

OR

EDT,

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11.5/9.2

General

Fuel Fuel

Injection

Pump Nozzle Fuel

Filter

Air

Cleaner

Fuel

Lift

Pump

Starting

Battery

Capacity

DC

Charging

Altemator

Starting

Aid

Starter

Cold

Cranking

Amp

Engine

Combustion

Requirements

60

Hz

General

Operating

Fresh

Raw

at

1800

(Measures

discharging

exhaust System

(Fresh

at

1800rpm

Temperature

Water

Pump

Water

Pump

Water

Flow

rpm

before

into

elbow)

Capacity

Water)

KW

EDT,

FUEL

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flow,

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diesel In-line Throttle Cartridge

Replaceable

12

volt

ELECTRICAL

12

Volt,

800

-1000

50

Amp

Glow

plugs,

12

Volt,

240 -250

Draw

41

Air

ctm

COOLING

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controlled 170

-190' F

Centrifugal

•

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belt

driven

7-8

gpm

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US

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SYSTEM

self

bleeding.

oil

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rating

of

45

or

plunger

type

(BOSCH).

type.

type

(PN#030200).

paper

filter

cartridge

(#039705).

DC

lift

capacity

of

5'

(1.5

mm)

SYSTEM

(-)

negative

ground

Cold

Cranking

Amps

(CCA)

rated,

belt-driven

sheathed

type

reduction

gear

amps

(approx.)

(1.16

cmm)

SYSTEM

water-cooled

displacement,

qts

block,

with

heat

(77 -88'

type,

metal

(25.9 -29.6

(4.7

liters)

thermostatically-

exchanger.

C)

impeller,

rubber

impeller,

gpm)

belt-driven.

EDT

higher).

solid

state

Engines & Generators

48

AC

GENERATOR

Single

Phase

Voltage

regulation:

Voltage

Frequency

Rating

60

10.0KW 50

7.5KW

Generetor

NOTE:

Engine Generator

Ambient

Recommendations

regulation:

(Volts

Hertz

(1800

Hertz

(1500

Cooling

Increase

Compartment

Temperature

AC)

rpm)

air

supply

SPECIFICATIONS

(Single

Brushle". Pre-lubricated,

Reconnectable,

regulation regulation).

120 230

±5%

.5

120

120/240

230

225 -250 Air

15%

100 -200

122°F

four-pole,

(optional

or

120/240

Volts -50

no

load

Hertz

(.60%)

Volts

cfm

Requirements(60

for

50

Hertz

cfm

(50°C)

Phase)

revolving

single-bearing

single-phase

solid-state

Volts -60

Hertz.

to

full

load.

no

load

to

83.3

Amps

83.3/41.6

22.6

Amps

(5.66 -6.37

Hertz)

operation

(1500

(2.83 -5.66

maximum

-

field.

design.

transformer

voltage

Hertz

full

load.

Amps

cmm)

at

1800

rpm

rpm).

cmm)

GENERATOR

10.7

n

AC

Three

Phase

10.0

KW·

60

7.5

Voltage (60

Voltage (50

Amperage (60

Amperage (50

Engine

Generator

Air

(60

NOTE:

Generator

Ambient Recommendations

Hz

KW·

50

Hz

-3

phase

Hertz)

-3

Phase

Hertz)

-3

phase

Hertz)

-3

phase

Hertz)

Compartment

Cooling

Requirements

Hertz)

at

1800

rpm

Incraase

air

supply

Compartment

Temperature

.SKW

GENERATOR

15%

EDT

(3

Brushless, lubricated, reconnectable

voltage

protection

Low High DELTA

High DELTA

Low

High DELTA

100 -200 225 -250

Voltage

for

122°F

six-pole,

Single-bearing

for

Delta.

Solid

cirCUitry

WYE

efm

elm

50

Hertz

(50°C)

maximum

(2.83 -5.66 (5.66 -6.37

operation

Phase)

revolving

design.

low

voltage

state

voltage

cmm)

(1500

field. WYE,

regulator

240 480

240 400

230 35

Amps

15

Amps

30

Amps

14

Amps

24

Amps

cmm)

rpm).

Sealed

12

Lead

high

Volts Volts

Volts

with

8.0/6.0KW

AC

GENERATOR

Single

Phase

Voltage

regulation:

Voltage

Frequency

Rating

60

8.0KW 50

8.0KW

Generator

Air

regulation:

(Volts

Hertz

(60

NOTE:

Engine Generator

Ambient

Recommendations

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Increase

air

Compartment

Temperature

rpm

supply

EDT

(Single

Brushless,

Pre-lubricated,

Reconnectable,

regulation

regulation). 120

230 ±5%

.5

120

120/240

230

15%

or

1201240

Volts -50

no

load

Hertz

(.60%)

Volts

175 -200

for

50

100 -200 122°F

(50°C)

four-pole,

(optional

to

elm

Hertz

elm

Phase)

revolving

Single-bearing

Single-phase

Volts -60

Hertz.

full

no

66

66133

22.6

(4.95 -5.66

operation

(2.83 -5.66

maximum

transformer

solid-state

Hertz

load. load

to

full

Amps

cmm)

(1500

cmm)

field.

design.

voltage

load.

rpm).

