Westerbeke 8.0KW BCDT, 7.0KW BCDT Owner's Manual

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OWNERS

8.0

7.0

'MARINE

DIESEL

KW KW

MANUAL

BCDT BCDT

GENERATORS

60Hz 50Hz

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WESTERBEKE

150

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FAX

mm

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PUBL

JOHN HANCOCK ROAD·

1-508-884-9688·

Member Natiomd

ATION

FIRST EDITION

...

JULY2001

CORPORATION·

WEBSITE:

Marine

NO.46294

MYLES

TAUNTON

ManufacturersAssociation

STANDISH

MA

www.WESTERBEKE.COM

02780-7319.

INDUSTRIAL

TEL.

1-508-823-7677

PARK

CALIFORNIA

Exhaust gasoline its

constituents)

the

State cancer, reproductive

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

-

Weakness

IF

YOU

GET

OUT

seek

medical

until

it

PROPOSITION

WARNING

gas

from

engines

are

of

California

birth

defects,

harm.

gasses

OR

has

contain

gas.

Carbon

can

include:

and

Sleepiness

ANYONE

INTO

THE

attention.

been

inspected

65

diesel

and

(and

some

of

known

to

cause

and

other

AWARNING:

Monoxide

and

death.

ELSE

FRESH

Carbon

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

ANY

the

unit

repaired.

an

of

Carbon

in

TWitching

to

OF

odorless

and

can Monoxide

Temples

Think

Coherently

THESE

If

symptoms

and

do

not

and

cause

SYMPTOMS,

persist,

restart

A

WARNING should generator.

WESTERBEKE MONOXIDE of

your

obtainable

DECAL

be

fixed

to a bulkhead

also

DETECTORS

vessel.

at

They

your

is

provided

recommends

are

local

by

near

in

the

living/sleeping

inexpensive

marine

Engines & Generators

WESTERBEKE

your

engine

installing

store.

and

easily

CARBON

quarters

and

or

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this caused tions. necessary and your The the American

PREVENT

A

while

power.

• Do not operate this machinery without electrical

• Shut off electrical power before accessing electrical

• Use insulated mats whenever working on electrical

• Make sure your clothing and skin are dry, not damp

• Remove wristwatch and all jewelry when working on

• Do not connect utility shore power to vessel's

• Electrical shock results from handling a charged capaci-

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant

A

• In case

safety

by

failure

Know

precautions

manual

when

carefully.

to

follow

fundamental

dangerous

conditions exist and

to

protect yourself, your

Most

accidents

rules

and

personne~

are

precautake

the

machinery.

following

WARNING:

enclosures and covers in place.

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment.

circuits, except through a ship-to-shore double throw transfer switch. Damage result

tor.

WARNING:

safety

instructions

Boat

and

Yacht

ELECTRIC

engine

is

Lethal

if

this procedure is not followed.

Discharge capacitor by shorting terminals together.

SHOCK

Do

not

lunning,

voltage

is

BURNS -HOT

Do

not

system

components. A lunning

are

Council

touch

AC

01

when

present

to

vessel's

ENGINE

touch

hot

in

compliance

(ABYC)

electrical

connections

connected

at

these

connections!

AC

generator may

engine

parts

engine

with

standards.

to

shole

AC

01

gets

hot!

recovery tank.

WARNING:

of

before touching the engine or checking the coolant.

Steam

can

cause

injury

an

engine overheat, allow the engine

01

death!

to

cool

PREVENT

A

• Prevent sparks

pump, or other potential sources

vapors. Use a suitable container to catch

removing the fuel line, carburetor, or fuel

• Do not operate with a Coast Guard Approved arrester removed. Backfire can cause severe injury or death.

Do not operate with the air cleaner/silencer removed.

• Backfire can cause severe injury or death.

• Do not smoke or permit flames or sparks the fuel system. Keep the compartment and the engine/generator clean and free chances of

• Be aware - diesel fuel will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin

after fueling. Check below for fumes/vapor before ning the blower. Run the blower for four minutes before starting your engine.

•

All when handling and storing fuels. Store fuel in a tilated area away from spark-producing equipment and out of the reach

•

Do

• Shut off the

the fuel system. Take care in catching spill. sources of ing. fuel system.

• Do not alter or modify the fuel system.

• Be sure all fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened and free of leaks.

• Make sure a properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment.

BURNS -FIRE

WARNING:

to

-

Fire

can

cause

injury

01

flash

fires.

Do not smoke or permit

occur near the carburetor, fuel line,

of

spilled fuel or fuel

of

debris

fire.

Wipe up all spilled fuel and engine oil.

death!

flames

filter,

all fuel when

filters.

flame

to

occur near

to

minimize the

BURNS -EXPLOSION

WARNING:

01

death!

fuel

not

DO NOT allow any smoking, open

Ensure proper ventilation exists when servicing the

Explosions

vapors are highly explosive.

of

children.

fill

the fuel tank(s) while the engine is running.

fuel

service valve at the engine

fire

near

the

fire

extinguisher is installed nearby and

flom

fuel

system or engine

vapors

Use

extreme care

any

flames,

can

when

fuel that might

when

cause

well-ven-

servicing or other

servic-

or fuel

run-

is

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect generator.

it

last.

• Make certain starting.

• Make certain installed before starting the

BATTERY

A

WARNING:

or

death!

•

Do

not smoke or allow being highly explosive

arcing or equipment ing servicing.

• Never connect tive not

test the battery condition together. Ventilate accumulation of explosive disturb is

being charged.

•

Avoid burns or wristwatch, the

battery.

•

Always the battery connections. Remove the negative lead

and reconnect it last whenservicing

STARTING

Accidental

the

battery cables before servicing

Remove

all

personnel

all

covers,

starling

the

negative lead

are

guards,

engine.

EXPLOSION

Battery

serviced.

(+) connection terminal of

the

contacting

Lead acid batteries emit hydrogen, a

by

lit tobacco products. Shut off all electncal

in

the

Sparks

any

compartment containing batteries

battery charger connections

sparks

rings,

turn

the

explosion

an

open

gas,

which

can

vicinity

could ignite battery gases or

that could cause

battery charger off before disconnecting

to

prevent electrical

negative (-) battery cable

by

gases.

the

terminals with tools, etc.,

and

any

other jewelry before handlmg

can

cause

injury

the

first

and

reconnect

clear of

the

engine before

and

hatches

can

flame

be

ignited

the

starter solenoid. Do

shorting the terminals

To

avoid sparks,

an

explosion.

the

are

re-

cause

injury

near the battery

by

elect?cal

arcing

to

the

fuel

to

while

the battery

to

Remo~e

battery.

engine!

dur-

posi-

vapors. prevent

do

prevent

first

BAnERYACID

A

WARNING:

severe

injury

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber tion. Batteries contain sulfuric

If

it comes in contact with your

water.

with inadvertently

Sulfuric

or

death!

Acid

when

acid

in

batteries

acid

skin,

may

splash

on

the

removing electrolyte

can

apron,

and

which

is

destructive.

wash

it

skin or into

caps.

cause

eye

off

at

the

protec-

once

eyes

not

TOXIC

• Ensure that the exhaust system

• Be

• Don't run the generator set or engine unless the boat

• For additional information refer

•

• Although diesel engine exhaust gases

AVOID

•

EXHAUST

A

WARNING:

discharged regularly

water-injected elbow

sure

the

Run blowers

equipped with a functioning marine carbon monoxide detector that complies with ABYCA-24. Consult your boat builder or dealer for installation of approved detectors.

(educational information on Carbon Monoxide).

A

WARNING:

odorless nausea

gas.

or

death!

Do

not

use

fumes

can Exhaust sulfur causes rapid deterioration of copper tubing resulting

Do

not

install exhaust outlet where exhaust through portholes, vents, or air conditioners. If exhaust discharge outlet enter

the

flow

of exhaust.

exhaust gas symptoms or signs of carbon poisoning

Vomiting Dizziness Headache Nausea

fumes

is

present in diesel exhaust

MOVING

A

WARNING:

or

death!

Do

not service the engine while it arises in which it ing adjustments, ing

parts

GASES

Carbon

from

for

leaks and

unit and its surroundings

when

Carbon

Inhalation

copper

rapidly

in

exhaust/water leakage.

exhaust

from gasoline engines, carbon monoxide

are:

monoxide

the engine. Check the exhaust system

make

is

securely attached.

running the generator set

monoxide

produces

tubing

in

destroy copper

is

discharge

Avoid

overloading the craft.

Inability to think coherently Throbbing in temples Muscular twitching Weakness

(CO)

is a deadly

is

adequate

sure

the exhaust

are

well

to

ABYC

(CO)

is

an

nu-like

diesel exhaust

tubing

near the waterline, outlet and close

fume~.

monoXide

symptoms,

in

are

not

S?me

mhalatlon or

and sleepiness

PARTS

Rotating

and

hot exhaust system components.

parts

can

is

absolutely necessary

use

extreme care

cause

is

running.

to

avoid

injury

to

expel gases

manifold!

ventilated.

or

engine.

T-22

invisible

systems.

exhaust

can

be

the

water

or

restrict

as

toxic

o~

the

If

a situation

make

touching

gas!

operat-

is

Diesel

systems.

drawn engine

could

the

as

mov-

Engines & Generators

ii

SAFETY

•

Do

not wear loose clothing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces could be caught in moving parts.

• Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times.

• Do not check fluid levels the engine is operating.

• Stay clear

when the engine is running; hair and clothing can easily

be caught in these rotating parts.

HAZARDOUS

A

WARNING:

of

the drive shaft and the transmission coupling

NOISE

High

loss!

• Never operate an engine without its muffler installed.

• Do not run an engine with the air intake (silencer) removed.

•

Do

not run engines for long periods with their enclosures

open.

A

WARNING:

mentally

or

Do

not

physically

or

jewelry when servicing

or

the drive belt's tension while

noise

levels

can

cause

work

on

machinery

incapacitated

by

fatigue!

bracelets that

hearing

when

you

are

INSTRUCTIONS

ABYC, INSTALLING

Read the following ABYC, NFPA and for safety codes and standards. Follow their recommendations

ABYC (American Boat and Yacht Council)

"Safety Standards for Small Craft" Order from:

NFPA

"Fire Protection Standard for Motor Craft" Order from:

USCG

"USCG Order from:

NFPA

AND

USCG

DIESEL

when

installing your engine.

ABYC

3069 Solomon's Island Rd.

Edgewater,

(National Fire Protection Association)

NFPA

11

Tracy Drive Avon Industrial Avon,

U.S. Government Printing Office Washington, D.C. 20404

MD

MA

02322

(United States Coast Guard)

33CFR183"

ENGINES

21037

Park

PUBLICATIONS

USCG

FOR

publications

OPERATORS

Many

of in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

ENGINE

Preparations to install an engine should begin with a thorough examination

(ABYC) standards. These standards are a combination sources including the

Sections

H-2 Ventilation P-l P-4 Inboard engines E-9

All installations must comply with the Federal Code Regulations (FCR).

MANUAL

the preceding safety tips and wamings are repeated

INSTALLATIONS

of

the American Boat and Yacht Council's

of

USCG

and the NFPA.

of

the ABYC standards

Exhaust systems

DC

Electrical systems

of

particular interest are:

of

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict attention

be

paid to the following information:

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to

or

will

be

below the vessel's waterline, provisions must

break: in the raw water supply hose to the exhaust elbow. This hose must be looped a

minimum

the exhaust manifold injection port raw

If

you have any doubt about the position

to the vessel's waterline under the vessel's various operating conditions,

water

of

20" above the vessel's waterline. Failure

is

at or

below

damage

to

the engine and possible flooding

of

the water-injected exhaust elbow relative

siphon-break.

NOTE:

A siphon-break operation. engine

EXHAUST

The exhaust hose must be certified for marine use. The system must prevent water from entering the exhaust under any sea conditions and at any angle

of

the vessels hull.

Failure

damage.

SYSTEM

"requires

to

properly maintain a siphon-break

Consult

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

be

made to install a siphon-

to

use

a siphon-break

the load waterline

of

the

boat.

to

ensure proper

can

result

in

when

will

result in

install a

catastrophic

be

designed to

A

detailed diesel, dealer.

40

page

engines

Marine

and

generators,

Installation

Engines & Generators

Manual

is

available

.

from

IV

covering

your

WESTERBEKE

gasoline

and

TABLE

Parts

Identification

Introduction .................................................................................................

Warranty Procedures ..........................................................................

Serial Number Location ...................................................................... 3

Installation

Exhaust System ................................................................................... 7

Raw Water Cooling ............................................................................. 8

Control Fuel,

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

Panel

Engine Preparations Starting/Stopping Break·ln Safety

Procedure

Shutdown Maintenance Cooling

Engine Fuel Glow

Starter Control 12V

Wiring Wiring Engine

Engine Shore Generator Generator Lay·up Generator Metric Standard Torque Suggested

System

Changing Coolant ............................................................................. 18

Thermostat ........................................................................................ 19

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

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

Heat Exchanger ................................................................................. 21

Lubricating

Oil Change ........................................................................................ 22

System

Fuel Lift Pump .................................................................................. 23

Plugs

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

Motor

Box

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

DC

Control

Battery Specifications ........................................................................ 28

Diagram Schematic

Adjustments

Frequency Adjustment .......................................................................

Fuel Run Solenoid ............................................................................ .31

Drive Belt Adjustments ..................................................................... 32

Torquing the Cylinder Head .............................................................. 32

Engine Compression ......................................................................... .32

Injection Pump Timing ...................................................................... 33

Valve Clearance ................................................................................ .34

Testing Fuel Injectors ........................................................................ 34

Troubleshooting

Power

Information Troubleshooting

and

Recommissioning

Specifications

Conversions

Hardware

Specification

Spare

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

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

Oil

and

Engine

for

Initial

Procedure

(Daily

Switches

Schedule

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

Oil

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

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

Circuit

(#41990)

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

Transfer

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

and

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

Partso

OF

CONTENTS

.2

.3 .3

.5

10

Coolant

Start·Up

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

Operation)

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

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

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

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

. 13

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

11

12

14

15

16

18

20 20

.......................................................................... 22

23

24

25

27

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

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

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

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

Switch

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

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

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

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

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

Sealants

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

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

H

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

n.coo

••.••••••••••••.•••••

0

•••

28

29

30

.31

31

35

.37

38

.39

40 .42 .43 .45 .46

47

Engines & Generators

1

PARTS

IDENTIFICATION

PREHEAT

COOLANT

SOLENOID~

EXHAUST

FILL

ZINC---'

INTERNAL

VIBRATION

COOLANT

DRIVE

MOUNTS~

BELT

AIR

INTAKE

THERMOSTAT

HOUSING

PUMP

OIL

I

FILTER

~

FILL

/HOUSING

THERMOSTAT

~AIR

INTAKE

FILTER

.CONTROL

BOX

MAN\FOlD~"""

.:;ft-'''\'I''---r''--:l7'''H'~I----'-FUEL

CONTROL

BOX·

EXHAUS.T OUTLET

GENERATOR BACK

ENO

Engines

t']'l/~%TI:_RAW

& Generators

2

LIFT

•

OIL

PUMP

SIDE

OIL

WATER

FILTER

FILL

PUMP

This

WESTERBEKE WESTERBEKE'S technology. dependable you

for

selecting

This

owner's installation, For

additional

INSTALLATION GENERATORS,

In

order

to

get

it

is

important

manual

is

designed

carefully

Should

WESTERBEKE

and

your

WARRANTY

YourWESTERBEKE

package.

registering registration information, commission

Cu~tomer

If

your

many

We

take

great

performance

WESTERBEKE.

manual

contains

operation,

installation

MANUAL

Publication

the

full

that

you

to

observe

generator

dealer

PROCEDURES

you

have

not

warranty

form,

please

including

date.

Identification

marine

generator

years

of

experience

pride

in

the

of

our

engines

infonnation

maintenance

information.

FOR

use

and

operate

help

you

all the

require

for

assistance.

Warranty

received a customer

60

contact

the

unit's

MARINE

#43268.

benefit

and

do

this.

safety

precautions

servicing,

is

included

days

after

the

serial

and

maintain

factory

Card

is a product

and

superior

from

durability

and

generators.

and

instructions

service

of

see

WESTERBEKE ENGINES

your

it

correctly.

Please

read

throughout

contact

in

the

identification

submitting

in

writing

number

and

INTRODUCTION

of

advanced

and

Thank

for

your

generator.

s

&

generator,

This

this

manual

your

nearest

documentation

card

the

warranty with

model

the

WESTERBEKE

OF

SUCH

SOFTWARE, REPRESENTATIONS ACCURACY, WIU

IN

NO

INJURY

INCURRED

THE

FURNISHING

WESTERBEKE span

between printings

and

the

unavoidable existence manuals. WESTERBEKE products, whether other suppliers, must not sively not representatives of WESTERBEKE be product software being consulted

In

as

the definitive authority

only

makes

consulted

SERIAL

Owners generator These information

I

may

will

CANNOT

TIMELINESS

EVENT

summation, product software provided

to

BE

RESPONSIBLE

MAKES

WITH

BE

LIABLE

IN

CONNECTION

OR

USE

customers should

good sense but determine the accuracy

NO

WARRANTIES

RESPECT

OR

THERETO,

COMPLETENESS

FOR

ANY

WITH

OF

SUCH

SOFTWARE.

also

of

WESTERBEKE product software

of

earlier

from

and

cannot

be

on

the respective

is

imperative that appropriate

or

by

the

FOR

TYPE

OR

keep

WESTERBEKE

relied

the

supplier in question

and

currentness of the

customer.

NUMBER

find

it

decal

provide

and/or

convenient

and

engine quick ordering parts.

.-

..

-~

to

identification

references

...

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enter

when

the

information

plate

shown

Seeking

THE

CONTENT

OR

INCLUDING

THEREOF

OF

ARISING

in

mind

upon

technical

AND

DAMAGE

OUT

the

with exclu-

product.

on

the

below.

OR

OF

time

or

It

,,,,.,,WESTERBEKE

, Engines & Generators

Customer Identification

WESTERBEKE

MAIN

STREET

HOMETOWN,

ModelS

E~pires

PRODUCT

Product software (tech data, parts catalogs) provided from sources other are

not

KW

SCOT Ser. #0703-xxxx

9/2002 .

SOFTWARE

within WESTERBEKE'S

OWNER

USA

lists,

CON1ROL.

manuals,

than

brochures and

WESTERBEKE

• !

~Tiii§ln:t#'3=i

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• MODEL

Fill

in

the

NOTES,

As maintenance schedules, engine, CAUTIONS,

NOTE:

A

CAUTIONS

this

manual

critical information will

An operating procedure essential

CAUTION:

observed,

your

engine.

A

WARNING:

lowed,

can

SPEC

information

for

AND

takes you through

and

WARNINGS.

Procedures

can

result

in

Procedures

result

in

personal

your

reference.

WARNINGS

the

and

troubleshooting of

be

highlighted

An

which,

the

damage

which,

injury

~

operating

explanation

to

note.

if

not

strictly

or

destruction

if

not

properly

or

loss

of

SER.NO.

pr~edures,

your by

follows:

life

0

marine

NOTES,

of

fol-

.

..

•

Engines & Generators

3

.

Generator

The

generator

decal

on

the

generator

Serial

model

SPECIFICATION

MODEL RPM KW

KVA VOLTS

AMPS

ENG. ENG.

GEN.

_______

__________

___________

__________

________ ________

HP

____ • __

SER.

SER. PF/PHASE WIRES

RATING INSUL

TEMP.

________

_______

CLASS

RISE

BATTERY

C.tD.

_________

i

~.

'Fill

i . -

in

COMPONENT

Component of

the located. straddling

is

at service are

located

ORDERING

Whenever tor

and this In

addition, each packaged made

locations

engine

which

Left

and

the

engine,

your

left,

the

side

of

in

an

replacement

engine

model

information

include a complete

part

needed

parts

to

the

same

the

air-cooled

PARTS

so

(see

because

Number

number

and

specifications

housing.

~

_ _

NO. NO.

___

_ _

_

__

___

_

_____

_

the

information!

LOCATIONS

in

this

manual

is

the

end

at

which

right

sides

are

determined

facing

the

front

right

side

is

at

your

generator.

we

specifications

parts

and

may

the

will

The

air

intake/control

are

serial

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INTRODUCTION

SPARES

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Engines & Generators

4

The

following

Diesel

Generator.

Westerbeke's

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2.

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6.

7.

8.

9.

10.

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Size Location Ventilation. Exhaust Fuel Raw Oil

fill

Electrical Maintenance Accessories.

to

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dimensions.

installation

INSTALLATION

factors

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Additional

Publication

should

Westerbeke

of

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mounting

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cover

general

information

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5

INSTALLATION

LOCATION

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MOUNTS-CAN TURNED

Engines & Generators

DAMPER

BE

ANY

DIRECTION

6

EXHAUST

It

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important flooding. entering angle by

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knowledge Westerbeke

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Westerbeke diesel marine design catastrophic sinking

SYSTEM

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diesel

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INSTALLATION

system

to

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to

prevent

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sea

conditions

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For

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Westerbeke's

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Carbon

The inspection around are

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best

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monoxide Westerbeke. your

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Make

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INSTALLATION

Publication # 43268.

against

the

complete

gaskets,

surrounding

the

situation

or

appearance

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have

mechanic.

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not

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people

the

boat

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warning

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Engines & Generators

7

RAW

WATER

COOLING

Siphon-Break

For

installations

or

below

a

siphon-break

The

siphon-break

system

to

the

engine's

A

CAUTION:

exhaust

will

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pOSSible

If

you

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way,

protect

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that

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siphohing.

the

sourtdshield.

where

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in

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flooding

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operating

install a siphon-break.

engine.

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siphon-break

during

all

Use a separate

SIPHON

BREAK

AV/,IILABLE

WESTERBEKE

the

waterline,

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water

when

Failure

is

located

water

of

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about

to

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angles

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DEALER

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provisions

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supply

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air

from

the

engine

to

use a siphon-break

at

or

damage

boat.

the

position

the

vessel's

conditions

installed

of20

inches

must

of

vessel

hose

for

vent

in

filling

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to

waterline

or

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in

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always

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of

when

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the

exhaust

raw

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load

engine

the

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vessel

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to

prevent,

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I-

1

SIPHON

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INSTALLATION

Raw

Water

A

flush-type

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close

to

install

elbow.

cooling

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when

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INSTALLATION

and

GENERATORS

guidelines.

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supplying

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BATTERY

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to

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CONNECTIONS

Generator

be

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of

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the

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boat's

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for

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through-hull

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BREAK

(TYPICAL)

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Consult

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the

schedule.

Engines & Generators

8

GROUND

BOLT

INSTALLATION

CONTROL

Mount The

panel cable installing, cable control

this

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at

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DESCRIPTION

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operation.

NOTE:

energized supplying STOP

NOTE:

is

preventing

failure.

fuel

shutoff

solenoid

is

pushed

blink

and

the

engine

too

low.

engine/generator "ON"

If

the

engine (yellow unneeded

button.

If

the

START

running,

an

electrical

its

solenoid

pressure

down

and

goes

is

LED

power

temperature

is

if

light

off

doesn't

light

not

running

is

blinking),

to

button

is

safoty

from

energizing.

too

low

it

overheats

(yellow)

after

the

start,

(green)

the

engine.

pushed

device

warning

or

the

blinks

engine

it

means

and

the

starting

by

protects

light

engine

or

there

when

starts.

the

will

be

shutoff

Reset

mistake

the

(red)

is

an

the If

starting

lit

during

solenoid

battery

by

pushing

while

starter

lights

up

overheated.

oil

START

it

continues

battery

normal

is

the

engine

motor

by

LED

PROPORTIONAL

LOAD

INDICATOR

©

FUEL

SHUTOFF SOLENOID (YELLOW)

LIGHT

PREHEAT

r

100%

CONTROL

OVER

PANEL

LOAD

(REMOTE)

h

ENGINE

RUNNING

ON

LIGHT

(GREEN)

COOLANT/OIL WARNING

HOURMETER

PRESSURE

LIGHT

Engines & Generators

10

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use 2-D

Care

Use your which finished The improper tank practice

Purchase a well-known Install

separator 220

ENGINE

Use a heavy CG-4. operation, recommended

A

engine additives produce

FUEL

fuel

that

meets

(ASTM),

only

fuel

best

for

or

of

the

clean injection

might

parts.

fuel

storage your is

advisable:

and

regularly

between

225

are

and

Fuel

diesel

pass

through

It

is

can

become facilities.

engine's

good

OIL

duty

engine

Change

the

and

every

oil

viscosity,

Operating

41° -68° F (5° -20°

Above

Below

68° F (20°

41

Temperature

° F

CAUTION:

oil

to

mix.

of

different

properties

the

has a cetane

Supply

fuel!

pump

important

daily

service a good,

the

fuel

examples

engine

100

(5°

Do

Each

requirements

rating

The

clearance

is

very

critical;

the

filter

to

buy

unsatisfactory

To

assure

use

is

clean

brand

of

fuel.

tank

and

of

such

oil

with

an

oil

after

hours

of

see

the

C)

not

allow

brand

brands

could

harmful

to

or

specifications

of

#45

of

invisible

can

damage

clean

by

that

the

and

visual-type the

engine.

spin-on

API

classification

an

initial

operation

following

Oil

SAE

30,

10W-30

SAE

20

SAE

two

or

more

contains

react

your

engine.

or

better.

the

components

dirt

these

fuel,

and

careless

fuel

going

pure,

the

filter/water Raycor

filters.

50

hours

thereafter.

chart:

Viscosity

or

15W-40

or

1

OW-3~

1

OW-3~

brands

its

own

in

the

of

Class

in particles finely

keep

it

clean.

handling

into

the

following

models

of

CF

or of

break-in

For

of

additives;

mixture

or

to

ENGINE

Westerbeke recommends a mixture

50%

that The antifreeze performs double

to the engine cooling circuit from rust and corrosion. Look quality antifreeze that contains Supplemental Cooling Additives balanced, crucial

The distilled water and antifreeze should being poured into the cooling circuit.

NOTE:

antifreeze that

Antifreeze mixtures will protect against and retard rust and add

Antifreeze Freezing

COOLANT

A coolant recovery tank kit WESTERBEKE diesel engine.The purpose of this recovery

tank

during engine operation, without the loss of coolant and without introducing

provided

COOLANT

of

50%

antifreeze and

distilled

can

run at proper temperatures by transferring heat

they

is

water.

Distilled water

corrode internal engine surfaces.

to

the coolant.

(SCAs)

to

Use

the

new environmentally-friendly

is

now available.

are

beneficial

ANTIFREEZE

concentration

Temperature

RECOVERY

to

allow for engine coolant expansion and contraction

and

must be installed before operating the

It

also lubricates

that keep the antifreeze chemically

long term protection.

to

the engine's cooling

to

the life of the circulating pump

PROTECTION

(-10°C)

TANK

is

air into the cooling

is

free

from

duty,

as

it

allows

and

be

an

CHART

23%

14°

30%

F

8°

F

(-13°C) (-20°C)

supplied with each

system.

protects the

for

premixed before

long

unexpected freeze

system.

35%

_4°

the

chemicals

the engine

away

a good

lasting

They

seal.

F

-40°

(-40°C)

This kit

engine.

from

50%

is

F

NOTE:

This located at or above can

be

located below

particular installation makes this

Engines & Generators

11

tank,

with

the

its

the

short

level

run

of

plastic

of

the

engine s manifold but it

of

the engine s manifold

necessary.

hose,

is

best

if

the

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting your generator for the first time or after a prolonged layoff, check the following items:

• Check the engine oil level: add oil to maintain the level at the full mark on the dipstick.

• Check the fuel supply and examine the fuel filter/separator bowls for contaminants.

• Check the DC electrical system. Inspect wire connections

and battery cable connections.

• Check the coolant level in both the plastic recovery tank

and at the manifold.

NOTE:

the engine s cooling system will be purged to the coolant

recovery tank. Open the air bleed petcock to ensure that the cooling system is purged

after the engine has cooled, the coolant from the recovery

tank will be drawn into the engine replace the purged

Before subsequent operation manifold should be topped off, and the coolant recovery

tank may need to be filled to the

• Visually examine the unit. Look for loose or missing

parts, disconnected wires, unattached hoses, and check threaded connections. Search for any gasoline leaks.

INSPECTION

After the initial running

air.

of

the generator, the air

of

air.

After shutdown and

s cooling system to

of

the generator, the engines

MAX

level.

in

MANIFOLD CAP

PRESSURE

• Check load leads for correct connections as specified in

the wiring diagrams.

• Examine the air inlet and outlet for air flow obstructions.

• Be sure no other generator or utility power is connected to

the load lines.

• Be sure that in power systems with a neutral line that the

neutral is properly grounded (or ungrounded) requires, and that generator neutral is properly connected to the load neutral. In single phase systems an incomplete

dr open neutral can supply the wrong line-to-neutral

voltage on unbalanced loads.

A

CAUTION:

recommended motors, to precaution pated cold

be

speed

operation

engine

and,

When

that

all

switched

in

cold

will

prevent

of

the

from

stalling.

starting

AC

loads,

OFF

until

climates,

damage

AC

machinery

the

generator..

especiallyJarge

the

engine

starts

caused

and

to

by

warm

as

the system

it

has

come

up.

unantici-

will

prevent

is

up

This

a

SPIN OIL

ON

FILTER

ADD

'OIL

OIL

COOLER

USE

THE

MOST CONVENIENT OIL

FILL

Engines & Generators

12

STARTING/STOPPING

PROCEDURE

ELECTRIC

A

before

caused will

This

generator generator, yellow Once will

go

NOTE:

continue

I

LED

II

PROPORTIONAL

LOAD

@

START

CAUTION:

starting.

by

unanticipated

prevent a cold

has a 12

push

the

START

indicator

the

engine

fires

out

and

the

green

If a start

INDICATOR

to

blink

attempt

To

..

All

AC

loads

This

precaution

operation

engine

START

and

reset

from

VDC

electric

button

light

will

runs, the

run

indicator

is

~borted,

the

circuit,

leOOLANT/OiL

[WARNING

must

be

switched

will

prevent

of

AC

machinery

stalling.

starter.

To

start

on

the

control

panel.

come

on

and

start

yellow

START

light

will

come

the

yellow

indicator

depress

the

stop

PRESSUR~

LIGHT

off

damage

and

the

The

to

blink:.

indicator

light

on.

light

will

button.

.JHOURMETER

@

OPERATING

After

the

generator

warmup.

STOPPING

Remove the its

•

To

\

shutdown

After

possible

Failure

If use until

NOTE:

pressing

Ifpossible,

A

CAUTION:

periods

of applied, can

cause

the

generator

operating

stop

the

is

shutdown,

leaks

to

the

engine

the

control

the

engine

Only

the

time

otherwise

severe

THE

AC

to

temperature).

generator,

automatic.

from

Stop

should

lever:

use

STOP

THE

GENERATOR

has

started,

run it with a

apply

the

Never

operate

without

an

carbon

damage

GENERATOR

loads

from

the

run

for

an

additional 3

press

the

carefully

comes

this

all

the

fail

to

Push

to a stop,

lever

button.

inspect

connections

stop

the

when

load in

stages.

the

engine

amperage

build-up

to

generator

STOP button

after pressing

lever all

then

the

generator.

engine

engine.

release

may

one

to 5 minutes

inside

the

medium

load

being

occur

at a time

on

the

Check

the

way

over

it.

doesn't

load

for

long

which

and

allow

(this

stabilizes

control

panel;

for

soundshield.