Engines & Generators

49

Single

Phase

Voltage

Regulation

frequency

Rating

60

11.5 50

9.2KW

Generator Air

(60

Regulation

(Volts

Hz

(1

BOO

KW

Hz

(1500

Cooling

requirements

Hz)

at

1800

SPECIFICATIONS·

AG

GENERATOR

Brushle", Pre-lubricated,

Reconnectable,

regulation regulator)

120

230

±5%

.3.Hertz

AC)

rpm)

rpm

120

120/240

230

225 -250

NOTE:

operation

(Single

four

(opuonal

or

120/240

Volts -50

no

load

(.5%)

volts

cfm

Increase

(1500

Phase)

pole,

revolving

single

bearing

single

phase

solid

volts -60

Hertz

to

full

load.

no

load

to

95.8

amps

95.8/47.9

40

amps

(5.66 -6.37

air

supply

rpm)

field.

design.

transformer

state

voltage

hertz

full

load.

amps

cmm)

15%

for

GENERATOR

Three

Phase

11.5

KW -60

9.2

KW -50

Voltage

-3

(60

Hertz)

Voltage

-3

(50

Hertz)

Amperage (60

Hertz)

Amperage (50

Hertz)

Generator

Air

50

Hertz

requirements

(60

Hz)

at

11.5/9.2KW

AG

GENERATOR

Hertz

phase

Phase

-3

phase

-3

phase

Cooling 1800

rpm

.

Brushless, lubricated,

reconnectable

voltage

protection

Low High DELTA

High DELTA

Low High

DELTA

High

DELTA 225 -250

NOTE:

operation

ETD

six-pole, single-bearing

Delta.

circuitry

Voltage

cfm

Increase

(1500

(3

Phase)

revolving

for

low

Solid

state

WYE

(5.66 -6.37

air

supply

rpm)

design.

voltage

cmm)

15%

field.

ME,

regulator

240

480

240 400

230

34

Amps

17

Amps

34

Amps

16

Amps

29

Amps

for

Sealed

12

Lead

high

Volts

50

with

Hertz

Generator

AmbientTemperature

Compartment

Recommendations

AC

GENERATOR

Single

Phase

Voltage

Regulation frequency Rating

60

12.6KW 50

10.4KW

Generator Air

(60

Regulation

(Volts

AC)

Hz

(1800

rpm)

Hz

(1500

rpm)

Cooling

requirements

Hz)

at

1800

rpm

122'f

(50'C)

maximum

NOTE:

Forced

to

maintain

temperatures

ven#lation

generator

below

SPECIFICATIONS·

(Single

Brushless,

Pre-lubricated,

Reconnectable,

regu~tion

regulator) 120

230

±5%

.3

120

120/240

230

225 -250

NOTE:

operation

or

120/240

Volts -50

no

Hertz

(.5%)

volts

vol'"

Increase

four

(optional

load

volts

cfm

(1500

should

compartment

122'F

Phase)

pole,

revolving

single

bearing

single

phase

solid

volts -60

Hertz to

full

load.

no

load

to

95.8

amps

195.8/49.9

40

amps

(5.66 -6.37

air

supply

rpm)

be

provided

(50'C).

field.

design.

transformer

state

voltage

hertz

full

load.

amps

cmm)

15%

for

GENERATOR

50

Hertz

Generator

Ambient

Compartment

Temperature

Recommendations

12.6110.4KW

AC

GENERATOR

Three

Phase

12.5

KW -60

10.4

Voltage

(60

Voltage (50

Amperage (60

Amperage

(50 Generator

Air

(60

Hertz

KW -50

Hertz

-3

phase

Hertz)

-3

Phase

Hertz)

-3

phase

Hertz)

-3

phase

Hertz)

Cooling

requirements

Hz)

at

1800

rpm

122'f

(50'C)

maximum

NOTE:

Forced

to

maintain

temperatures

ventilation

generator

below

ETD

(3

Brushle", lubricated, reconnectable voltage

protection

Low High DELTA

High DELTA

Low High DELTA

High DELTA

225 -250

NOTE:

operation

six-pole, single-bearing

Delta.

circuitry

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

ctm

Increase

(1500

for

Solid

should

compartment

122'F

Phase)

revolving

design.

low

voltage

state

voltage

(5.66 -6.37

air

supply

rpm)

be

(50'C).

field. WYE,

regulator

240 480 240

400

230 38

Amps

19

Amps

3BAmps

18

Amps

32

Amps

cmm)

15%

for

provided

Sealed

12

Lead

high

Volts

Volts Volts

Volts

50

Hertz

with

Generator Ambient Recommendations

Compartment

Temperature

122'f

(50'C)

maximum

NOTE:

Forced

to

maintain

temperatures

ventilation

generator

below

compartment

122'F

should

(50'C)).

be

provided

Engines & Generators

Generator Ambient Recommendations

50

Compartment

Temperature

122'f

(50'C)

NOTE:

Forced

to

maintain

temperatures

generator

maximum

ventilation

compartment

below

122'F

should

(50'C).

be

provided

SPECIFICATIONS·

ENGINE

Engine

Type

Displacement Aspiration

Combustion

Bore & Stroke

Rring

Direction Compression

Dimensions -inches

Engine

Inclination

Weight

12.5!9.4KW

15.0!12.0KW Fuel

(full

12.5KW

9.4KW

15.0KW

12.0KW HP@1800RPM

HP@1600RPM

Chamber

Order

of

Rotation

Ratio

Only

(dl)')

Consumption

amperage

load)

(mm)

Diesel, cooled,

mechanism.

107.3 Naturally Swirl

3.07 x 3.62 1-3-4-2 Clockwise, 22:1 Height:

Width: Length:

Continuous Temporal)'

5611bs 5691bs

1.19

0.19

1.42

1.12

12.5/9.4KW

GENERAL

25 22

type.

gph gph

HP

four-cycle,

cubic

19.0

vertical

in-line

Inches

aspirated.

inches

when

24.0

inches

34.6

inches

15'

25'

(254.5 (258.1

(4.50 (3.44lph)

(5.38Iph)

(4.24Iph)

four-cylinder,

overhead

(1.758

(78 x 92

viewed

(609.6

(482.6

(878.8

(all

directions)

(not

to

kgs) kgs)

Iph)

liter)

mm)

from

mm)

exceed

fresh valve

the

front.

30

minutes)

EDT

water-

&

15.0/12.0KW

Starting

BatteI)'

Capacity

OC

Charging

Alternator

Starting

Aid

Starter

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

System

Capacity

(Fresh

Water)

Raw

Water

1800

rpm

before

elbow)

Combustion

1800

rpm

Combustion

1500

rpm

Flow

into

at

at (Measures discharging exhaust

Engine

Requirements at

Engine Requirements

at

EDT

ELECTRICAL

12

Volt, 800 50

Amp Glow 12

Volt,

COOLING

Fresh

controlled 170

Centrifugal Positive

belt

8.0

7-8

56

Air

46

Air

SYSTEM

(-)

negative

-1

000

Cold

rated,

plugs,

sheathed

reduction

SYSTEM

water-cooled

with

-190' F (77 -88' type,

displacement,

driven

US

qts

(7.6Itters)

gpm

(25.9 -29.6

cfm

(1.60

cfm

(1.31

ground

Cranking

belt-driven

type

gear

block,

heat

exchanger.

C)

metal

impeller, rubber

gpm)

cmm)

Amps

(CCA)

thermostatically-

belt-driven.

impeller,

Compression

Pressure

Minimum

Spilled

TIming

(StatiC)

Valve

Seat

Angle

Engine

Speed

Valve

Seat

Angle

Valve

Clearance

Injector

Pressure

Engine

TIming

TUNE-UP

427 384

.17'

Intake Exhaust

1800

1500 Intake

Exhaust

0.25 1991

17'

SPECIFICATIONS

psi

(30

kg!cm')

at

280

psi

(27

(spill)

45'

30'

rpm rpm

45'

30'

inches

+ 71-

BTOC

kg!cm')

BTOC

(60Hz)

(50Hz)

(0.0098 Opsi(140+

rpm

mm)

5- 0

kgf!cm~.

General

Oil

Riter

Sump

Capacity

(not

including

Operating (engine

hot)

Oil

Grade

LUBRICATION

filter)

011

Pressure

fed

Full

flow,

4.5

U.S.

qts

40 -60

psi

API

Specification

SAE

30,

10W-40,

SYSTEM

system.

paper

elemen,

(4.3

liters)

(3.5 -4.2

CF

15W-40

spin-on

kg!cm')

or

CG-4,

type.

CH-4

OR

CI-4

~

WESTERBEKE

Engines & Generators

51

AC

GENERATOR

Sing.

Phase

Voltage

regulation:

Frequency

Rating

60

12.5 50

9.4KW

Generator

Air

(60

Generator Ambient

Recommendations

Regulation

(Volts

AC)

Hertz

(1

BOO

rpm)

KW

Hertz

(1500

rpm)

Cooling

Requirements

Hertz)

at 1 BOO

rpm

Compartment

Temperature

SPECIFICATIONS·

(Single

Brushless, Pre·lubricated,

Reconnectable,

regulation regulation).

120 230

±S%

.3

120

120/240

230

225·250

NOTE:

operation

122'F

or

120/240

Volts'

no

Hertz

Volts

Increase

(50'C)

four·pole,

(optional

50

load

(.5%)

Volts

cfm

(1500

Phase)

revolving

single·bearing

single'-phase

solid'state

Volts'

60

load.

load

104

Amps

104/52

60

Amps

supply

rpm).