STOP

button,

and

hold

stop

after

it

Apply a light up

to

operating

NOTE:

Some

condition

the

should

generator

load

to

the

temperature

unstable

smooth

loads

are

generator

running

out

applied. .

before

may

as

the

and

allow

applying

occur

engine

the

engine

heavy

in a cold warms

up

loads

engine.

and

to

when

@

warm

This

Engines & Generators

·13

BREAK-IN

After the generator has been started, check for proper operation and then encourage a fast wann-up. Run the generator between

A

tor

PROCEDURE

20% to 60%

CAUTION:

by

running

without a load.

of

full load for the fIrst 10 hours.

00

not

attempt

to

break-in

PROCEDURE/DAILY

your

genera-

OPERATION

NOTE:

Some unstable running

This condition should abate as normal operating temperature

is reached and loads are applied.

A

CAUTION:

periods

of

00

not

time

without a load

generator.

may

operate

occur in a cold engine.

the

generator

being

placed

for

on

long

the

After the fIrst 10 hours can be increased to the full-load rated output; then periodically vary the load.

Avoid overload at all times. An overload is signaled by a smoky exhaust with reduced output voltage and frequency. Monitor the current being drawn from the generator and keep it within the generators' rating. Since the generator operates at

3600 rpm to produce 60 hertz, or at 3000 to produce 50 hertz, control by the current drawn from the generator.

To

protect against unintentional overloading the generator's output leads should be routed through a circuit breaker that is rated at the rated output

NOTE:

current drawn required amperage drawn can be age. See GENERATOR INFORMATION

CHECK

Follow this checklist each day before starting your generator.

• Record the hourmeter reading in your log (engine hours

relate to the maintenance schedule).

• Visually inspect the engil!e for fuel, oil, or water leaks.

of

Be aware

LIST

of

the generators' operation, the load

the generator's engine break-in

of

motor starting loads and the high

for

starting motors. This starting

3 to 5 times normal running amper-

in

this manual.

is

governed

the generator,

the generator.

STOPPING

Remove the major AC loads from the generator one at a time. Allow the generator to run for a few minutes to stabilize the operating temperature and press the STOP switch down, (see

CONTROL PANELS).

NOTE:

the maintenance schedule

GENERATOR

Once the generator has been placed in operation, there may be governor adjustments required for engine speed (hertz) during the engine's break-in period (fIrst 50 hours) or after

this period (see ENGINE under ENGINE ADJUSTMENTS. A no-load voltage adjust- ment may also be required in conjunction with the engine's speed adjustment (see GENERATIOR INFORMATION).

THE

GENERATOR

After the first 50 hours

for

ADJUSTMENTS

SPEED (HER1Z) ADJUSTMENT

of

generator operation check

the 50 hour service check.

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

• Check the drive belt for wear and proper tension (weekly).

• Check for abnormal noise such as knocking, vibration and blow-back sounds.

• Confmn exhaust smoke: When the engine is cold - White Smoke. When the engine is wann - almost Smokeless.

When the engine

is

overloaded - some Black Smoke.

Engines &.Generators

14

SAFETY

SHUTDOWN

SWITCHES

SAFETY

The generator is protected by three automatic shutdown switches. Should shutdown occur,

without finding ENGINE

The following is a description

switches:

High

A high water temperature switch housing. Normally closed, this switch, should the fresh water coolant's operating temperature reach approximately

(99°C), will open and interrupt the DC voltage to the fuel

solenoid on the injection pump, thereby shutting off the

engine. This switch resets at

SHUTDOWN

and

TROUBLESHOOTING

Water

Temperature

SWITCHES

correcting the cause. Refer

do not attempt

section

of

this manual.

of

these automatic shutdown

Switch

is

located on the thermostat

19SOF

(107°C).

to

restart

the

210°F

Low

Oil

Pressure

A low oil pressure shutdown switch is located off the engine's oil gallery. Normally

switch's sensor monitors the

the engine's oil pressure fall to 5-10 psi, this switch will

open interrupting the DC voltage to injection pump, thereby shutting

Switch

engine's

open

in

the

off

the engine.

OIL

PRESSURE

LOCATED

.

OF

THE

CRANKSHAFT

a static state, this

oil pressure. Should

fuel solenoid on the

SWITCH

AT

THE

ENGINE

FRONT

TO

Engine

The generator's engine

I manual reset circuit breaker (20 amps

! draw or electrical overload anywhere in the instrument panel

wiring event most generators will shut down because the opened breaker disconnects the fuel supply.

; check and repair the source

the fault, reset the breaker and restart the generator.

Circuit

or

engine wiring will cause the breaker to trip.

Breaker

is

protected by an engine mounted

DC).

Excessive current

If

this should occur,

of

the problem. After repairing

In

this

Engines

15

& Generators

In

order

to

log

your

engine

hours

NOTE:

Many

simple

but

knowledge

use

this

Maintenance

hours.

by

running

of

the

following

others

are

of a service

Use

your

time.

more

difficult

mechanic.

Schedule,

engine

hourmeter

maintenance

and

may

MAINTENANCE

it

will

be

necessary

or

record

to

your

SCHEDULE

A

while

procedures

require

the

are

expert

equipment

correct terminals electrical

FREQUENCY

WARNING:

the

generator

tools

when

such

for

Never

as

goggles

each

servicing

equipment.

attempt

is

running. job.

any

to

perform

Wear

the

and

gloves,

Disconnect

of

the

engine's

any

proper

and

the

battery

service

use

DC

safety

the

COMPONENT

Engine

oil

level

Engine

oil

Oil

filler

Fuel

supply

Fuellilter/water separator

Fuel

lift

pump

Fuel

filler

Fuel

injector'

Raw

water

pump

Thermostat

Engine

hoses

Exhaust

system'

Starling

batteries

and

house

batterie

Starler

motor'

AFTER

50

FIRST

HRS

DAILY

OR

EVERY 8 HOURS

WEEKLY

•

• • •

• •

•

• •

•

EVERY

100

HOURS

•

EVERY

600

HOURS

•

EVERY

2100

HOURS

•

MAINTENANCE

Oil

level

should

be indicating necessary.

Change

the

Check

the

Check

for

Drain

and

Clean

and

connection. Change

the

Check

and

pressure

ADJUSTMENTS).

Remove

the impeller, Check

the

turn,

but

when

reassembling

Check

the

THERMOSTAT

Hoses

should

soft

and

hose

clamps.

Inspect

for operation. Check

the corrosion clean

and Warning: A defective carbon

monoxide

Check

electrolyte connections excessive

Check

the

Remove

the

starter

marks

on

oil:

see

fuel

supply.

water

and

replace

inspect

the

filter.

adjust

the

and

spray

pump

gasket,

cam

bearings

not

wobble).

functioning

under

be

hard

spongy.

Check

leaks.

Check

that exhaust buildup replace

as leakage!

levels

are

very

corrosion. solenoid

and

lubricate.

motor

pinion

between

LUBRICATION

the

condition

cover

and .

elbow

on

and

the

dipstick.

Top

up

if

dirt

in

the

fuel.

filter

if

necessary.

wiring

injection

opening

(see

and

inspect

and

cover

seals

(the

Lubricate

of

the

thermostat;

COOLING

and

tight.

and

tighten

the

anti-siphon

all

connections

for

carbon

inside

passages;

necessary.

exhaust

elbow

and

make

tight.

Clean

motor

for

Clean

and

drive.

full

and

low

Top

up

if

SYSTEM

necessary.

ENGINE

the

for

wear.

shaft

can

see

SYSTEM.

Replace

if

all

valve

are

tight.

and/or

can

cause

sure

off

corrosion.

lubricate

'Westerbeke

recommends

that

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

16

(continued)

COMPONENT

Valve

clearances'

Cylinder

compression

Cylinder

head

Visual

inspection

Hardware and connections

Generator connections

Generator speed

Cleaning generator

fastenings

electrical

no-load

the

bolts

MAINTENANCE

FREQUENCY

AFTER

50

FIRST

HRS

DAILY

OR

EVERY 8 HOURS

WEEKLY

EVERY

100

HOURS

• •

•

• •

•

SCHEDULE

EVERY

600

HOURS

EVERY

2100

HOURS

•

MAINTENANCE

Adjust

the

valve

(see

ENGINE

Check (see

ENGINE

Retorque

CYLINDER ADJUSTMENTS.)

Check I

nspect accessible all

wiring

Check secure

INFORMATION

Check

Keep

the

dirt

and

to

remain

clearances;

ADJUSTMENTS}.

the

compression

ADJUSTMENTS}.

the

bolts

(see

HEAD

under

for

oil,

fuel

and

tighten

screws,

and

electrical

that

AC

connections

with

no

chafing. for

additional

the

no-load

speed.

generator's

oil

will

inhibit

cool.

pressure

TIGHTENING ENGINE

water

leaks.

all

fastenings

bolts

and

nuts.

connections.

are

See

GENERATOR

surface

clean.

the

generator's

THE

and

Inspect

clean

and

information.

Surface

ability

'Westerbeke

recommends

that

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

17

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolant cools the engine block, its internal

is

moving parts, and the engine oil. The heat externally from the fresh water coolant to raw water by means of a heat exchanger, similar in function to automotive radiator. Raw water flows through the tubes the heat exchanger while fresh water coolant flows around _ the tubes; engine heat transfern;Ci is

conducted through the tubewail;,-t:o the raw water which then pumped into the exhaust system where finally it discharged overboard. In other words, the engine fresh water coolant, this coolant the raw water carries the transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent coolant within the engine allows the cooling water passages to stay clean and free from harmful deposits.

FRESH

NOTE:

recommended antifreeze and water mixture

fresh water coolant.

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

When the engine is started cold, external coolant flow prevented by the closed thermostat (although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion of the cooling system.

Coolant

A coolant recovery tank allows for engine coolant expansion

and contraction during engine operation, without any

significant loss the cooling system. This tank should be located at or above

the engine manifold level and should be easily accessible.

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE SCHEDULE.

become contaminated, it can lead to overheating problems.

WATER

Refer to the ENGINE COOLANT section

Recovery

of

COOLANT

of

COOLING

Tank

coolant and without introducing air into

to

the fresh water coolant

is

cooled

each other. Using only fresh water

CIRCUIT

of

the circulating pump.

If

the coolant

transferred

an

is

cooled by

by

raw water, and

for

the

to

be used as the

of

the engine's

is

allowed to

of

is

Drain the engine coolant engine block and opening

, the system with fresh water,

NOTE:

The drain petcock on

be used to help drain engine coolant.

A

WARNING:

Wear

protective

is

COOLANTDRAIN

Refilling

. After replacing the engine

exchanger'S coolant drain. coolant into the manifold the manifold, start the

NOTE:

When a steady flow

the petcock and fill the

· Monitor the coolant in

· the manifold to the filler pressure cap.

· Remove the cap on the coolant mix to halfway

the cap. Run the engine flow into the recovery

After checking for leaks,

· Coolant should draw

· engine cools down. Add :needed. Clean up any

the

Open the air-bleed

by

Beware

gloves.

•

MANIFOLD/HEAT

Coolant

engine

of

coolant

system

the

neck

coolant between

and

tank.

stop

back

coolant

spilled

loosening the drain plug on the

the

manifold pressure cap. Flush

then

start the refill process.

the

heat exchanger should also

of

the

hot

engine

coolant.

/'

EXCHANGER

block

drain plug, close the heat

Then

pour clean, premixed

and

when the coolant

and run it at slow idle.

petcock

manifold

into the cooling system

on the thermostat housing.

appears at the petcock, close

until the manifold remains full.

and add

and install the manifold

recovery tank and

LOW

and MAX and replace

observe the coolant expansion

the engine and allow it

to the recovery tank

coolant.

is

visable in

as

needed. Fill

fill

as

with

to the if

cool.

A

CAUTION:

Proper critical; a substantial traced

back

to

cooling

number

system

of

maintenance

engine

corrosion.

failures

is

can

be

Engines & Generators

18

NOTE:

Periodically check

pressure

are and closes

cap.

Ensure

in good condition and check that

tightly.

INSPECT

SEAL

the

condition

that

the

upper and lower

Carry a spare

the

<:ap.

THERMOSTAT

A thermostat, located near the manifold engine, controls the coolant temperature continuously the engine coolant from

hole in the thermostat

overheating).

gradually opens. The thermostat

checked, cleaned, or replaced

and gasket.

flows

through

is

first

started, the closed thermostat prevents

flowing

As

the engine warms

the

closed cooling circuit. When

(some coolant is by-passed through a

to

prevent the exhaust manifold from

up,

is

accessible

easily.

Carry a

of

the

vacuum

at

the

as

the

thermostat

COOLING

manifold

rubber

seals

valve

opens

front

of

th~

coolant

and

can be

spare

thermostat

SYSTEM

COOLANT

The

coolant housing reaches red

(LED)

down

AIR

Cooling trol

panel

a

filter

INCOMING

•

COOLING

TEMPERATURE

temperature

(see

illustration).

approximately

engine

the

generator.

COOLING

air

is

continuously

and

around

into

the

engine.

AIR

switch

2100 F

overheat

to

the

is

If

the

coolant's

(99

indicator

circulated

engine

SWITCH

located

near

operating

0

C)

this

switch

on

the

control

(by

air

hose)

air

intake

the

will

where

thermostat

temperature

light

up

panel

and

thru

the

con-

it

passes

."

.

V·::

}·TrVATER

the

shut

thru

.

~FROM

RAW

PUMP.

Replacing

Remove the cap screws and disassemble the thermostat housing gasket, apply a thin coat of sealant gasket before pressing it into place. Do not over-tighten the cap screws.

Run the engine and check for normal temperatures and that there

HIGH

WATER TEMPERATURE SWITCH

the

Thermostat

as

shown. When installing the

are

no

leaks at the thermostat housing.

.>-------lS~::.;:..~

on

new

both

thermostat

sides

of the

and

RAW

WATER

The

raw impeller pump. This pump draws water directly from the raw

water source (ocean, lake, or river) through a hose the water strainer. The raw water passes from the strainer through the raw water pump and then to the heat exchanger. The raw water passes thru the heat exchanger tubes where it cools the circulating fresh water (coolant). The raw water

water-injected exhaust elbow, mixing with and cooling the exhaust gasses. This mixture is discharged overboard by the engine's exhaust gas discharge pressure.

water

flow

COOLING

CIRCUIT~

is created by a positive displacement

to

the water cooled generator

is

then discharged into the

of

exhaust

gas

and raw water

to

!

THERMOSTAT

ASSEMBLY

Engines ~ Generators

19

RAW

WATER

The

raw

water

non-ferrous

flexible

vanes impeller should

this impeller. cover

gasket

failures

occur

engine

operation. are

cautioned

The

neoprene

inspected

NOTE:

new

Inspecting/Changing

Close with out blades into of valve.

NOTE:

of

(seals

pump

the

of

the

lubricant

dry

Should a failure

and

the

aid

the

to

pump's

Never

running

pump

housing

which

housing,

pump

There

should

(an

when

to

impeller

regularly.

bearings), and

rebuild

raw

water

of

two

pump.

conform

to

the

allow

may

PUMP

is a self-piiming,

and a neoprene

wipe

against a curved

producing

be

run

dry

always

impeller

make

Install

housing.

lubricant

Such

failures

sure

has a limited

it

may

the

intake

small

the

to

the

impeller

the

destroy

kit)

occur

screwdrivers,

curved When

pump

raw

original

the

valve.

new

and

the

pumping

as

water

be a spare

onboard.

(raw

water)

are

not

water

with

be

more

pump

Raw

Remove

impeller cam

assembling,

gasket.

tOntil

impeller.·

rotary

pump

impeller.

lifetime

the

cost

plate

dry.

The

cam

plate

action.

On

acts

as a lubricant

impeller

Raw

water

is

not

present

warrantable

flow

is

present

and

must

pump s internal

effoctive as a spare.

Water

Pump

the

pump

carefully

Open

pry

and

gasket.

and

push

apply a thin

the

raw

Even-a-inortperiod I

COOLING

with

a

impeller

and

pump

to

-

within

no

account for

impeller

during

and

qperators

at

start-up.

be

parts

purchase

Impeller

cover

and,

the

impeller

Move

the

impeller

coating

water

has

the

a

the

intake

SYSTEM

RAW

WATER

NOTE:

Always

install

strainer

A engine's strainer the

Perform

clean

glass

of

operation:

I:

2.

3.

4.

5.

6.

7.

NOTE:

hard

aground.

If

the

engine

the

cause

up

in

the

cooling

will

always

raw

water

cooling

when

making

should

be

the

following

Close

the Remove Clean

the Replace Reassemble QRen

the

Run

the

Also

follow

temperature

may

be

strainer,

system.

INTAKE

intake

system.

raw

and

glass.

the

seacock.

engine

that slowing

STRAINER

the

strainer at or

be

self-priming.

strainer is a

Include a visual

your

periodic

clear.

maintenance after

water

clean

the strainer

sealing and

install

and

the

above

seems to

silt,

leaves the

.~

seacock.

washer

the

strainer.

check

for

procedure

be

or grass

flow

of

below

vital

inspection

engine

every

filter.

if

necessary.

leaks.

after

running

may

raw

water

the

waterline

component

of

check.

The

100

hours

having

higher have

been

through

of

this water

run

than

so

the

in

normal,

caught

the

IMPELLER

i

SHOULD BEND

EACH

ITS

BASE.

.

CRACKS

RAW

PUMP

BLADES

BE

INSPECTED. BLADE

AT

LOOK

FOR

OR

SPLITTING.

WATER

ASSEMBLY

IMPELLER

PN#33636

SEALlN.G

WASHER~-

STRAINER

~

....

TYPICAL

(OWNER

DRAINING

When be

drained

will

then

freezing

by

flush

THE

COOLING

temperatures

unscrewing

back

down

are the the

INTAKE

pump

inlet

STRAINER

INSTALLED)

SYSTEM

expected,

cover.

line.

the

The

cooling

raw

water

system

can

Engines & Generators

20

COOLING

Zinc

Anode

A zinc anode, or pencil, circuit within the heat exchanger. The purpose zinc anodes is to sacrifice them to electrolysis action taking place in the raw water cooling circuit, thereby reducing the effects

of

electrolysis on other components

The condition

and the anode cleaned

should be carried on

of

.

ZINC

is

located in the raw water cooling

of

having

of

the system.

the zinc anode should be checked monthly

or

replaced as required. Spare anodes

board

.

ANODES

SYSTEM

Heat

Exchanger

After approximately 1000 and pressure test the engine's motive radiator shop should exchanger.)

NOTE:

Operating

that a heat exchanger cleaning be performed more often than

1000 hours.

every

Service

in

silty

hours

of

operation, remove, clean

heat

exchanger.

be

able to clean and test the heat

and/or

tropical waters may require

(A

local auto-

NEW

NOTE:

Electrolysis action is the result

installation and vessel location; not that

If

the zinc anodes need replacement, hold the hex boss into which the zinc anode is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. After removing the zinc, note the condition poor condition, there are probably a lot of zinc flakes within the exchanger. Remove the end clean the inside exchanger end gasket

aged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part num-

ber),

O-ring and cover, and 'install a new zinc anode.

NOTE:

The threads do not require sealant. Sealant should not be used as it may insulate the zinc from the metal ing preventing electrolysis action on the zinc.

of

REPLACE

of

the heat exchanger and

all zinc debris. Always have a spare heat

in

case the present one becomes dam-

of

the zinc anodes are pipe threads and

of

the heat exchanger hous-

CLEAN REUSE

of

each particular

of

the engine.

of

it.

If

the zinc

AND

is

in

,/

/

AIR

INTAKE/SILENCER

AIR

INTAKE

SILENCER

Description

A marine diesel engine running at high speed will typically consume more than must the engine room engine must be umestricted.

Air

Filter

The air filter cartridge prevents engine room dust and dirt from entering the engine, quiets the engine.

·

Maintenance

, The filter should be cleaned every 100 operating hours. Tap

· the cartridge on a flat surface to dislodge loose dirt or clean

· off with compressed air. nated or oily, replace it.

6,000 cubic feet

be

well ventilated, the air flow into

it

also extends engine life, and

If

the cartridge

of

air per hour. Not only

is

badly contami-

the

HEAT

EXCHANGER

fAN

ZINC

ANODE

iDa

NOT

OUT

DEBRIS

Engines & Generators

21

USE

SEALANT

ENGINE

1.

2.

NOTE:

OIL

CHANGE

Draining the oil sump. Discharge the used

the

sump

drain hose (attached

while

the

engine is replace the hose in securely.

NOTE:

Thread

is

II4NFT.

Always observe yellow/gray emulsion indicates the

oil.

Although this condition is rare, it prompt attention qualified mechanic should water be present in Raw

water present the exhaust system attached siphoning of circuit into often caused

poor location or lack of maintenance.

\114"

!FOR

THE

WARMFolJlL

ALSO

BE

THRU

Replacing the oilfilter. When-removing

filter, in

the upper

oil

from

to

lessen spillage. A small automotive filter wrench

should be helpful in removing

Do

make

Place some paper towels filter

(Oil

cooling

oil

filter sealing gasket comes off sealing gasket remains sealed against gently remove

When installing the gasket's sealing surface apply a thin coat of clean engine oil on

the new oil filter firmly

NOTE:

through

the

i8MM

/11116

INCH

;SOCKET

t,

NFT

EXTENSION~

PUMPED

THE

DRAIN

you

may

it into a container before removing

not

punch

certain

when unscrewing it

or

any

ability.

as

nipple on

by

hand.

The

engine

passages

warm. its

bracket and replace

size

for

the

used

to

prevent serious

in

the

raw

water through the

exhaust, filling

by

the absence of

.

;

I'

CAN UP

,

HOSE

find

it helpful and cleaner

and

lower portion of

this

hole

it

can

be

removed.

other

fluid

Keep

your engine clean.) Inspect the old

it is removed

it.

new

filter.

Screw

the

oil

is

cooled

in

the

to

the front of

Drain the used

lube

oil

drain

oil

as

it

is

removed.

the

presence of water damage.

oil

can be the result of a fault

to

the engine and/or a

raw

the

engine.

an

anti-siphon valve,

])

the

old oil

without

first

and

a plastic bag around the

to

catch

any

on the engine reduces

to

make sure that

with

the old

oil

filter element,

on

the bracket

to

the

filter onto

filter

oil

brac,ket,

filter

by

engine

bracket

and

ENGINE

oil

the

oil

completely,

the

hose

capped

does

Call

water cooling

This

the

used oil

to

punch a hole

old

filter

it.

filter.

loosening

oil left

the

filter.

If

the

filter

wipe

free

of oil and

the

rubber gasket

the

tighten the

coolant

housing

LUBRICATING

through

engine)

end cap

end

A

in

require

a

the

oil.

problem

its

to

drain

This helps

the

filter

in

the

filter.

the

engine's

rubber

this

rubber

bracket,

the

filter

threaded oil

filter

flowing

assembly.

I

in

is

the

to

SPIN

ON

OIL

PN#36918

NOTE:

3.

OIL

The panel.

shutdown generator

to

TESTING

NOTE:

reading

pressure

depending

placed

OIL

APPLY

CLEAN

OIL

WHEN

Generic standards might after sure around

Filling the oil sump. Add

cap After refilling, run the engine for a checking the oil pressure. Make sure there around the new oil filter or from the oil

stop the engine. Then check the quantity of oil lube oil dipstick. Fill the dipstick, should the engine require additional oil.

or

be

entirely

an

oil

the

oil

the

on

the

A

CAUTION:

contaminates. skin

and Launder oil.

Discard

PRESSURE

engine's

The

red

if

without

A

newly

upwards

reading

upon

on

the

oil

the

THE

ENGINE

INSTALLING

filters

are

diameters

difforent

filter

change

pressure

new

oil

filter.

top

of

the engine or through the side oil

Avoid

nails

thoroughly

or

discard

used

pressure,is

light

will

oil

pressure

checking

OIL

PRESSURE

started,

of

60

psi. A warmed

as

low

the

temperature,

generator.

I

TURN

ON

i

BYHAND

I_OIL

not

recommended,

of

important

from

genuine

and

oil

fill,

is

normal

and

new

to,

but not over the high mark on

Used

engine

prolonged

using

clothing

oil

properly.

constantly

illuminate

cold

as

fall

below 5 psi.

the

oil

engine

35

psi.

ojtheengin;e

and

in

can

These

REAL

FILTER

ASSEMBLY

as

the

items

on

parts.

run

the

engine

that

there

oil through the oil filler

few

moments while

drain system, and

oil

contains

skin

contact.

soap

and

or

rags

containing

monitored

the

generator

Do

finding

the

this

manual.

have

an

engine

can

readings

and

TiGHT,

material

generic

parts

Immediately

to

make

are

no

leaks

is

no

leakage

with

harmful

Clean

water.

by

the

control

will

not

restart

problem.

oil

pressure

have

an

will

vary

the

load

fill.

the

used

the

Refer

oil

'

Engines & Generators

22

FUEL

SYSTEM

DIESEL

Use not use kerosene

FUEL

A primary fuel filter installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can

be Most installers include a fuel filter/water separator with the

installation package as they are aware contaminants in the fuel can cause.

A typical fuel filler/water separator is illustrated below. This is the separator type filter is not installed between the fuel supply

tank

will affect the fuel pump, engine filter, and injection equipment. the fuel reaching the engine's injection equipment is free impurities. This process is accomplished maintaining a proper fuel filter/water separator.

FUEL

No.2

diesel fuel with a cetane rating

or

home heating fuel.

FILTER/WATER

carried to the fuel system

Rayeor

and

Model

engine-mounted fuet system, any water in the fuel

The

owner/operator is responsible for making certain

1

t(t

SEPARATOR

of

the water separating type must

on

the engine.

500

MA.

Keep in mind that

~'11

of

45

of

the problems that

by

installing and

-~

or

if

:

higher.

be

a water

FUEL

Do

of

LIFT

FUEL

FILTERS

The

fuel injection

manufactured

water

from must pass through at least two fuel filters, a fuel filter/water separator

clean, schedule

A

when

any

open tem when

and

change

in

WARNING:

servicing

fuel

"ames

when

servicing

pump

and

the fuel injectors

and

they

must

receive clean diesel fuel, free

and

dirt. To ensure this flow

the engine's spin-on fuel filter. Visually inspect,

these,filters according

this manual.

Shut

off

the

fuel

valve

the

fuel

that

may

or

other

servic!ng.

the

spill.

sources

Ensure

fuel

system.

DO

system.

NOT

allow

of

proper

Take

fire

ventilation

of

to

at

care

any

near

are

clean

the

in

smoking.

the

PUMP

precisely

fuel, the fuel

maintenance

tank

catching

fuel

sys-

exists

TO

FUEL

i

FILTER,

Q.,:;:~i;;-:-r-----i'DRAIN

The

fuel injection pump is a very important component the diesel engine, requiring the utmost care in handling. The fuel injection pump has been thoroughly bench-tested and the owner-operator requires servicing, remove

injection pump service facility.

ble and repair it. The

only adjustment the servicing mechanic should make to the fuel injection speed.

FUEL

LIFT

Periodically check the fuel connections to and out pump

and make sure that no leakage is present and that the

fittings are tight and secure. The

of

the pump's mounting bolts should

one secured tions.

When

energized thru the preheat circuit, the fuel lift pump

will purge air from the fuel system and provide a continuous

of

flow

fuel as the engine is running.

is cautioned not to attempt to service it.

it

and take

pump

is the adjustment for engine idle

it

to an authorized fuel

Do

not attempt to disassem-

PUMP

DC

ground connection at

be

clean and well

by

the mounting bolt to ensure proper pump opera-

of

Ifit

the

ENGINE

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

Changing/cleaning

1.

2.

3.

4. Replace the sealing

FUEL

FILTER

MAINTENANCE

the

Shut

off

the fuel supply.

Unscrew housing and allow the bowl to come away housing,

Remove

the housing. Thread the retainer ring

to

tighten

run

the retainer ring that holds the filter

and replace the filter element and

"0"

cross thread.

114 -112

the engine to inspect for leaks.

When

turns

SCHEDULE.

filter

element

ring and reassemble

retainer contacts the by

hand. Open the fuel supply.and

I

OR

carefully

IBOWL,

,

bowl

50

bowl

from

clean

the

"0"

for

hours

to the

the

the bowl.

bowl to

so as not

ring,

Engines & Generators

23

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid.

is

When the START button solenoid should to get hot.

"click" on and the glow plugs should begin

pressed at the control panel this

INSPECTION

To inspect the plug, remove the electrical terminal connec-

tions, then unscrew or unclamp each plug from the cylinder head. Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and bum erosion; if it has eroded too much, replace the plug.

TESTING

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the other to the body plug will have a used with the plug in or out an ammeter to test the power drain

A

WARNING:

to

the

touch.

testing

the

of

the glow plug, as shown. A good glow

1.0 - 1.5 ohm resistance. This method can be of

Be

careful

These

glow

not

the engine.

plugs

to

burn

You

can also use

(8

- 9 amps per plug).

win

become

your

fingers

very

when

plugs.

hot

Re-install the plugs in the engine and test them again. The

for

20 to

more

plugs should get very hot (at the terminal end) within 25

seconds. short circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

A

than

Glow

If

the plugs

WARNING:

30

seconds.

Plug

Tightening

Torque

00

not

don't

heat up quickly, check for a

keep a glow

1.5 -2.0

Ib-II

plug

(10-14

on

kg-m)

TERMINAL

,ENO

TESTING A GLOW

.

WITH

AN

OHMMETER

.

TIP

PLUG

FUEL

INJECTOR

GLOW

PLUG

.

TESTING A GLOW

,

USING A TEST

LIGHT

PLUG

Engines & Generators

24

DESCRIPTION

The

starting

system

and

starter

button.

When

the

starter

current

flows

and energized into

to

serves

flywheel.

,

T()

pinion is engine

motor Once

ping contact flow

,,'

.magnetic

plunger from

!TERMINALS

coil

becomes

the

coil,

and

reach

the

starter

to

push

that

prevent

damage

gear

incorporates

splined

tothe$J:ter

may

speed

itself .

the

started

the

activation

with

the

of

electricity

fields

and

is

released,

its

engagement

~

includes

button

energizes

closes a set

motor.

starter

to

ti1erotation

button

of

battery-to-start

is

interrupted

the

its

the

on

the

an

electromilgnet,

of

At

the

pinion

the

starter

an

,over-running

armature

is

released,

the

solenoid.

starter

movement

with

the

engine

battery,

instrument

starter's

contacts

same

time,

to

mesh

motor

when

shaft.

The

of

the

pinion

the

cUrrent

The

cables

by a coil

to

the

starter.

ceases

its

also

pulls

flywheel.

starter

panel

solenoid

which

the

with

the

(one-way)

rotation

but

flow

plunger

This

rotation.

the

STARTER

motor,

solenoid,

is

depressed,

coil.

The

pulls

the

plunger

allow

high

current

plunger

also

teeth

on

the

engine

starts,

the

clutch

which

of

the

rutming

not

the

starter

ceases,

stop-

is

pulled

out

of

spring,

and

the

weakens

As

starter

the

drive

the

solenoid

gear

MOTOR

IGNITION', TERMINAL\

'fOcoNfifoi.

PANEL

To

test

the

ignition

circuit,

locate

of

the

small

tenninal Use a screwdriver, ignition

terminal

the

solenoid.

H the starter cranks, the fault H the

solenoid

is

motor

probably

don't

to

the

clicks

faulty.

studs

touch

positive

but nothing

and

the

ignition(s)

is

wired

the

blade,

battery

lies

with the ignition circuit

else

terminal

to

the

ignition

to

jump

from

connection

happens, the starter

(it

circuit).

that

terminal

is

on

one

TYPICAL

STARTER

MOTOR

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

and

that

the

starting

system

wiring

clean

and

tight.