Hertz

to

tuilioad

Amps

Hertz.

to

full

no

(6.37 • 7.08

air

maximum

design.

transformer

cmm)

15%

GENERATOR

field.

voltage

•.

for

50

Hertz

12.5/9.4KW

AC

GENERATOR

Three

Phase

12.5

KW • 60

9.4

Voltage· 3 phase

(60

Voltage· 3 Phase (50

Amperage· 3 phase (60

Amperage· 3 phase

(50

Generator

AmbientTemperature

Recommendations

Generator

Air

(60

HERll

KW • 50

HERTZ

Hertz)

Compartment

Cooling

Requirements

Hertz)

at

1800

rpm

EDT

(3

Brushless, lubricated, reconnectable voltage

protection

Low High

DELTA High

DELTA Low

High DELTA

122'F

225·250

NOTE:

operation

six·pole,

single·bea~ng

for

Delta.

Solid

circuitry

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

(50'C)

maximum

cfm

Increase

(1500

Phase)

revolving

low

voltage

state

(6.37

'7.08

air

supplY

rpm).

field.

design.

WYE,

voltage

240 480 240

400 230

38 18 37

17 30

cmm)

15%

Sealed

12

Lead

high

regulator

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps

for

50

Hertz

with

AC

GENERATOR

Single

Phase

Voltage

regulation:

Frequency

Rating

60

15.0 50

12.0

Generator

Air

(60

Generator

AmbientTemperature

Regulation

(Volts

AC)

Hertz

(1

BOO

(1500

Cooling

at

1800

rpm)

KW

Hertz

KW

Requirements

Hertz)

Compartment

rpm

Recommendations

(Single

Brushless,

Pre-lubricated, Reconnectable,

regulation regulation).

120 220

±5%

.3

120

120/240

220

225·250

NOTE:

or

120/240

Volts·

no

load

Hertz

(.5%)

Volts

Increase

operation

122'F

(50'C)

four·pole,

single-bearing

Single-phase

(optional

Volts'

50

Hertz.

to

full

no

105

105/52.5

45.2

cfm

(5.66'

air

(1500

rpm).

maximum

Phase)

revolving

solid'state

60

Hertz

load.

load

to

full

Amps

6.37

supplY

15.0/12.0KW

field.

design.

transformer

voltage

load.

Amps

cmm)

15%

for

50

Hertz

EDT

AC

Three

Phase

15.0

KW • 60

12.0

Voltage· 3 phase (60

Voltage' 3 Phase

(50

Amperage· 3 phase (60

Amperage· 3 phase (50

Generator

Air

(60

Generator

Ambient

Recommendations

HERll

KW·

50

HERll

Hertz)

Cooling

Requirements

Hertz)

at

1800

rpm

Compartment

Temperature

GENERATOR

Brushless,

lubricated, reconnectable voltage

protection

Low High DELTA

High

DELTA

Low High DELTA

High DELTA

225·250

NOTE:

operation

122'F

six·pole, single·bearing

Delta.

circuitry

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

cfm

Inareaseair

(1500

(50'C)

(3

for Solid

(6.37 • 7.08

maximum

Phase)

revolving

design.

low

voltage

state

voltage

supplY

rpm).

field.

WYE,

240 480 240

400 230

38 18

37 17

30

cmm)

15%

Sealed

12

Lead

high

regulator

Volts Volts

Volts

Amps Amps Amps

Amps Amps

for

50

Hertz

with

~

WESTERBEKE

Engines & Generators

52

LAY-UP & RECOMMISSIONING

•

1:1.

GENERAL

Many

owners

rely

on

their including off-season to

The

own check

These during maintenance

If

your

provide

Propeller

The be out of storage severe the

shaft apply

.

not period

Fresh

A recommended This antifreeze, solution

Should amount mixture. and

.

cooling

Lubrication

With sump. with

ENGINE LUBRICATING OIL

oil

.

engines

or

for

accomplish

procedures

lay-up

you

local

lay-up

and

list

if others

procedures

a lay-up

needs

have

any

servicing

assistance.

ShaH

transmission

opened

up

and

the

water

in

the

cradle.

strain

on

boat

is

taken

has

actually

to

small

boats

in

use,

unless

of

time.

Water

50-50

solution of

for

solution

mixture

depending

to

make

more

from

Operate

of

system.

may

antifreeze

the

System

the

engine

Remove

new

oil.

Use

changing

pressure

A

in

the combustion chemicals internal

procedure.

and

CAUTION:

sump

over deposits

which

parts.

and

generators,

long

periods

preparation

which

follow

recommissioning,

do

the

procedures.

should

afford

and

also

help

of your

questions

dealer;

Coupling

and

propeller half

the

bolts

or

moved

The

flexibility

the

propeller

out

or

put

been

bent

that

are

they

have

Cooling

sure

engine the

Now

warm,

and

make

Circuit

antifreeze

use

in

the

require

on

the

be

block

engine

antifreeze

recheck

drain

replace

the

correct grade

Run

sure

Do

not

the

lay-up

combine

can

reduce

boatyards

engine.

regarding

he

removed

from

in

by

hauled

been

coolant

a higher concentration of

area's

antifreeze

needed,

to

concentration

the

there

leave

to

prepare

for

lay-up

during

of

inactivity.

themselves.

will

allow or

your

familiarize

will

you

engine

lay-up

be

more

Others

you

to

may

protection

you

procedures,

than

[Propulsion

couplings

when

the

land

to

water,

of

the

boat

shaft

or

coupling

the

water.

In

some

these

strains.

This

out

of

the

dry

for a considerable

and

distilled

winter

drain

and

add a more

ensure a complete

the

antifteeze

all

the

oil

filter

pages

the

engine

are

the

period.

to

the

water

system

at

climate.

protection

an

appropriate

throughout

solution's

engine

oil

and

fill

of

oil.

Refer

in

this

manual

and

check

no

leaks.

engine's

Lubricating

produce

life

of

your

their

perform

use

with

willing

Engine]

should

boat

and

often

or

cases,

water

all

is

concentrated

circulation

from

the

to

old

harmful

engine's

craft,

the

prefer

your

them

as

the

call

to

always

is

hauled

during

puts

both,

while

the

does

not

when

is

times.

Check

adequate.

the

strength.

the

oil

sump

the

for

the

for

proper

engine

oil

and

a

the

oil

Fuel

System

Top

off your

or

higher. A fuel stabilizer gasoline/water

and

fuel.

Fuel

Top

additives mix Additives

should

condition

used

separator

primary

sediment

Change

fuel

for

system.

the

needed.

allow equipment

Raw

Close hose gallon check the

any zinc

Start

fresh stop

solution

protection

Start through the water circuit

as

Remove antifreeze Examine

a cover until

Cylinder

Spray arrester

oil

spark

should

make

certain

System

off

your

should

with

the

such

be

added the

are

compatible

used

fuel

bowl.

the

fuel

system,

5 -

10

minutes

Check

fuel

system

Operating

movement

on

Water

the

through-hull

from

the

bucket

the

zinc

engine

and

zinc

debris

anode

is

the

engine

water

through

the engine

slightly

in

the

engine

the

engine.

providing

This

the

mixture

the

gasket.

recommissioning,

Lubrication[Gasoline]

fogging

removed,

will stall out the

plugs

[Gasoline]

fuel

tanks

with

unleaded gasoline

conditioner be

added.

separator

there

and

are

such

Change

clean

no

leaks.

as

the

Sta-Bil

element

metal

Clean

up

[Diesel]

fuel

tanks

with

No.

2D

diesel

fuel.

be

added

prior to

topping

fuel

being

added

and

as

Bio-bor

at

fuel..

in

the

filter/water

filter

as

needed.

for

during

of

the

engine.

COOling

seacock.

of clean

anode

clean

from

located.

and

stronger

your

and

raw

water

antifreeze mixture should protect the

from

corrosion

impeller

impeller.

Do

oil

for

winter

and

Diesel

this

time

to

control bacteria growth

Care

should

be

with

the

primary

system.

to

any

the

separator

elements

Start

make

sure

leaks

that

this

servicing,

engine

treated

Change

and

on

the

engine

no

may

for

5 -

fuel

Circuit

seacock.

Place

fresh

found

or

replace it

inside

Clean

allow

the

system.

refill

area.

allow

system.

freezing

protection.

from

will

accompany

Acquire a replacement,

not

replace the impeller

into

the

while

engine

protection.

Remove

the

end of

water.

in

the

as

the

heat exchanger where the

the

raw

the

raw

When

the

bucket

than

needed

all

of

this

Once

during

your

raw

but replace the

open

air

the

engine

and

coat

off

fuel

still

in the tank.

Kleen

taken

that the additives

fuel

filter/water

the

element

clean

engine and bleed

and

air

is

left

have

been correcting 10

minutes

through

the

this

Before starting

primary

required,

water

the

with

for

mixture the

the

winter

water

it,

so

cover

intake,

is

running.

the

pump

bucket

valves,

heat exchanger

strainer.

bucket

an

winter freeze

catch

of

89

octane

gasoline

in

your

bowl. Re-install

any spilled

Fuel

to

ensure

they

+ Cetane Boost

and

in

your

the

separator

the

allow

it

to

run

in

the fuel

created in

them

as

will

help

the

injection

raw

water intake

hose into a

and also

to

antifreeze

to

be

lay-up,

pump

it

if

(into

and

with

The

five

the

engine,

clean

draw

the

is

empty,

drawn

is

empty,

raw

as

well

(some

in a bucket).

needed,

the

pump)

gasket.

the

flame

fogging

cylinders

on

stop

and

",y"

WESTERBEKE

Engines & Generators

53

Starter

Lubrication if battery the connections

Cylinder

If WES1ERBEKE access each the revolutions

If

to be

the

.Intake

Clean cloth block through-hull

to

Motor

access

to

the

connections

startei.