Pay

connections To

check never the

wires

resistance. Using a multimeter,

stud

H

you

more

on

read

the and

the

on

the

wiring,

than

terminals

Repair

start

12

volts,

10

or

solenoid

particular

engine

try

seconds

replace

test

the starter

attention

block

cranking

at a time,

looking

any

the

voltage

and

the

for

ships

batteries

connections

to

the

starter

then

warm

trouble

spots.

between

engine

block

is

faulty.

the

ground

for a few

run

your

spots

the

(ground).

are

at

full

(terminals)

wire

seconds,

hand

that

indicate

positive

tenninal

charge

are

along

IGNITION

TERMINAL

TOCONTROD

PANEL

Unothing at

Check

the

battery

connections.

A

WARNING:

fly

when

space

is

gasoline.

all

happens the

isolation

It

is

also

jumping free

of

potentially

solenoid

switch

possible

There

that

will

terminals.

~r"'r~------J(+)

isn't getting current

and

inspect

the

solenoid

be

arching

Be

certain

explosive

is

and

the

fumes,

POSITIVE

L

TERMINAL'

~

wiring defective.

sparks engine

especially

will

Engines & Generators

25

IGNITION TERMINAL

TO

CONTROL

PANEL

Test

again

by screwdriver screwdriver would

A

starting

blade blade

cause a short.

WARNING:

current

screwdriver.

jumping

firmly to

touch

should

the

two

between

the

There

~.-\\

~"------1:

large

terminal

the

studs.

solenoid

will

be

or

be

arching

flowing

thru

\(+)

POSITIVE

TERMINAL

(M)

studs.

Do

not

starter

as

the

STARTER

TERMINAL

Hold

the

allow

the

casing,

this

the

full

blade

of

the

MOTOR

SERVICE

Westerbeke

serviced If

replacing certified standards.

TO

1.

Disconnect

.

2.

If

starter

3.

Label wires

4.

Remove

5.

Remove will

uses a standard

or

rebuilt

the

starter

for

marine

If

in

dO)lbt,

REMOVE

the

necessary,

have

motor.

and

disconnect

to

touch,

the the

to

remove

starter

be

at

any

starter

motor,

use.

Automotive

contact

FOR

SERVICE

negative

any

the

tape

over mounting from

turned

marine

starter

motor

make

certain

starters

your

WESTERBEKE

battery

cable.

components

wiring

from

the

terminals).

bolts.

the

engine.

to a different

motor

which

automotive

the

new

do

not

to

gain

full

the

starter.

In

some

cases

angle

to

clear

can

be

service

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

the

starter

obstructions.

the

allow

If

the

starter

If

the

starter

If

no

arching

NOTE:

Starter

the

pre-engaged engages screwdriver motor

provide

magnetic the

the

without

the

field for

solenoid

spins, fails

occurred.

motors

model, starter to

bypass

engaging

power

are

bad.

the

to

motor

to

the

solenoid

spin,

There

are

the

to

the

solenoid the solenoid.

arm

to

the

motor

is

either

inertia

solenoid

the

flywheel

flywheel.

move

is

faulty.

is

probably

,no

juice

type

also

moves

of

on

such a starter

TUrn

Hopefolly

even

though

reaching

or

pre-engaged.

an

the

engine.

the

starter

it

will

the

faulty.

the

solenoid.

arm

that

Using

will

run

switch

create

contacts

In

a

the

on

to

enough

inside

Engines & Generators

26

8

KW

BCOT

CONTROL

BOX

TERMINAL

K1

RELAY

REDIWHITE TO

TB·3

~

~20A

K2

RELAY

'COOLlN,~G

AIR

m~

i

iBRIDGE

•

RECTIFIER

,BATTERY

(INTEGRAL

CHARGER

CONTROLLER)

BOARD

K3

RELAY

/,RESET

FUSE

,PROTECTS

'CHARGER

CURRENT

BUTTON

THE

AGAINST

BATTERY

EXCESSIVE

230V

50Hz 120V 60Hz

,

CURRENT

TRANSFORMER"

120/240V

NOTE:

Ll

(lnd

L2

lW,.t pll ....

!~~~f~tm":rellt

NOTE:

W/=

chen~

froto (;0

H~

tl>

50

H:t

$tOe

opel1ltDl"smanulI1

60Hz

GENERATOR CONNECTION

/W'/WESTERBEKE

{EngineS &

CAPACITOR

Generators

27

12

VOLT

DC

CONTROL

DESCRIPTION

The engine has a 12 volt shown on the wiring diagrams that follow. Refer to these diagrams when troubleshooting electrical system on the engine.

A

CAUTION:

circuit, the however,

engine's

INTEGRAL

The Integral Controller (I.e.) is an encapsulated, solid-state . unit that supplies a DC charging voltage to the generator's starting battery while the generator is operating.

A separate group bridge rectifier which converts the AC current to supply the I.C. unit. The I.C. unit senses the needs and supplies a DC charge when one is needed. that the I.C. unit is faulty (that is, low), check the charging circuit and it's components as described in the following steps. Check all connections for cleanliness and tightness including the ground before replacing the I.C. unit.

NOTE:

produce a

the

The IC is mounted inside the generator control box. There is a voltage output adjustment a DC voltage output adjustment

never

engine

to

electrical

-

,-,

Charging Charging

When

low

generator

shut

is

running.

avoid

CONTROLLER

Voltage: Amperage:

the

generator

charging

is

operated.

DC

electrical control circuit that is

or

when servicing the DC

To

avoid

damage

off

the Shut

electrical

engine

off

the

shorts

to

the

battery

engine

when

charging

switch

while

battery

working

switch,

on

circuit.

_(I.C.)

13.0 -14.0 0 -

of

stator windings supplies AC voltage to a

rate.

volts

DC

10-

amps

DC

of

the starting battery

If

you suspect

if

the battery's charge is

is

first

started,

This

on

the controller that will allow

of

charging

± 2 volts.

the

l.

rate

C.

will

unit will

rise

the

as

CIRCUIT

TEST

WITH

THE

ENGINE

RUNNING

To test the battery charger,

positive indicate 13.5V to 14V with the engine running. battery voltage is indicated, check that the battery charger terminal connections are tight. With the unit running, test again between the

If

BATTERY

The minimum recommended capacity the engine's 12-volt Amps (CCA).

Battery

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

(+) and negative (-) leads to the battery.

(+) and (-) terminals for the 13.5V to

no charge is indicated, replace the charger.

SPECIFICATION

Care

put

a multimeter between the

It

should

If

only the

of

the battery used

DC

control circuit is 170 Cold Cranking

BLACK

14Y.

in

(-)

-"

BRIO

TlflER

REC

GE

",-

"--

-'T

_

1#14

f-=

RED

0

(+)

:#14

""~

I

TAN

H

I

BAtTERY

I

CHARGER

,I

I

i

I

(I.C.)I

1..

+

\

i

#14

BLACK

(-)

~DTERMINAL

OARD

6

D Check the electrolyte level and specific gravity with a

D Use only distilled water

D Make certain the battery cable connections are clean and

iw.l!-

"

D Keep your batteries clean and free

A

cause

l?UTPU

T \

IADJUSTMENT

protective

\

1--

28

hydrometer.

to

bring electrolytes

level.

tight to the battery posts (and

WARNING:

severe

______

burns

gear.

Sulfuric

on

skin

--,-

__________

acid

and

to

your engine).

of

corrosion.

in

lead

batteries

damage

to

a proper

can

clothing.

Wear

--1

8

KW

BCDT

.12

VEL/RED

WIRING

\

#41990

DIAGRAM

..J

FUEL

WHi

o

SOlENel

BlK

D

BATTERY

SWITCH

1_

~;:

------ --

:

-~;~oc

~-~

_1:_:..:_:_:.:_.:_:..:_;t~~===~·!l12l...!!!REc!lO_-,

\~

;

STARTER

MOTOR

~~~~~~I~m~

BRIDGE

ECTlfIER -

i1Q

+

~4P

w

~

" '"

..

.

'B

CAPACITOR

'14

___

RED

TRANSFORMER

I

ZJ!A...I!!ll.

U_-+

112

YEL/RED

CURRENT

"'

--

~

w

...

ii

~

.

___

-+_~~~~~

3B

~1J-f'flll'1I';'l

i

~

>

.

1---t=l:::::j=t;~

4---=:::~

116

BlK

BlK~

!W!!..!!...j---+--/~~rr

114

JAN

~

.

1'4

RED/WHT

II.

RED

+

3A

BATTERY

CHARGER

L-+~~~~_-...l

114

REO/VIO

~

I

~;;u

~'plo-~i-!---*--..!lJL.!!l.b.b!!!!""-+---,

..

tJ'

I

IC3

181

•

~

/....!l---!

®

.......

L

~~~~~

I~n

./

----E:

-~

~

'"

~

.

-

1S*=

~~~

../

"""lOW

•

.::I.~VI~O:.....

114

___

~'~I~'~R~EO~~

__

-..!JIIW!6...!B!!.l~K+_+_+_--,

'"

~

.

IB

__

RED

z

w w

..

~

. .

4A

~

...J

~

IA

28

~

....

VIO

re

5

'

n

z

~

ZA

I 2 3 ~ 5 6

GENERATOR

114

BLACK

GENERATOR

CONNECTOR

,

"fIV',WESTERBEKE

I Engines & Generators

29

8

KW

BCOT

WIRING

SCHEMATIC

C I

RCUI

T

BREAKER

r-

____

~~r~-~d~~--~

I

___

J

BlA

K3-PREHEAT

T81-3

r-

________

30

#41990

__

~------o_--_r~

*-

__________________

BATTERY

12

voc

~~--------------~86~

r-

K2-RUN

KI-START

86

K3~PREHEAT

______

~8~6~

RELAY

85

RELAY

85

RED

,.

BATTERY.

,

0

-.f.----

rUSE

BROWN

2.

fUEL

2

0

3A

-,.

futi:A

1

_____ -__

SAFETY

GREY

••

START

•

~,.:..:: -~

L~.:':!'..I~CO."ECTOR

CIRCUIT

BRUMEI

GREEN

..

OILIT[NP

•

)

GENERATOR

BLACK

,.

GROUND

S

)

YEllOW

2.

GLOW

G

0

OIL

SWITCH

WHITE

3 •

LOAD

,

9

PRESS.

eN/C.

BLUE

••

RUN

e

-

)

I

lO<

,g

)0(

"¥¥

r

-- -----

,

1

...

[_~_;:(--Zj

SAFElY

_____

FUEL

-,

-

-"

lO<

~

__ .-"_

-f-

,

-"

,

~-

I

__

~.;

'

-r-

START

SWITCH

r-2.

.E-

~L~

STOP

SWITCH

Engines & Generators

30

~

HOUR

METEI

-

....

ELECTRON

INDICATOR

~

IC

LOAD

I

NOTE:

be

performed

provided

ENGINE

WESTERBEKE

by a competent

to

assist

the

mechanic.

ADJUSTMENTS

recommends

engine

that

the

following

mechanic.

The

i"riformation

engine

adjustments

below

is

GENERATOR

Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (Hertz) during the engine's break-in period (first this period. A no-load voltage adjustment may also be required in conjunction with the engine's speed adjustment. These are not warrantable adjustments as they relate to normal break-in and maintenance.

Frequency is a direct result indicated by the following:

When the generator is output When the generator output

Therefore, to change the generator's frequency, the engine speed

must be changed. To accomplish the frequency

change, perform the following:

1. With the engine stopped, connect the AC output leads to the AC terminal block in accordance with the voltage connection diagram shown here.(This diagram is also affixed inside the control box).

230V

FREQUENCY

of

run

at

frequency is 60 Hertz.

is

run

at

frequency is 50 Hertz.

50Hz

120V

60Hz

ADJUSTMENT

engine/generator speed, as

1800

rpm,

1500

rpm,

1201240V

(HERTZ)

50

hours)

or

the AC voltage

60Hz

after

FUEL

RUN

SOLENOID

The fuel run solenoid is mounted the engine's block injection pump. Proceed as follows replacement

1. Visual access needed. To obtain this, remove the small square side cover and gasket

2. Thread the locknut onto the solenoid and then apply a small amount solenoid.

3. Thread the solenoid into the hole observe the solenoid plunger through the cover opening. Allow the plunger into the injection pump. push the plunger into the solenoid.

4. Back the solenoid out position with the locknut.

5. Properly connect the three electrical leads from the solenoid. Two harness and the third grounds to the engine block at an

adjacent inboard threaded hole with a 8mm bolt.

6. Reassemble the cover and gasket and test run the unit. Make certain that the unit stops when the solenoid is

de-energized.

just

aft

or

new fuel run solenoid.

to

the fuel injection pump's fuel rack is

just

below the fuel injection pump.

of

Teflon sealant to the threads

to

contact the fuel rack and move fully

114 -112

of

the connections plug into the engine

in

a threaded hole

of

and

below the engine's fuel

when

on

the engine and

Do

not

thread further so as to

of

a turn and secure it in

" ,

installing a

on

the

'23456

2.

Start

the engine and adjust the engine's speed to obtain the frequency corresponding to the voltage selected by adjusting the stop bolts and positioning the throttle arm against these stop bolts to either increase engine no-load speed to adjust the Hertz produced.

3. To arrive at the the

spt<ed monitor the frequency with a frequency meter, the latter method being the more precise

"

i

THROTTLE CONTROL LEVER

'

"appropriate frequency, either monitor

of

the engine/generator with a tachometer, or

of

the two.

or

decrease

I

mOM

I

I'

FUEl

FlLTER~

Engines & Generators

31

NOTE:

WESTERBEKE

be

peiformed

provided

ENGINE

by a competent

to

assist

the

mechanic.

ADJUSTMENTS

recommends

engine

that

the

following

mechanic.

The

information

engine

adjustments

below is

DRIVE

Excessive drive belt tension can cause rapid wear and reduce the service life A slack belt or the presence of oil on the belt can cause belt slipping, resulting in high operating temperatures.

The drive belt

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

Adjusting

1.

2. With the belt loose, inspect for wear, cracks and frayed

3. Pivot the idler sheave to the left or right

4. Tighten the pivot bolt anp the adjusting bolt.

5. Operate

BELT

ADJUSTMENT

of

the fresh water pump's bearing.

is

properly adjusted if the belt can be

no

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

as

the belt is depressed with the thumb at the

A

WARNING:

drive

belt's

Loosen the pivot belt that holds the idler sheave and loosen the adjusting bolt.

edges.

loosen or tighten.

the

the generator down and recheck the belt

Never

attempt

tension

Belt

while

Tension

generator for about 5 minutes and then shut

the

to

check

engine

or

is

in

operation.

as

tension.

adjust

required, to

the belt .

112

of

the

TORQUING

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

Tighten the cylinder shown. Make sure the engine is cold when this is done. Before applying the specified torque to the bolt, loosen it to

112 cedure according to the numbered sequence shown in the illustration to the right.

Bolts Bolts #3, 4, 5, 6, Rockershaft Hold

ENGINE

FRONT

THE

CYLINDER

500 hours thereafter, the cylinder head bolts should be

head

of

a tum and then apply the torque. Follow this pro-

#1

and #2, (12rnm socket)(14 - 22 ft-Ib.

7,8

(l4mm

Down

HEAD

BOLTS

bolts according to the sequence

socket) 54 -

Bolts - (12mm socket)

61

ft-Ib

11 -16

TORQUE

DIAGRAM

114

ft-Ib.

IDLER

SHEAVE

ADJUSTING

BOLT

ENGINE

Check the engine's compression pressure at 600 operating hours or whenever engine performance is reduced. Remove

each glow plug and check each cylinder's compression

pressure. The engine's cranking speed is at

Compression values:

The maximum acceptable difference between cylinders is

35.5 psi (3.5 kglcm2).

TESTING

Oil pressure and the load placed pressure problem, remove the oil pressure switch and install a mechanical gauge in its place. After allowing the generator to warm up, read the gauge and it should indicate about psi and steady at 3600 (or 3000) RPM.

COMPRESSION

Standard

397.6 psi (28 kg/cm2)

OIL

PRESSURE

will

vary depending on the engine temperature

on

the generator,

280 rpm.

Minimum

312.4 psi (22

If

you suspect an oil

kg/cm2)

50

Engines & Generators

32

NOTE:

be

ments

is

below

ENGINE

WESTERBEKE

performed

provided

to

by

assist

ADJUSTMENTS

recommends

a competent

the

that

engine

mechanic.

the

following engine adjust-

mechanic.

The

information

Injection

If

your engine's fuel injection timing is not properly adjusted, the engine will not operate properly, and may be start. Have the injection pump delivery rate checked by a well-established fuel injection shop. Adjust the injection follows:

NOTE:

while making injection

Pump

Timing

The

fuel shut-off lever must

the

adjustment or

pump.

Adjustment

be

no

fuel will

(Spill

in

the

RUN position

flow

Timing)

difficlllt to

as

from

the

fuel

1. Remove the high pressure fuel line from between the

No. 1 injector and the No. 1 fuel delivery valve holder.

2. Remove the No. 1 fuel delivery valve holder over

ring and remove the delivery valve spring beneath the holder.

3. Reinstall only the

high pressure fuel line to the delivery holder. Attach it so that the end that would connect to the fuel injector is pointing away from the engine fuel will flow from this line during the timing check.

Rotate the engine's crankshaft in its normal direction rotation to position piston the No. 1 at the beginning compression stroke.

Move the throttle lever to its the electric (as viewed from the front), catching the fuel from the fuel line, until the instant the fuel completely stops flowing (no drips). crankshaft pulley should be directly aligned with the timing indicator

If

the specified injection timing (190 BIDC) attained, adjust the timing thickness ing flange to change the injection timing point. Changing the shim thickness

timing decrease the shim thickness, as required. To retard the timing,

increase the shim thickness, as required. Refer to your gener-

ator's

lift

At

on

the front

of

shim material under the injection pump's mount-

by

approximately one degree. To advance the timing,

Parts List for shim part numbers.

delivery valve holder and reattach the

full open position and operate

pump. Slowly rotate the crankshaft clockwise

this instant, the 190 BIDC

of

the gear case ±

by

increasing or decreasing the

by

0.004 inch (O.Olmm) changes the injection

timing mark on the

.5

degrees.

cannot be

"0"

of

its

No.1

HIGH

PRESSURE

FUEL

LINE

! !

MARK

CRANKSHAtT

ON

pULIEY.

Engines & Generator!!.

33

'TIMING

IPOINTER

..

L

TIMING

MARKS.

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be below

peiformed by a competent engine mechanic. The information

is

provided

to

ADJUSTMENTS

assist the mechanic.

VALVE

NOTE:

engine's valves.

BOLTS.

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

Remove the glow plugs from each the engine to be easily rotated by hand to position each cylinder for valve adjustment.

Valves are adjusted with the piston adjusted at TDC (top dead center)

Valve crankshaft slowly and observe the operation cylinder #1. Watch for the intake valve to open indicating the piston the cylinder). Continue to rotate the crankshaft slowly and look for the intake valve to close. This indicates the piston is now starting it's compression stroke (the piston is moving up in the cylinder towards TDC).

Align the TDC mark on the crankshaft front pulley with the timing marker on the front gear case cover when positioning

the

by rotating the crankshaft approximately

and after this point and the two valves for the should not move.

CLEARANCE

Retorque the cylinder head bolts before adjusting the

A

WARNING:

engine

is

cold.

firing

order

of

bolts

to

the

specified

adjustment

is

on it's intake stroke (the piston

#1

Piston at TDC

ADJUSTMENT

See TORQUING

Adjust

Valves

are

the

engine.

torque

beginning with cylinder

of

it's compression stroke. Confirm this

the

valve

adjusted

Tighten

before

TIlE

clearance

the

of

in the cylinder being

of

VALVE

CYLINDER HEAD

by

cylinder

adjusting

the cylinders to enable

its compression stroke.

#1.

of

is

moving down in

20 degrees before

#1

CLEARANCE

when

the

in

the

head

the

valves.

Rotate the

the valves for

cylinder

Re-install the glow plugs (use anti-seize compound on the threads) and assemble the rocker cover and rocker cover

belts. See the TIGHTENING TORQUE SCHEDULE in this

manual.

TESTING

Remove and check fuel injectors. The injector spray pressure

should be 1991 psi ± 142 psi (140 kg/cm2

Undesirable injector conditions, to include after dripping,

should be eliminated.

NOTE:

performed

FUEL

INJECTION PRESSURE

Fuel

injector in a clean

INJECTORS

TEST

testing

must

room

be

environment.

AFTER

DRIP

TEST

±1O

kg/cm2).

!

SHIM

·O.1mm O.2mm O.3mm O.Smm

THICKNESS

WI

GOOD

CHATTERING

For the chattering test, operate the tester level slowly.

nozzle sprays sharply and intermittently, the nozzle is consid-

ered good. The nozzle should spray fuel straight

direction. A nozzle is defective direction, in several separate strips, or in the form particles. These defects may sometimes be caused by clogging with dust, therefore all parts should be cleaned carefully before reassembly

TEST

,BAD

if

it sprays fuel in a wrong

If

the

in its axial

of

Adjust the valves in Proceed to the #2 cylinder. Rotate the crankshaft 240 degrees in normal direction

rotation and adjust the #2 cylinder.

Adjust each valve's clearance by inserting a

(0.2Srnm) feeler gauge between the rocker arm and the valve

stem. Make sure to adjust all valves while the engine is cold.

#1

cylinder for both intake and exhaust.

0.010 inch

of

Engines & Generators

34

ENGINE

TROUBLESHOOTING

The following troubleshooting table describes certain problems

relating to engine service, the probable causes

of

these prob-

lems. and the recommendations to overcome these problems.

Start

switch

panel

Start engagement.

START indications fuel

Generator start,

Battery

Generator

depressed,

indications.

switch

depressed,

switch

OK;

solenoid

engine

fuel

solenoid

runs

down.

not

charging

engine

Problem

is

depressed;

starter

solenoid

not

functioning.

cranks,

energized.

stops.

no

but

start,

starter

panel

OK

does

no

not

Probable

1.

Battery

Switch

2.

20-Amp

3. 1 O-Amp preheat

4.

Loose

battery

Preheat

5.

1.

Connection

2.

Faulty

switch.

3.

Faulty

solenoid.

4.

Loose

battery

5.

Low

battery.

1.

Poor

connections

2.

Defective

Faulty

Preheat Low

Oil

Pressure

High

Low

Poor

Battery DC

Faulty Fuel

2.

Switches or

disconnected.

3.

Fuel

4.

20

Amp

Exhaust

5.

Water

6.

7.

Air

fueling

battery.

resistance

battery

charge

battery

lift

starvation.

in

intake

1.

2.

3.

1.

2.

3.

4.

5.

1.

2.

1.

not

circuit

breaker

solenoid.

connections.

solenoid

to

solenoid

connections.

fuel

solenoid.

system.

solenoid

switch.

leak.

connections.

charger

circuit

charger.

pump

failure.

and/or

circuit

breaker

system

fuel.

obstruction.

Cause

on.

tripped.

tripped

not

operating.

faulty.

to

fuel

faulty.

leak

to

not

charging

faulty.

wiring

is

restricted.

on

solenoid.

ground.

loose

tripping.

Note:

The engine s electrical system is protected by a 20 amp

manual reset circuit breaker located on a bracket at the rear of

the engine.

Verification/Remedy

1.

Check

switch

and/or

battery

connections.

2.

Reset

breaker;

if

breaker

trips

again,

check

circuit

and

check

circuit

for

shorts

3.

Check

voltage

at

and

after

breaker

4.

Check

(+)

engine

5.

Check

1.

Check

2.

Check

3.

Check

4.

Check

5.

Check

1.

Check

2.

Check

fuel

Check

1. 1a.

Switch

1

b.

Check

1

c.

Fuel

2.

Check

3.

Switch

3a.

Replace

1.

Observe running.

2.

Check lines. after

3.

Check

4.

Check corrosion.

..

5.

1.

Check

2.

1.

2.

3.

4.

5.

6.

7.

connection

ground solenoid connection.

switch that

12

battery battery

connections. that

run

solenoid.

that

fuel

to

combine

batteries.

lift

pump

solenoid.

to

combine

batteries.

if

panel

Test

Wiring.

(Do

not

short

all

wires

cable

connections,Test

Pertorm

D.C.

Replace

charger.

Fuel

lift

pump

with

Inspect

wiring

Inspect

switches

Check

fuel

Check

for

Ensure cause

Check exhaust

Pump bleed

Check

high

breaker

tripping.

for

blockage,

elbow.

water fuel

system.

air

intake

12

is

spare.

supply,

to

starter

stud.

Check

"S"

terminal

with

ohmmeter.

volts

are

present

connections. charge

state.

volts

are

present

valves

are

house

at

injection

all

batteries.

lights

are

the

oil

pressure

Insert

sensitive

start

engine.)

located.

for

temperature

connections

battery

voltage

check

should

make a distinct

for

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

from

fuel

tank(s);

filter

cartridge.

solenoid

battery

for

voltage.

at

open. and

start

pump

activated

switch.

(0 -.25

Remove

rise

at

battery

charger

of

generator

and

operation.

fuel

draw

sensitive

hose,

change

may

preheat

to

ground.

on

preheat

and

cable

connections.

the

solenoid

the

(+)

connection

batteries.

be

clogged.

when

engine

amp)

connections

to

locate

for

loose

in

control

charging

ticking

loose

connections.

lift

pump.

during

operation.

to

heat

carbon

filters

solenoid.

(-)

connection

connection.

is

meter

in

and

the

fault.

connections,

box. circuit.

sound.

which

buildup

and

solenoid

on

the

not

battery

replace

Replace

would at

to

Engines & GefJerators

35

ENGINE

TROUBLESHOOTING

Generator

Low

oil

pressure.

Exhaust

smoking

Problem

engine

overheats/shuts

engine

shuts

problems

down,

down.

1.

2.

1.

2.

1.

2.

3.

Probable

Raw

water

Coolant

Loss

of

Oil

pressure

Blue

smoke.

White

smoke.

Black

smoke.

not

circulating.

oil.

switch.

Cause

circulating.

VerificationJRemedy

1.

Raw

water

pump

2.

Obstruction

2a.

Thermostat -remove Replace

2b.

Loss for

2c.

Broken

2d.

Air

bleed Check

1. oil

2.

Replace

1.

Incorrect

1a.

Crankcase

through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel insufficient exhaust

3b.

Improperly

3c.

Lack ventilation.

3d.

Overload.

?t

thermostat.

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add

coolant

dipstick,

drain

hose

connection.

oil

pressure

grade

is

overfilled

the

exhaust).

is

running

injector

grade

burn

incomplete

air

system;

timed

of

air -check

failure.

Check

impeller -replace.

raw

water

intake

or

raw

and

test

in

hot

hoses,

hose

belts -tighten/replace.

run

engine

and

open

needed.

leaks

at

oil

oil.

engine

oil

injector

timing.

to

high

back

combustion

intake.).

or

valves

and

air

or

filter.

look

of

engine

cold.

or

incorrect

of

fuel.

for

proper

check

injectors

as

for

oil

switch.

with

due

air

intake

water

filter.

water. clamps,

the

pressure

filter

and

(oil

is

blowing

pressure

(Check

poor

compression.

Check

drain

plug,

at

in

exhaust

for

restrictions

for

etc.

cap

to

out

proper

or

in

Engines & Generators

36

SHORE

If

the installer connects shore power to the vessel's AC

be

done

by

means

of

circuit, this must

Transfer Switch

diagrams to the simultaneous connection

A

CAUTION:

utility

at

the

covered

sibility

Switching

A

CAUTION:

before

vice-versa ing

with

may

cause

the

generator.

120

VOLT/GO

..

Set the transfer switch shown in the

OFF

Damage

shore

power

same

time.

under

the

to

make

Shore

Heavy

switching

because

heavy

AC

damage

HERTZ

position. This switch prevents

and

This

warranty;

sure

Power

shore

voltage

loads

to

of

shore power to generator output.

to

the

generator

type

of

all

AC

connections

to

motor

power

surges

on

the

exciter

TWO

WIRE

the Shore Power

generator

output

generator

it

is

the

Generator

leads

should

to

generator

induced

vessel

circuit

CONFIGURATION

POWER

can

result

are

connected

damage

installer's

are

correct.

Power

be

shut

power

by

being

operated

components

if

is

not

respon-

off

or

switch-

TRANSFER

230

VOl.T/50

G

Z

IU IU

a::

o

in

SWITCH

HERTZ

,..----7----\-(3

~

SHORE POWER

230V

IU

....

i

3:

50HZ

TWO

N

l1

:.:

(,)

...

'"

..

'----'Y1

WIRE

CONFIGURATION

GENERATOR I SHORE

SWITCH

1'''-

.......

,

.~

I I

2 I

" /

....

_...-

'::' SHORE

GROUND

PH

32133

Ll

~N

_

SHIP'S

- GROUND

SHIP'S

LOAD

Generator

~

r

"L

__

,j

I "

~

co

;:

L---4-4--+</;ID9

" ,

~

Z

~

Shore

Power

NOTE:

Diagram

shows-

wire,

120-Volt

~W_it-,h_th_r,,_e-_Wir.'120-VOlt

I 7

~-,

'\

I

"!"+--t--:';"::'::':="

I

__

r;

//

Ground

(GRN)

connections

system from the generator,

'----.L1

Neutral

__

(WHT)

boat

system.

L2}

N Ships

!I'

for a

two-

Load

NOTE: No

240-Volt

Equipment

Ship·

to·

Shore

PN (40Amps!Pole)

rto

PN (125

PN (200Amps/Pole)

Switch

32008

~~~~~

Pole)

32010

Amps!

Pole)

32133

; Shore power transfer switches are

available from your WESTERBEKE dealer.

(3

Pole)

Engines & Generators

37

USE

OF

ELECTRIC

The

power

required

than

is

required require (Ae)

motors circumstances, easy-starting applied Because run,

their

motor

is repulsion-induction current varies

with to

an

air

motor

to

In

general,

to

medium

MOTOR

(HP)

*NOTE:

more

for

this

is

that

larger

sizes.

Because required can

bring experienced and,

if

possible,

to

much

more

require

than

loads,

after

the

motor

they

require 5 to 7 times

use

should

to

be

driven

to

start

as

to

the

load

compressor,

which

no

the

current

starting

SIZE

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

1

In

the

above

some

small

the

hardest

the

heavy

for

only

an

the

motor

in

starting

reduce

MOTORS

to

start

keep

it

running

current

more

current

other

types.

such

as

is

started,

be

avoided,

by a small

motors

run.

The

connected

for

example,

load

is

connected.

required

loads

will

AMPS

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2

table

motors

starting

surge

of

instant,

up

to

speed

motors,

the

an

electric

after

to

start

them

to

They

washing

such

as

whenever

generator.

require

from 2 to 4 times

current

to

it.

will

to

start

be

approximately

FOR

13

the

maximum

than

for

types

current

the

generator

in a few

tum

load

on

GENERATOR

motor

is

it

is

started.

than

start,

under

are

commonly

machines,

as

small

much

current possible,

Capacitor

required

An

electric

require

1I5-Volt

Amps

larger

ones.

(split-phase)

needed

for

will

seconds.

off

all

other

the

electric

considerably

others.

similar

or

where

power

to

start

motor

more

motors

as

follows:

AMPS

STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4 26

for

Starting

The

are

starting

not

be

If

electrical

motor.

Some

motors

Split-phase

used

on

loads

tools.

start

as

if

the

electric

and

as

much

any

motor

connected

current

connected

FOR

to

22.4*

to

32.2*

to

72.8*

to

29.2*

to

40.8*

to

52

reason

not

made

motors damaged difficulty

loads

more

than

is

INFORMATION

to

for

are

in

is

if is

GENERATOR

Frequency

by

the

•

When output

•

When output

Therefore, drive

engine's

of

the

GENERATOR

•

a

Maintaining Connections corroded, salts, up. heating

•

For petroleum

all

•

In inspected overheated

Carbon

WESTERBEKE detector even

The from

it

exhaust entering

If

carbon

air

following:

AC

surfaces

addition

presence

and

FREQUENCY

is a direct

the

generator

frequency

the

generator

frequency

to

change

speed

output

connections

MAINTENANCE

reasonable

of

and

dust,

engine

Clogged

unusually

and

reduce

based

to

for

terminals

ventilation

tightness

Monoxide

in

the

vessel's

in

small

amounts,

of

the

engine

hose,

or

your

boat.

monoxide

correct

ADJUSTMENT

result

of

engine/generator

is

run

at

3600

is

60

Hertz.

is

run

at

3000

is

50

Hertz.

the

generator's

must

be

terminal

insulation

exhaust,

life

severe

conditions,

coatings

reduce

rusting

periodic

and

of

frequency,

changed

at

the

generator.

cleanliness

boards, surfaces

carbon,

openings

of

windings.

should

and

cleaning,

all

connections,

loose

or

along

relays,

may

thin

be

corrosion.

the

damaged

Oetector---------.

recommends

carbon

or

generator

that

fumes

is

the

problem

mounting a carbon

living

quarters.

is

deadly.

monoxide

or

from a nearby

present,

ventilate

immediately!

indicates

from

speed,

rpm,

the

AC

voltage

rpm,

the

AC

voltage

the

generator's

with a reconfiguring

is

important.

etc

may

become

start

conducting

etc.

are

allowed

cause

excessive

rust-inhibiting

sprayed

the

or

generator

evidence

wires.

Carbon

an

exhaust

vessel

the

area

brushed

should

monoxide,

exhaust

elbow/

are

with

as

indicated

if

to

build

over

be

of

monoxide

leak

clean

REQUIRED

Run

the

ator's

capacity,

on

the checked plant

and

meter

portable

NOTE:

tains

AC

generator's

volt

AC

good

motor

OPERATING

generator

and

generator's

periodically

the

appliances

is

not

installed

meter

and

When

the

equipment

AC

terminal

hot

leg

for

starting

first

with

finally

data

plate.

to

ensure

to

monitor

amprobe.

vessel

of

120

the

vessel's

response

no

loaded

The

it

supplies.

in

which

volts

block

from

SPEED

load

applied,

to

its

full

output

proper

operation

If

an

voltage

the

generator

only,

it

is

be

configured

distribution

the

generator.

then

at

capacity

voltage

should

of

the

AC

voltmeter

and

load,

check

is

installed

recommended

to

provide

panel.

This

half

the

as

indicated

be

generating

or

it

that

one

will

gener-

amp-

with

a

con-

the

120

ensure

Engines & Generators

38

GENERATOR

TROUBLESHOOTING

Problem

Alternator

High (over

Low (under

Proper but

Unstable

excitation

no-load

135V)

no-load

110V)

no-load

low

voltage

failure

voltage

under

load.

Probable

1.

Low

engine

2.

Faulty

3.

Faulty

1.

Engine

2.

Capacitor

1.

Engine

2.

Faulty

3.

Break

4.

Capacitor

1.

Low

loaded

2.

Overload.

3.

Rotating

1.

Loose

2.

Uneven

Cause

speed.

capacitor.

windings.

speed

too

rating

speed

too

rotating

diodes.

down

in

windings.

rating

engine

diodes

contacts.

rotation.

high.

is

too

high.

low.

is

too

low.

speed.

short-circuited.

Remedy

1.

Check

rpm

3700

rpm

(3100

rpm

2.

Check

and

3.

Check

the

Stator

0.65

Rotor

3.90

Excitation

1.

Check

and

2.

Check/replace

1.

Check

and

2.

Check/replace.

3.

Check

windings

4.

Check

and

1.

Dirty

fuel

filter;

2.

Check

the

3.

Check/replace.

1.

Check

connections.

2.

Check

for

and

set

at a nominal

without a load

for

50

Hertz).

replace.

windings'

ohms

2.60 adjust

adjust

replace

load

uniform

resistance

ohms

rpm.

capacitor.

rpm.

resistance

from

replace. indicator.

rotation

for

as

16

to

speed

value

60

Hertz

as

follows:

25

mF.

(dirty

of

fuel

filter).

Noisy

generator

1.

Broken

2.

Loose

bearings.

coupling.

1.

Replace

2.

Check

bearings.

and

repair

coupling.

Engines & Generators

39

LAY-UP

AND

RECOMMISSIONING

GENERAL

Many

owners

rely

on including or lay-up

The lay-up if

These lay-up of

If local assistance.

LUBRICATING

With Fill to

an for

A

FUEL

Top as and used used

.

filter/water arator leaks.

Change

SYSTEM)

and left

~reated

needed. movement the

engines

for

long

periods

preparation

procedures

and

others

procedures

and

your

you

have

servicing

the

SPECIFICATIONS

API

proper

which

recommissioning,

do

the

procedures.

also

help

engine/generator.

any

questions

dealer;

engine

sump

with

specification

oil

pressure

Caution:

oil

in

the

sump combustion chemicals internal

deposits

which

parts.

SYSTEM

off

your

fuel

Biohor

and

Sta-Bil

condition

are in

allow

in

engine.

compatible

the

system.

separator, sediment Clean

up

the

fuel and it

to

the

fuel

in

the

Operate

of

the

bowl. any

bleed

run

system.

fuel

and

of

themselves.

should

SYSTEM

warm,

the

00

over

tanks

fuel.

filter

for

system

the

treated

their

boatyards

generators,

inactivity.

follow

will

or

afford

familiarize

regarding

he

will

drain

all

correct

section

of

CF

or

and

make

not

leave

the

lay-up

combine

can

reduce

with

No.2

should

be

Care

should

with

the

primary

Change

the

if

the

fuel

Reinstall

spilled

fuel.

elements

the

fuel

system,

5-10

minutes

Check

during

engine

for

fuel

through

for

Others

allow

you

your you

lay-up

be

more

the

engine

amount

of

CG-4.

sure

the

period.

to

the

diesel

added

filter

system

and

on

the

for

any

this

5-10

to

prepare

lay-up

prefer

you

may

use

engine

with

the

procedures,

than

willing

oil

of

oil

this

manual).

Run

the

there

are

engine's produce

life

of

fuel.

at

this

be

taken

fuel

filter/water

element

has

one,

make

certain

engine

as

needed.

to

make

leaks servicing, minutes. the

injection

their

craft,

during

the

to

accomplish

to

perform

them

as a check

protection

maintenance

to

provide

from

the

for

your

engine

Use

engine

and

no

leaks.

old

engine

Engine

oil

harmful

your

engine's

Fuel

additives

time

to

control

that

the

additives

separator

in

your

primary

and

clean

there

(see

FUEL

Start

the

sure

there

that

may

have

correcting

This

will

equipment

off

season

your

during

needs

call

your

oil

sump.

an

oil

check

and

the

are

no

engine

is

no been them

allow

own

list

(refer

with.

such

algae

fuel

sep-

air

of

as

RAW

WATER

Close

the

from

the

fresh

water.

Start

the

through

and

than

Start through engine. circuit corrosion

Remove mixture impeller. Do recommissioning,

refill

needed

the

from

not

replace

the

the This

will

THROUGH-HULL

Place a clean of

the

through-hull

the

cloth

an

attempt assistance cloth

prior

CYLINDER

To

protect

cover.

Then opening. Spray

fogging

box

side

COOLING

through-hull

fitting.

Clean

engine

system.

the

bucket

for

engine

raw

antifr-eeze

freezing

protection.

the

impeller

accompany

Acquire a replacement,

Place

the

and

winter

and water

the

impeller

but

fitting. the

raw

allow

When

with

freeze

allow

system.

mixture

during

from

replace

EXHAUST

cloth,

lightly

exhaust

out

of

sight

(if it

is

made

to

start

of a

servicing

to

start-up.

AND

VALVES

the

cylinder

spray

Rotate

cover.

the

oil

and

fogging

engine

into

the

CIRCUIT

Remove

end

of

water

the

raw

the

bucket

an

antifreeze

protection in

all

of

Once

the

your

it,

so

catch

(into

the

soaked

to

block

is

not

the

engine,

dealer).

valves,

oil

into

two

air

intake

the

this

hose

strainer.

water

pump

is

empty,

solution

this

mixture

the

bucket

should

protect

winter

lay-up,

raw

water

it

in a

if

needed,

the

pump)

cover

and

in

lubricating

the

opening.

visible

at

you

Make a note

remove the

cylinder

revolutions

again.

raw

water

intake

into a bucket

to

stop

slightly

your

to

be

the

as

pump bucket).

and a cover until gasket.

recommissioning,

may

need

to

the

control

head

using

Replace

draw

the

area.

drawn

is

empty,

raw

well

(some

Examine

oil,

in

Do

the

remove

air

the

of

fresh

engine

stronger

stop

water

as

providing

antifreeze

gasket.

the

opening

not

shove

the

box

intake

hand

control

hose

clean

water

the

and

side

crank.

Engines & Generators

40

LAY-UP

AND

RECOMMISSIONING

STARTER

Lubrication Make to

remove

electrical

CYLINDER

If

you Westerbeke the

cylinder,

to

prevent

After

Make sealing

GENERATOR

Remove AC

terminal making corroded, Make Make they

SPARE

Lay-up Westerbeke or

coolant and during

MOTOR

and

cleaning

sure

the

battery

the

starter.

connections

LUBRICATION

anticipate a long

recommends

then

the

piston

squirting

sure

you

washers.

the

have

END

the

control

block

sure

they

should

sure

all

AC

sure

all

AC

exit

the

generator

PARTS

time

provides a good

generator

hoses

need

order

items

not

the

lay-up,

squirting

rings

oil,

replacements

box

and

are

leads leads

on

such

BATTERIES

Ifbatteries

sure

them

remain enviromnental warmer,

they

from

are

full

more

are

to

be

fully

freezing.

charged,

conditions,

compatible

left

charged,

or

of

the

starter

connections

Take

care

removed

secure.

be

to

replacement.

If

from

lay-up

period

removing

light

from

move

the

cover.

those

running

Should

removed,

are

properly

are

properly

housing.

opportunity

see

if

external

hand,

or

as

filters.

on

board and

there

is

that

they

remove

enviromnent.

sticking

Check

any

drive

are

shut

in

properly

the

starter.

(12

the

fuel

lubricating

to

piston

by a quick

for

the

all

to

the

these

cleaned

cleaned supported

items

Check

replace

those

See

SPARE

during

will

remain

doubt

will

be

subjected

the

batteries

pinion

offbefore

replacing

months

or injectors oil

into

the

cylinder

injector

and

wire

connections

bridge

connections and

reconnected.

and

reconnected

and

to

inspect

such

your

basic

items

PARTS.

the

lay-up

that

way,

the

batteries

and

is

advisable.

attempting any

more)

for

access

the

cylinders walls.

electric

return

rectifier,

appear

not

chafing

your

as

the

spares

used

period,

to

prevent

will

to

severe

store

start.

line

on

drive

make

not

them

kit

to

the

as

belt

in

RECOMMISSIONING

The

recommissioning seasonal described section However, counteracted

1. Remove the oil-soaked cloth from the through-hull

2. Remove the raw water pump cover and gasket and

3. Reinstall the batteries that were removed during the

lay-up

in

the

regarding

some

before

exhaust port.

discard the old gasket.

NOTE:

It

solution

from

is

put

into

period

of

time

Install the raw water pump impeller removed during lay-up (or a replacement, water pump cover with a new cover gasket.

lay-up, and reconnect the battery cables, making sure the terminals are clean and that the connections

Check to make sure that the batteries are fully charged.

A

Caution:

and

eye

acid

batteries

which

can Cigarette, open

name

all

electrical

4. Start the engine in accordance with the procedures

described in the

START-UP

a

of

your

WESTERBEKE

generally

PREPARATIONS

of

is

not

operation,

protection

arcing

section of this manual.

follows

preparation

the

starting

necessary

the

with

lay-up

raw

the

no

Wear

for

procedures

the

water

system

adverse

rubber

when

emit

hydrogen, a highly

be

ignited

cigar

near

or

the

by

pipe.

battery

equipment

during

PREPARATIONS

the

FOR

starting

engine.

to

flush

coolant

if

required). Install the raw

servicing

electrical

Do

in

servicing.

same

INITIAL

and

will

the

system.

will

self-flush

eifocts.

gloves, a rubber

not

smoke

being

the

vicinity

FOR

generator

procedures

normal

need

antifreeze/fresh

as

START-UP

starts.

to

be

When

the

in a short

are

tight.

apron

batteries.

Lead

explosive

arcing

or

a

lighted

or

allow

serviced.

to

prevent

INITIAL

Shut

after

thpse

water

engine

gas,

an

a

off

STORAGE

Thoroughly generator

in

clean

a

dry

the

outside

place,

of

the

protected

generator,

against

the

then

store

weather.

the

Engines & Generators

41

8.0

KW

BCDT/7.0

KW

BCDT

GENERATOR

SPECIFICATIONS

Engine

Type

Governor Combustion Bore and Piston Direction Compression Maximum Dimensions

Dry Sound

Max.

Compression Valve Valve

Engine

Injector

Lubrication Lubricant Operating

(engine Oil

Fuel Fuel Fuel Fuel

Nozzle Fuel

(full Fuel AirAow

(engine

System

Stroke

Displacement

of

Rotation

Ratio

Torque

Weight

with

Guard

Angle

of

Seat

Angle

Clearance

Timing

Pressure

System

Capacity

Oil

hot)

Grade

System

Lift

Pump

Injection

Consumption

load)

Filter

combustion)

ENGINE

Operation

SPECIFICATIONS

Diesel, vertical,

Mechanical,centrifugal Direct

2.98-x

38.75 Clockwise, 23:1

30.0 Height:

Width:

Length:

371

25°

TUNE-UP

Pressure

398 Intake I

ntake

0.010 25° 1991

LUBRICATION

Pressure

3.0

Pressure

15.0

API

SAE

FUEl

Open No.2 4

ft.

Pump

Bosch Throttle

1.08

Replaceable

40.6

four-cycle,

Injection

2.76-

cu.

ft/Ibs

Ibs

continuous,

in-line

in.

(0.635

when

(4.15

23.8-

19.0-

28.3-

(168.4

two

cylinder,

overhead

(76

mm x 70

liters)

viewed

kg-m)

(605.3 (482.6 (717.6

kg)

30°

raw

valve

mechanism

weight

type

mm)

from

the

mm) mm) mm)

intermittent

front

SPECIFICATIONS

psi

(128

kg/cm')

at

280

rpm

45°;

Exhaust

45°

and

Exhaust

in

(0.25

mm)

engine

cold

± 1 °

BTDC

static

psi

(140.0

kg/cm')

SYSTEM

driven

by

trochiod

pump

U.S.

gal.

(2.8

liters)

-45.0

psi

(1.0 -3.1

kg/cm')

speCification

30,

10W-30,

CF

or

CG-4

15W-40

SYSTEM

flow,

self-priming

diesel

oil,

cetane

rating

of

45

(1.22

m)

lift

max

type

U.S.

galJhr.

(4.09Iiterlhr.)

cfm

filter-spin

(1.1

on

cmm)

water

or

higher

cooled,

Cooling

System

Operating Raw

Raw at

Raw

Capacity

Emission Exhaust

Electrical

Battery Starting Cold

Voltage

Temperature

Water

Pump

Water

Flow,

3600

rpm

Water

Connection

Control

Systems

Elbow

Connection

System

Charging

Motor

Cranking

Amps

Electromagnetic Interference

DC

General

Voltage Frequency Rating

Insulation

Cooling Air

(60 Note: Engine

Requirements Generator

Ambient Recommendations

Temperature

Level

No-Load

Current

Regulation

(Volts

AC)

Requirements

Hertz

at

3600

rpm)

Increase

air

Combustion

Compartment

Temperature

Rise

COOLING

Fresh

thermostatically

170 -190°F Positive

gear-driven,

11.1

112

2.9

EXHAUST

Meets 2,in

SYSTEM

water-cooled

displacement,

gpm

(42Ipm)

in

(12.7

qts.

(2.7

SYSTEM

U.S.C.G.

(50.8

mm)I.D.

ELECTRICAL

12

volts

DC,

(except

when

4-5

amps

12

volt

solenoid,

125

amps @ 805

Exceeds

requirements

radiotelephones 100

amps@11.5v(3000

AC

GENERATOR

Brushless lubricated capacitor

120 230

Standard ± 7% 3Hz 60Hz

50Hz -230 Class H as

two single

regulation.

volts -60 volts -50

(5%)

no-load

-120

GENERATOR

Raw

water

450

cfm

(12.74

supply

15%

for

Hertz

Air

60

Hz

-15.397

50

Hz-12.819

Note:

Forced

to

maintain

temperatures

Within

NEMA

block,

controlled

(77 -88°C)

self-priming

mm)

Liters)

rubber

I.D.

Regulation

SYSTEM

negative

ground

starting)

actuated

rpm

minimum for

and

standard

pole,

revolving

bearing

design.

hertz

(3600

hertz

(3000

no-load

to

full-load

volts;

66.0

30.4 by

amps amps

NEMA

volts;

defined

COOLING

cooled

cmm)

operation

3000

ft'/min

(0.436

ft'/min

(0.363

ventilation

generator

below

MGI-22.40

should

compartment

140°F

operating

impeller,

33

CFR

183

shift

most

marine

TVs

rpm -minimum)

field.

Sealed

Single

phase,

rpm) rpm)

full-load

MGI-1.66

rpm

ma/min) ma/min)

be

provided

(40°C)

at

full

load

Engines & Generators

42

REVISED

APRIL

2002

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

1

Minute

of

Latitude

Latitude = 60

VOLUME

Cubic

Inches

(in3) x 16.387 = Cubic Imperial Imperial Imperial Imperial

Imperial Fluid US

US

Pints

(IMP

Quarts

(IMP Gallons Quarts

(IMP Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds

Per

Sq

In

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

Nm = 111.120

= 1

Nm = 1.852

pt) x .568 = Liters

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kilopascals

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

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

(H20) x .248 = Kilopascals

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts

(US

qt) x .833 = IMP

Gallons

(US

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kPa) x .145 = psi

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026=

3

=in

pt

qt

gal

qt

gal) x .833 = IMP

H20

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

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

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

gallon = 6.1

US

(in-I

b) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L) x 2.352 = US

(OF) = (OC X 1.8) + 32

gallon = 7.131bs

gallon = 8.33

gallon = 8.56

Ibs

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

Engines & Generators

43

METRIC

INCHES TO MILLIMETERS MILLIMETERS TO INCHES

Inches

1 25.40 2 3 4 101.60 30 5

10 254.00

10

Inches

1 0.0254 7 0.1778 2 3 4 5

,6

TO

Yards

1 2 3 4 5

mm

50.80 20

76.20 25 635.00 3

127.00 35

MILLIMETERS

Inches

15 381.00 1 0.0394

40 1016.00

= 1

CENTIMETER,

INCHES TO METERS METERS TO INCHES

Meters

0.0508 8

0.0762

0.1016

0.1270

0.1524

CONVERT

METERS

Inches

9 10 11 12

TO

CENTIMETERS,

YARDS TO METERS METERS TO YARDS

Meters

0.91440 6

1.82880 7 6.40080 2

2.74320 8

3.65760 9

4.57200

MOVE

DECIMAL

Yards

10

POINT

FOR

HIGHER

CONVERSIONS

(3.3

FEET)

RIGHT

YARDS

Inches

0.5906

0.7874

1.1811

1.5748

Inches

43.307

Yards

6.56168

7.65529

8.74891

9.84252

10.93614

mm

508.00

762.00

889.00

100

CENTIMETERS

Meters

0.2032

0.2286 0.3

0.2540 0.4 15.748 1.0 39.370

0.2794 0.5 19.685

0.3048 MOVE

Meters

5.48640

7.31520

8.22960 4 4.37445 9

9.14400 VALUES -e.g.

mm

2 0.0787

4 5

10

= 1

Meters

0.1

0.2

0.6

DECIMAL

Meters

1 1.09361 6

3

5

Inches

0.1181 25 0.9843

0.1575

0.1969 35 1.3780

0.3937

METER = 39.37

Inches

3.937 0.7 27.559

7.874

11.811

23.622 1.2 47.244

POINT

TWO

Yards

2.18723

3.28084

5.46807

6,000

METERS = 6,561.68

mm

15 20

30

40

INCHES

Meters

0.8 31.496

0.9 35.433

1.1

PLACES

TO

Meters

10

THE

7

8

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Ib

1 0.454 2 3 4 1.814 9 5

kg

:I

0.907

1.361 8

2.268

GALLONS TO LITERS

Gallons

1 3.79 2 3

4 15.14

5

Liters

7.57

11.36

18.93

PINTS TO LITERS

Pints

1 0.47 6 2 3 4 1.89 9 5

32

0

Liters

0.95

1.42 8

2.37

40

I

50 60

I

I I I I I I I I

5

10

Ib

6 2.722 1 2.205 7 3.175

10

kg

3.629

4.082 4 8.818

4.536

kg

2 3

5

LITERS TO GALLONS

Gallons

10 20 75.71 2 0.53 30 40 50

Liters Liters

37.86 1 0.26

113.57

151.42

189.28 20 5.28 180 47.54

5 1.32

10

Gallons

LITERS TO PINTS

Pints

7 3.31 2 4.23

10

Liters

2.84 1

3.79

4.26 4 8.45 9

4.73

Liters

3

5

TEMPERATURE

70

75

85

95

105

I I I I I I

15

20

25

30 35 40

Ib

4.409

6.614

11.023

2.64 150 39.62

Pints

2.11

6.34 8

10.57

140

kg

6 7 8 9

10

Liters

60 90

120 31.32

Liters

6 7 14.79

10

13.228

15.432

17.637

19.842

22.046

Gallons

15.66

23.77

Pints

12.68

16.91

19.02

21.13

175 212

I I I

60

80 100 °C

Ib

OF

Engines & Generators

44

BOLT

HEAD

Bolt

strength

Customary

(inch) (strongest), Le.; a grade

MARKINGS

classes

are

embossed

bolts

are

The

marks

correspond

seven

bolt

will

Use

the

torque

These

torques

Reduce

torques

on

identifed'by

to

two

display

five

values

are

based

by

30%

the

head

of

markings

marks

embossed

listed

below

on

clean,

or

more,

STANDARD

each

bolt.

two

to

grade

eight

less

than

the

actual

grade,

marks.

when

specific

torque

dry

threads.

when

Reduce

threading

capscrews

HARDWARE

Metric

bolt

class

strongest.

values

torque

into

are

not

by

10%

aluminum.

numbers

available.

when

engine

identify

oil

is

·used.

bolts

by

their

strength

with

10.9

the

STANDARD

Capsrew

Body

1/4

-

5116

-18

-24

318

-16

-24

7/16

-14

-20

112

-13

-

9116

-12

-18

518-11

-18

314-10

-16

7/8-

-14

1- 8

-14

Formula

Size

20 28

20

9

(Inches) -(Thread)

MOTE:

BOLT & NUT

3AE

Grade

5

Torque

Ft-Lb

(Nm)

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(47)

49

(66)

55

(75)

75

(102)

85

(115)

110

(149)

120

(163)

150

(203)

170

(231)

270

(366)

295

(400)

395

(536)

435

(590)

590

(800)

660

(895)

to

convert

Ft-Ihs

TORQUE

SAE

Grade

Torque

Ft-lb

,

10

19

34(46)

55

85

120

167

280

440

660

. ,

to

Nm

SPECIFICATIONS

6-7

(Nm)

(14)

(26)

(75)

(115)

(163)

(226)

(380)

(597)

(895)

(Newton

SAE

Grade

Torque

R-Lb(Nm)

12 14

24

27 44

49

70

78

105 120

155

170

210 240

375 420

605 675

910 990

Meters)

8

(16) (19)

(33) (37)

(60) (66)

(95) (106)

(142) (163)

(210) (231)

(285) (325)

(508) (569)

(820) (915)

(1234) (1342)

multiply Ft-Ihs

METRIC

Bolt

Dia.

Wrench

M3

5.5mm

M4

M5

MB ' 10mm M9

Ml0

M12

M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

by

7rrim 8mm

13mm 16mm

lBmm 21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

1.356 .

BOLT & NUT

Grade

Size

R-Lb

(Nm)

0.3

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

TORQUE

4.6

Grade

Ft-lb

118 166 225

288 417 568

774 992

0.5 1

2

4

10 18

33 55

85

SPECIFICATIONS

4.8

Grade

(Nm)

(0.7)

(1.5)

(3)

(5.5)

(13) (25)

(45) (75),

(115)

(160) (225) (305)

(390) (565) (770)

(1050) (1345)

Ft-lb

1

2

4.5

7.5 18 37

63

103 159

225 321 435

553

811

1103

1500 1925

B.B -9.B

(Nm)

(1.3)

(3)

(6)

(10) (25)

(50)

(85)

(140)

(215)

(305) (435) (590)

(750)

(1100)

(1495)

(2035) (2610)

Grade

FI-Lb

1.5 3

(4.5)

6.5

11

(15)

35

(26)

55

(75)

97

(130)

151

(205)

232

(315)

321

(435)

457

(620)

620

(840)

789

(1070)

1154

(1565)

1571

(2130)

2139

(2900)

2744

(3720)

10.9

(Nm)

(2) (9)

GASKETS}SEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper ing

assembly.

Specialized ing copper

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

LIQUID

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers

properties.

gaskets

and

irs

effective

fuel.

should

oil

pan seal

grease.

such

as

HYLOMAR

as

HIGH

TACK

in

just

TEFLON

can

be

used

gasket

with

around

water

are

useful

HYLOMAR

it

resists

equivalent

about

any

be

tlsed

on

high

(coolant)

for

holding

work

is

particlarly

fuel,

oil

SEALANTS

are

excellent

joint

in

contact

on

rubber

gaskets

oil

adapter

hoses

temp

RED

SILICONE

passages,

gaskets

in

position

well

in

applications

effective

on

and

water.

&

all

with

and

the

oil

sealer.

coat

both

dur-

requir-

Engine~

f

LUBRICANTS

Use

LIQUID

TEFLON

for

sealing

pipe

passages.

Do

not

use

tape

sealants!

BOLTS & FASTENERS/ASSEMBLIES

Ughtly

oil

head

bolts

and

other

plugs

that

HIGH

TACK.

When

assembling

Anti-seize

threaded

LOCTITE LITHIUM

ing

boxes.

Heavily use

clean

& Generators

45

'

penetrate

compounds components offers

based

oil

levels

grease

all

sliding

engine

the

water

the

flywheel,

and

yet

of

locking

is

and

reciprocating

oil!

thread

allows

waterproof,

plugs

fasteners

jacket

should

coat

the

locking

them

to

according

ideal

components

as

bolt

adhesives

came

and

fillings

you

be

sealed

threads

apart

to

the

for

water

that

assemble

with

LOCTITE

such

as

when

job.

pump

when

assembling.

connect

coolant

them.

Bolts

and

PERMATEX

#2

blue.

LOCTITE

protect

necessary,

bearings

and

Always

or

stuff-

TORQUE

SPECIFICATIONS

Cylinder Cylinder Connecting Flywheel Crankshaft Main Rocker Rocker Nozzle

Nozzle Nozzle Fuel Delivery Injection

Head

Bolt,

Bearing

Shaft

Cover Holder Union Retaining

Injection

Valve

Pump

Bolt, Bolt,

Rod

Cap

M10

Pulley

Nut,

Cap

Bolt,

Hold-down

Nut,

M6

(fitting

Color

Nut,

Pipe

Holder,

Hollow

main

sub

(wet),

Nut,

(17)

M16

M10

(10)

to

engine),

Fixing

M16

Nut,

M12

M16

Screw,

(wet),

M8

(17)

Bolt,

Nut,

(21)

(17)

M6

(14)

(17)

M8

M12

(17)

M10

(12)

M20

(14)

(21)

(17)

(14)

lb-ft

54.36 -61.46

14.46 -21.69

23.14 -25.31

61.45 -68.69

72.31 -86.77

36.15 -39.77

10.85

-15.91

3.62 -5.06

36.15 -43.38

18.08 -21.69

25.31 -28.92

18.08 -25.31

25.31 -28.20

7.23

-10.85

(Kg-m)

(7.5-8.5)

(2.0 -3.0)

(3.2 -3.5)

(8.5 -9.5)

(10.0

-12.0) (5.0 -5.5) (1.5-2.2) (0.5 -0.7) (5.0 -6.0) (2.5 -3.0) (3.5 -4.0) (2.5 -3.5) (3.5 -3.9) (1.0

-1.5) Solenoid Water

Temperature

Oil

Filter,

Oil

Relief

Oil

Drain

Glow

Plug,

Glow

Plug

Locknut,

M20

(17)

Plug,

M18

Hose

Plug,

M10

(12)

Lead

Wire

M30

Gauge

(22)

M18

Fitting

(36)

(19)

JOint,

Nut,

M16

M4

(23)

(7)

28.92 -36.15

14.46 -21.69

7.95 -9.40

28.92 -36.15

36.15 -43.38

10.85

-14.46

0.723

-1.08

(4.0 -5.0) (2.0 -3.0) (1.1

-1.30

(4.0 -5.0) (5.0 -6.0) (1.5 -2.0) (0.1 -0.15)

Engines & Generators

46

SUGGESTED

SPARE

-,,-"

, r

PARTS

CONTACT

YOUR

WESJERBEKE

WESTERBEKE

'

~

. . ,

-

~

DEALER

COl

~

..

./f

. ' .

•

HARDWARE

KIT

MARINE

fOR

0.,

~

DIESEL

ADDITIONAL

GENERATORS

SUGGESTIONS

AND

INFORMATION

,

WESTERBEKE SPARE CHANGE COOLANT

RECOMMENDS

ENGINE

AND

ALSO A GALLON

FOR

FO'EL/WATER FILTER

Il;jlRTRIDGES

OIL

(YOUR

BRAND)

THE

COOLING

.

CARRYING

OF

SYSTEM.

ENOUGH

FOR

AN

OIL

PREMIXED

PARTS

KITS

:IiAWWATER

!PUMP

IMPELLER

lAND

GASKET

!

WESTERBEKE

,

t.fwo·sparep'artskits~\Each

;·;rdflgedrusf

spares,

off~hpr~

'lirA

ZINC DRIVE OIL FUEL HEAT

IMPELLER

also

offers

proof

hiifg~dtoOI

.KIT B includes

cruisi99

ANOOES

FILTER

..

,

BELTS

FILTER

EXCHANGER

KIT

GASKET

engine

spares

kit

1~;<dfferediH;tlie

bok

spares

for

i

KIT

·

ZINC

!

DRIIJE'BEtTS

!

OIL FUEL HEAT

.

IMPELLER INJECTOR.

·

GASKET

i

AIR

·

GLOW

in

KIT

i\f1as'basl'c

more

extensive

B

ANODES

FILTER

fiLTER

EXCHANGER

KIT

FILTER

PLUG

same"

.""

GASKET

.

i

;

Engines & Generators

47

Engines & Generators

1

054-WMJDW-7/2001