Take

Lubrication

you

anticipate a long

to

the

cylinder

and

your

engine

removed.

injectors

Manifold

the

filter

lightly

any

opening.

start-up!

and

removed

cylinders.

to

walls.

and

soaked

exhaust

cleaning

starter

permits

are

shut

care

in

properly

from

recommends

Squirt

help

prevent

Rotate

re-install

does

not

Be

sure

return

[Gasoline]

screen

in

lube

Also

port,

of

the

starter

its

off

before

the

starter.

[Diesel]

lay-up

period removal

some

the

engine

the

glow

have

glow

to

have

replacement

fuel

line

the

flame

oil

around

place

an

Make a note

LAY-UP

drive

pinion

easy

removal.

attempting

replacing

piston

plugs.

as

oil-soaked

(12

of

Marvel

rings

crankshaft

plugs,

the

needed.

arrester,

the

to

any

months

the

Mystery

injectors

sealing

and

flame

cloth

remove

&

is

advisable,

Make

sure

to

remove

electrical

or

more)

glow

plugs

Oil

from

adhering

by

hand

will

w'ashers

place a clean

arrester

in

the

cloths

RECOMMISSIONING

Spine

Parts

Lay-up

time

the

for

into two

have

to

prior

Westerbeke

or

coolant

kit

and

during

SPARE

engine

hoses

order

the

lay-up,

PARTS

Recommissioning

The

recommissioning

to

for

seasonal those tion However, counteracted

1.

2.

3.

lay-up

described

regarding

some

Remove Remove

discard removed

Install

the

Reinstall lay-up, terminals Check

to

the

and

provides a good

to

need

items

not

such

section

generally

in

the

preparation

of

the

before

starting

the

oil-soaked

the

raw

water

old

gasket.

during

lay-up

raw

water

the

batteries

reconnect

are

clean

make

sure

opportunity

see

if

external

replacement.

on

hand,

as

filters

of

this

of your

follows

PREPARATIONS

for

lay-up

the

cloths

pump

Install

(or a

pump

that

the

and that

that

items

Check

or

replace

and

zinc

manual.

Westerbeke

the

starting

procedures

engine.

from

cover the

raw

replacement,

cover

with a new

were

removed

battery

the

connections

the

batteries

to

such your

those

anodes.

engine

same

FOR

and

normal

will

the

and

water

cables,

are

inspect

procedures

intake gasket

your

as

'drive

basic

items

Refer

after

STARTING

starts.

need

to

manifold.

and

pump

if

required).

cover

during

the

making

are

tight.

fully

charged.

belts

spares

used

to

the

a

as

sec-

be

impeller

gasket.

sure

the

Cylinder

Spray arresier will plugs fat winter protection.

NOTE:

the

tightening onto

Lubrication

fogging

removed,

stall

out

the engine

At

spring

crankshaft

properly

each

spark

oil into

two

thp

while

the

and

commissioning,

full

revolutions.

and

connecting

plug.

Batteries

If

batteries make to

prevent

batteries

subjected batteries

environment.

A

highly-explosive arcing smoke

serviced.

to

are

to

be

sure

that

they

are

them

from

will

not

remain

to

severe

environmental

and

store

them

WARNING:

Lead

gas,

Dr a lighted

or

aI/ow

an

Shut

off

prevent

electrical

left

on

fully

freezing.

fully

in a warmer,

which

cigarette,

open

all

electrical

arcing

[Gasoline]

open

alr

intake, with

engine

is

coat

the

valves,

remove

Re-install

the

board

during

charged,

If

there

charged,

conditions,

acid

batteries

can

be

cigar,

flame

near

equipment

during

the

rurming.

and

more

ignited

the

high

the

will

is

any

or

that

compatible

emit

Dr

pipe.

the

battery

The

cylinders

plugs

the

tension

lay-up

remain

doubt

they

remove

hydrogen,

by

Do

in

servicing.

flame

fogging

and

rotate

spark

plugs,

leads

fully

period,

that

the

will

be

the'

a

electrical

not

being

.

the

vicinity

oil

spark

way,

A

CAUTION:

and

eye

batteries

can

be

ignited cigarette, flame

near electrical arcing

during

4.

Remove proper

5.

Check circuit

that

it

solution

engine

short

advisable, service,

heat

exchanger

area.

6.

Start in

the

manual.

Wear

rubber

protection

emit

cigar,

the

equipment

when

hydrogen, a highly

by

electrical

or

pipe.

battery

In

servicing.

the

spark

plugs,

tightness the

and

is

period

to

the

PREPARATIONS

condition

clean

not

necessary

from

the

put

into

of

as

either

inspect

engine

{gasoline1.

of

or

replace

raw operation, the

time

with

an

the

and

clear

in

accordance

gloves, a rubber

servicing

arcing

Do

not

smoke

being

serviced.

the

vicinity

wipe

clean,

the

zinc

the

anode

to

flush

the

water

coolant

no

adverse

end

of

season

area

where

any

and

with

FOR

STARTING

batteries.

explosive

gas,

or a lighted

or

allow

Shut

off

to

prevent

re-gap,

anode

in

the

as

needed.

antifreeze/fresh

system.

system

will

affects.

or

recommissioning

the

zinc

is

all

zinc

debris

procedures

section

apron,

Lea/f,acid

which

an

open

all

electrical

and

install

raw

water

Note

water

When

the

self-flush

It

located

in

is

in

from

that

described

of

this

the

to

a

Transmission

Check

or

off

grime

the

coupling coating. additional

Check

[Propulsion

change

the

and

grease

and

the

that

the

information,

fluid

in

the

and

touch

output

flange

transmission

refer

to

Engine

J

transmission

up

any

unpainted

with

an

vent

is

the

TRANSMISSION SECTlON.

as

required

areas.

anti-corrosion

open.

For

"tiIY"

Wipe

Protect

WESTERBEKE

Engines & Generators

54

POWER

TAKE

OFF

SYSTEMS

POWER

A backend. engine

The rpm

The The

·1500 This

output

Contact inforrru;ttion.

TAKE

power

take

This

for a variety

8.0,

10.0.

(16hp

at

11.5Kwproduces

15.0Kw rpm.

horsepower

or

to

your

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

GENERATOR BACKEND

OFF

ADAPTER

off

adapter

~an

be

attached

adapter

and

1500

generator

operate

WESTERBEKE

of

12.6 rpm).

can

the

iillows

hydraulic'

'Kw

generators

15hp

at

produces

be

utilized

power

flU,'

-

access

and

1800

25hp

either

takeoff.

DEALER

"REMOVE

/!V<../

~\

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r!~"f.tl

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/

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THREADED

to

the

generator

to

the,

full

power

of

the

electrical

produce

rpm

at

for

I_~

COUPLING

accessorie~.

18hp

at

1800

(12hp

at

1500

rpm)

1800

rpm

(221ip

at

generator

for

additional

AC

COVER

(§)

END

STUDS

AND'

HOLD

,ADAPTER

ACCESSDRY

@@

POWER

KIT KIT

TAKE

#034786,FOI\ #037134

HARDWARE

TO

THE

OFF

KITS

12

STUD

FOR 6 STUD

BT

UNITS

~

WESTERBEKE

Engines & Generators

55

RAW

WATER

DISCHARGE

HOSE

RAISE LEVEL A

GENTLE

THE

EXHAUST

WIRETIETO

THE

HOSE

OF

THE

MANIFOLD

LOOP

ELBOW

HEAT

EXCHANGER

[When a siphon

ABOVE

THE

OOWN

IN

break

is

not

required]

RAW

WATER DISCHARGE IOWNER

TO

HOSE

INSTALLED]

/

•••

"."

EXHAUST

INJECTED

ELBOW

WHEN A SYPHON

WESTERBEKE

(installer

the

heat

elbow

be

fitting

on

a

plastic

BREAK

recommends

supplied)

exchanger

looped

above

the

elbow.

wire

tie

as

IS

NOT

REQUIRED

that discharging to

the

water

and

down

The

hose

can

illustrated.

the

hose

raw

water

injected

to

the

be

secured

from

exhaust

Inlet

bV

~

WESTERBEKE

_

g'!fl~~es

56

&.

G~l1.erators

HOT

WATER

TANK

CONNECTIONS

WATER

These of engme The

either in a that run

trap

Hoses heater heater then

on

HEATER

engines

coolant

water

the

counecting

in a

reasonably

air.

should

to

the

to

the

an

air

the

heater

heater high

.\

I

INSTALLATIONS

are

equipped

to

.transfer

should

or

low

position

hoses

d4'ect

rise

continuously

engine

so

engine.

If

bleed.petcock

for

bleeding

REMOVE ENGINE

I'

I

",",A-

;'

,-

THE

EXISTING

H~S!

____

/

with

counections

heat

to

an

be

mounted

in

relation

from

the

heater

line

without

from

that

air

will

rise

trapped

air

is

rilUstbe.illstailed

aii

while

filling

_

-:-:

__

--

-.

.--

_/

-.

on-lloard

in a

convenient

to

any

their

naturally

able

to rise to

-

for

the

loops

low

at

.the

the

plumbing

water

location.

engine,

engine

which

.

point

at

from

the

•••• , .. ~ ••

s·~

/stem

..

heater.

so

can

might

the

heater,

' ..... 0

"""~:;"

.

WATER

'-~CONNrCj-1wifHOS{S

HEATER

.

FROM

THE

AS

SHOWN INOICATHHE FLOW

DIRECTION),

OWNER

INSTALLED

CONNECTIONS

~iOANiF

HOTWATER·HfATER

HERE.

(ARROWS

COOLANT

.

HOSE

.

: .

......

,:

..

.

HEATING

NOTE:

If

any

portion engine's remote circuit

tank connections single engine's

convenient The system

when'

·tank

..

recovery

ownpl'!'ssure

expansion

to

become

into

the

Jar

line

up

return.

location

remote

expansion

fill

point.

the

remote

serves

the

tank

the

heater

the

to

the

Install

The

expansion

same

if it

oj

the

cap,

(Kit

highest

circuit,

return.

tanks

the

so

the

tank

plastic JunctiOI/.

has

been

heating

Tee

location

remote coolant

circuit

rises. then a pressurized #024177)

point.

choosing

will

coolant

tank kit

aiready

Tee

at

the

and

expansion

level

no",

Remove

installed.

must

the

higher

heater.

the

can

s.erve

recovery

is

installed,

and

(aluminwn)

be

installed

remoieexpansion

.and

other

tank

easily

as a

store

CIRCUIT

above

the

in

the

oJthe

two

plumb

a

back

to

the

in

a

be

checked.

check

and

tank

is

not

used

since

this

the

plastic

"tiIY':

WESTERBEKE

Engines & Generators

ABOVE

.

57

THE

ENGINE·

.-

TYPICAL

HOT

WATER

TANK.···

',EXPANSION

#024177

TANK

KIT

STANDARD

AND

LENGTH·DlSTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

VOLUME

Cubic

Inches

(in') x 16.387 = Cubic Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints

(IMP

pt) x .568 = Liters

Quarts

(IMP

qt) x 1.137 = Liters Gallons Quarts Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces Pints Quarts

Gallons

(IMP

gal) x 4.546 = Liters

(IMP

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

(US

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

(US

qt) x .946 = Liters

(US

gal) x 3.785 = Liters

MASS·WEIGHT

Ounces Pounds

(oz) x 28.35 = Grams

(Ib) x .454=

Kilograms

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

CONVERSION

Centim~ters

(L) x 1.76 = IMP

(L)

Quarts

Gallons

(L) x 1.057 = Quarts

(L) x .264 = Gallons

x

.061

=in'

pt

x.88 = IMP

(L) x .22 = IMP

(US

qt

qt) x .833 = IMP

gal) x .833 = IMP

DATA

gal

qt

gal

PRESSURE

Pounds

Inches

Inches Inches Inches Inches

TORQUE

Pounds-Force Pounds-Force

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

.

VELOCITY

Miles

Per

Hour

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Per

Hour Kilometers Miles

Per

Gallons Kilometers

Sq

In

(psi) x 6.895 = Kilopascals

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

(H,O) x .07355 = Inches

(H,O) x .03613 = psi x 27.684 = H,O

(H,O) x .248 = Kilopascals

Inches

(in-I

b) x .113 = Newton

Feet

(ft-Ib) x 1.356 = Newton

(MPH) x 1.609 = Kilometers

(Hp) x .745 = Kilowatts

IMP

(MPG) x .354 = Kilometers

Per

Liter

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

Per

Liter

(Km/L) x 2.352 = US

of

(Kw) x 1.34 = MPH

MPG

(kPa) x .145 = psi

(kPa) x .2961 = Hg

Mercury x 13.783 = H,O

(kPa) x 4.026 = H,O

Meters

Per

Hour

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

(KPH) x .621 = MPH

Liter

(Km/L)

Per

Liter

=in-Ib

(Km/L)

TEMPERATURE

Degree Degree

Fahrenheit Celsius

('F) = ('C X 1.8) + 32

('C) = ('F -32) x .56

.....

WESTERBEKE

Englnes.& Generators

58

CONTACT

WATERPYMp

.

iMPEi.~~R

l

KiT

YOUR

.

..

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

DIESEL

SUGGESTIONS

PARTS

GENERATORS

AIVD

ADDITIONAL

INFORMATION

DRIVE

FILTER

,

BELTS

HARDWARE

KIT

FUEL

LIFT

PUMP

WESTERBEKE ENGINE AND A GALLON

WESTERBEKE also offers two Spare Farts Kits,

each packaged in a rugged hinged toolbox.

Kit "A" includes the basic spares.

Kit

"B"

is

for

more

extensive off-shore

A

Kit

Impeller Kit

Heat Exchanger Gasket

Fuel

Filter with Gasket

Oil

Filter Drive Belt Zinc Anodes

cruising.

RECOMMENOS

OIL

(YOUR

BRAND)

OF

PREMIXED

59

CARRYING

FOR

AN

OIL

COOLANT.

ENOUGH

CHANGE

SPARE

(5

QTS.)

B

Kit

Impeller Kit Water Pump Repair Thermostat

Zinc Anodes

. Complete Gasket Kit

Heat Exchanger Gasket Injector Fuel Filter

Oil Filter Drive Belt

Kit

with

Gasket

Kit

-.v-

WESTERBEKE

Engines & Generators

1149-11/2011

Westerbeke 12.6KW EDT, 12.5KW EDT, 7.5KW EDT, 10.4KW EDT, 11.5KW EDT Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual