Westerbeke 8.0KW BTDAR, 12.5KW BTDBR, 10.0KW BTDAR, 15.0KW BTDCR, 14.0KW BTDCR Operator's Manual

OPERATORS

.

MOBILE

I

.....

.

8.0KW

...GENERATORS

. .

..

BIOAR

and

. - -

r

-"

•

MANUAL

INDUSTRIAL

.

,.

10.0KW

BIOAR

12.5KW

BIOBR·

14.0

REVISION 2

WESTERBEKE

MYLES

WEBSITE:

..

...,~~

NMMA

CORPORATION

STANDISH

Member

INDUSTRIAL

WWW.WESTERBEKE.COM

National

--

·15.0KW

CR

'150

JOHN

Marine

PARK'

TAUNTON

Manufacturers

HANCOCK

ROAD

MA

02780

Association

BIOCR

A

WARNING

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

IF

GET seek until

~W·

, "

,

'G!lneratots

gasses

Weakness

YOU

OR

OUT

medical it

has

~!"!A!!'ii!!R~'

Prod~

Regular

1Fj=~~~

contain

gas.

Carbon

can

include:

and

ANYONE

INTO

THE

attention.

been

"!!N~I!'!N~G~

QARSON

~n!9nance

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

MONOXIDE

Required

and

A

WESTERBEKE

bulkhead

WESTERBEKE CARBON

\,

,inexpensi~e

local

'j

i

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY. down

repaired.

WARNING

maflne

an

of

Carbon

in

TWitching

to

Think

ANY

OF

It

the

unit

and

DECAL

and

near

your

also

MONOXIDE

and

easily

or

hardware

odorless and

can Monoxide

Temples

Coherently

THESE

SYMPTOMS,

symptoms

do

not

is

provided

should

be

engine

recommends

DETECTORS.

obtainable

and

cause

persist,

restart

by

fixed

or

generator.

store.

to

a

installing

They

are

at

your

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

of

State

gasoline

its

birth

WARNING

engine

constituents

of

California

defects,

Jtarm.

INTRODUCTION

Read

this

safety manual

caused

by

failure precautions. take the

necessary

personnel, and your

The

following

the

American

to

follow

Know

when

precautions

machinery.

safety instructions

Boat

and

carefully.

fundamental

dangerous

to

Yacht

Council

Most

conditions

protect

are

in

(ABYC)

SAFETY

accUIents

rules

yourself,

compliance

are

and

exist and

your

with

standards.

INSTRUCTIONS

•

Do

not operate with

Backfire can cause severe injury

•

Do

not

smoke

fuel

the engine/generator clean chances of

• Be

PREVENT

system.

fire.

aware

- diesel fuel will burn.

BURNS -EXPLOSION

the

or permit

Keep the compartment

Wipe

air cleaner/silencer

or

death.

flames

or sparks to

and

free of debris

up

all spilled fuel

removed.

occur

and

the

to

minimize the

and

engine

near

oil.

PREVENT

A

while these

•

Do enclosures and

• Shut off electrical equipment.

• Use insulated

equipment.

•

Make

(particularly

•

Remove electrical equipment.

• Electrical shock results from handling a charged capacitor. together.

PREVENT

A

exhaust

very

•

Always recovery tank.

A

•

In

before touching

PREVENT

ELECTRIC

WARNING:

engine

connections!

not

operate

sure

00

is

running.

this

covers

mats

your

clothing

shoes)

wristwatch

Discharge capacitor

BURNS -HOT

WARNING:

system

hot!

WARNING:

case of

00

components. A running

check

the

Steam

an

engine overheat, allow the engine to cool

the

BURNS -FIRE

SHOCK

not

touch

AC

electrical

Lethal

voltage

machinery without electrical

in

place.

power

before accessing electrical

whenever working

and skin

when

handling electrical equipment.

and

all jewelry

by

are

shorting

connections

is

present

on

electrical

dry,

not damp

when

working

terminals

ENGINE

not

touch

hot

engine

parts

engine

engine coolant level

can

cause

engine

or

checking

injury

at

the coolant

or

death!

the

coolant.

at

or

gets

on

A

WARNING:

injury

or

death!

•

All

fuel

when

handling and storing

well-ventilated area

equipment and out of the reach of children.

•

Do

not

• Shut off the fuel spill.

DO

sources

servicing.

the

fuel

•

Do

not alter or modify

• Be sure

• Be certain fuel line fittings free

oflealrs.

• Make

sure a fire

properly maintained. Be faruiliar with its proper use. Extinguishers rated for all applications encountered in this environment.

ACCIDENTAL

A

WARNING:

or

death!

•

To

prevent accidental starting

generator,

• Disconnect the battery generator.

it last.

•

Make

certain all personnel

starting.

• Make certain all covers, guards, re-installed before starting

Explosions

vapors

are

highly

fill

the fuel tank(s) while the engine

the

fuel

service

system.

of

system.

all

Take

NOT

allow

fire

near

the

Ensure

proper

fuel supplies have a positive shutoff

extinguisher

from

fuel

explosive.

fuels.

Store

away

from spark-producing

valve

at

the care in catching any

smoking, open

fuel

system

or

ventilation

the

fuel

system.

are

adequately tightened and

is

installed

ABC

by

the

NFPA

vapors

Use

engine

any

engine

exists

STARTING

Accidental

remove the 8

Remove the negative lead

starting

when

amp

fuse from

cables

before servicing

are

the

can

servicing

clear of

and

engine.

first

hatches

extreme

fuel

flames,

when

nearby

are

cause

the

and

the

can

cause

care

in

a

is

running.

when

servicing

that

might

or other

when

servicing

valve.

and

appropriate

injury

the

control

panel.

the

engine/

reconnect

engine

before

are

is

A

WARNING:

• Prevent sparks to occur near pump, vapors. removing the

flash

or other potential sources of spilled fuel or fuel

Use a suitable container to catch

Fire

fires.

fuel

can

cause

Do

not

the

carburetor,

line,

carburetor, or

injury

smoke or permit

fuel

or

death!

line,

all

filters.

flames

filter,

fuel

when

-..v

or fuel

WESTERBEKE

Engines & Generators

SAFETY

INSTRUCTIONS

BATTERY

A

or

•

Do being highly arcing equipment during

•

Never positive (+) connection terminal of Do together. Ventilate accumulation of explosive disturb is

•

Avoid bums wristwatch, the

•

Always

BATTERY

A

severe

•

A

EXPLOSION

WARNING:

death!

not

smoke or

serviced. Lead acid batteries emit

explosive

or

servicing.

connect the negative (-) battery

not

being charged.

contacting

or

battery.

the

battery connections. Remove the negative lead

and

reconnect it last

Battery

by

lit tobacco products. Shut off all electrical

in the

test the battery condition by

Sparks could any

compartment containing batteries to prevent

the

battery

sparks that could cause

rings, and

tum

the

explosion

allow

an

open

gas,

which

can be ignited

vicinity

battery charger off before disconnecting

to

ignite

gases.

charger

the

connections while

terminals with

any

other jewelry before handling

when

disconnecting

prevent

battery gases

ACID

WARNING:

injury

When

servicing the battery or checking

level,

wear rubber

protection. Batteries contain sulfuric acid

destructive.

off

at

once with

into

the

caps.

WARNING:

Sulfuric

or

death!

If

it

eyes inadvertently

Carbon

gloves,

comes

water.

acid

in

Acid

monoxide

in

a rubber

contact

may

when

can

cause

injury

flame

near

the

battery

hydrogen,

by

electrical

the

shorting

To

avoid sparks,

tools,

an

explosion.

batteries

apron,

with

splash

removing electrolyte

(CO)

arcing

cable

to

the

starter solenoid.

the

terminals

or

fuel

the

battery

etc.,

to prevent

Remove

the

battery.

can

cause

the

electrolyte

and

eye

which

is

your

skin,

on

the

skin or

is a deadly

a

vapors.

do

not

first

wash

gas!

A

WARNING:

odorless nausea

•

• Although diesel engine exhaust

AVOID

A

or

•

• Do not wear loose clothing

it

• Make

•

gas.

or

Do

not

use copper tubing in

fumes

can systems. copper tubing resulting in exhaust/water

Do

not

install exhaust outlet

through vents,

exhaust gas

is

present in diesel exhaust

symptoms poisoning

Vomiting

Dizziness

Throbbing

MOVING

WARNING:

death!

Do

not situation make

operating adjustments, touching components.

eqnipment;

jackets, shirts, sleeves, rings, necklaces

could be caught in moving

sure

Keep

protective shields and

places

at

Do

not

the engine

HAZARDOUS

Carbon

Inhalation

monoxide

produces

flu-like

(CO)

is

an

invisible

symptoms,

death!

diesel

exhaust

rapidly

destroy

copper

tubing

Exhaust sulfur causes rapid deterioration of

where

or

air conditioners.

gases

fumes

from gasoline engines, carbon

fumes.

or

signs of carbon monoxide inhalation

are:

Muscular twitching Intense headache

in

temples

Weakness

systems.

in exhaust

leakage.

exhaust can

are

not

as

monoxide

Some of

and sleepiness

be

toxic

the

PARTS

RotaUng

service

the

arises

in

moving

tie

back long hair

all

attaching hardware

all

times.

check

fluid

is

operating.

NOISE

parts

can

cause

injury

engine while it

which it

parts and hot exhaust system

levels

or

is

running.

is

absolutely necessary

use

extreme care

or

jewelry

and

parts.

guards

the

when

avoid

wearing

or

bracelets that

is

properly

in their respective

drive belts tension while

.

servicing

If

a

to

tightened.

Diesel

drawn

as

or

to

avoid

loose

• Ensure that the exhaust system the

discharged from

regularly for leaks

are

securely

attention

• Be

sure

•

In

addition to routine inspection of install a carbon monoxide detector. Consult your dealer for installation of

attached

to

the manifold

the

unit

engine.

and

its

approved

make

is

adequate

Check the exhaust system

sure the exhaust

no

warping

and

exhaust.

surroundings

detectors.

to

expel gases manifolds

exists.

Pay

are

well

ventilated.

the

exhaust system,

...v'

A

loss!

close

• Never operate

•

A

mentally

WESTERBEKE

Engines & Generators

ii

WARNING:

Do

not run

removed.

Do

not

run engines for long periods with their enclosures

open.

WARNING:

or

High

noise

levels

can

cause

an

engine without its muffler installed.

an

engine with the air intake (silencer)

00

not

work

on

machinery

physically

incapacitated

by

tatigue!

hearing

when

you

are

TABLE

Parts

Identification

Introduction

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

Serial

Diesel

Generator

Description Description

Remote Panel .................................................... 6 Description .... : ............................................ : ....

Preparations

Prestart Inspection ............................................ 7

Generator Voltage ............................................. 7

......................................................... 3 Engine

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

Fuel,

Engine

Control

for

Starting/Stopping

Safety Shutdown Switches ............................... 9

Generator The

Daily

Break-in

Operation

Maintenance

Cooling

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

Thermostat ........ : .............................................

Fuel

Fuel FilterIWater Separator ............................ 16

Fuel Injection

Fuel Lift Pump ................................................ 16

Engine Remote

Oil DC

Starter

Glow

Generator

Remote Generator

Generator

System

Fuel Lift Pump Filter. .................................... .16

Fuel Filter ....................................................... 16

Engine Fuel Filter .............

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

Lubricating

Engine Oil Change ......................................... 17

Oil

Filter

Pressure

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

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

Electrical

Alternator Troubleshooting ............................ 20

12 Volt DC Control Circuit ............................ 21

Battery Care .................................................... 21

Motor

Troubleshooting .......................................... : ...

Service ............................................................ 23

Plugs .........................................................

Wiring

Instrument

Wiring

WiringSchematic

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

Oil,

and

Coolant

Panels

of

Switches .................................... 6

of

Gauges· ...................................... 6

Initial

Procedure

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

Start-Up

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

Procedure

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

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

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

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

Schedule

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

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

Pump ...................................... .16

: ............................. 16

OiL

.................................... 17

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

System

....

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

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

Diagram Schematic ~ ..

Panel

Diagram

#44744

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

~.~

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

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

#044927

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

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

OF

CONTENTS

2

Engine

.3

5

6

Valve Clearance Adjustment .......................... 30

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

Fuel Injectors .................................................

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

Control Electronic

7

Controller Adjustment ....................................

Inspect and Adjust ..........................................

Linear

8

GenRemote GenRemote

.10

.11 .12

14

15 16

GenRemote

Stop/Start Rocker Switch ..............................

GenRe

.

Generator

mote

Power BT

Generator

BT

Generator

BT

Generator Generator BT

Generator

BT

Generator Regulator BT

18

19

Generator Specifications Specifications

20

Generator

Generator Generator

22

Generator Engine

Standard

24

25

25A

26

Sealants and Lubricants .................................. 56

.

Metric Suggested

27

A

Troubleshooting

Adjustme·nts

Panel

Troubleshooting

Governor

Actuator

Troubleshooting

Calibration

Control Wiring Installation

Specifications

[Chart] ........................

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

[Chart] ............. 32

Adjustments

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

[Chart] ..........

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

Station

Diagram

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

Oiagram

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

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

litformation .......................................

Take

Off

Systems

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

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

Wiring

Single

Voltage

Voltage Internal

Sensing

Troubleshooting

Specifications Specifications

Specifications Specifications14,KW

Torque

Hardware

Conversion

Spare

Schematic

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

Phase ..............................

Adjustment

Regulator..

Wiring

Wye-Delta

1D.DKW/B.DKW

15KW/12.5KW

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

......

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

Configurations

[Chart] ............ 50 .

BTOAR,_

BTOB

R~

1D.DKW/B.oKW

15KW

12.5KW

BTOCR

BTOBR"

BTOC'R _ .....

Specifications

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

................................ : .. ; ........

Data

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

Parts

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

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

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

28 30

31

.31

31

33

33 33

33 34

35

36·

.37

38

.38

.39

.41 .42

.43

.44 .45

.48

..

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

.........

..........

........

54A

40

47

49

51

52

53 .54 .54

55

56

57

58

Engines & Generators

1

AIR

INTAKE/AIR

.~SSEMBLY

FILTER

PARTS

IDENTIFICATION

STOP

SWITCH

CHARGING

ALTERNATOR

;REMOTE

PANEL

CONTROL

PANEL

FRONT

OIL

EXHAUST

SUMP

20A

CIRCUIT

REAR

______

OIL

FILL

~

~~l----:;:;J~-

~-i~OOLANT

START

•

LEFT

PRESSURE

,RADIATOR

RIGHT

J---EN'''N.

NUMBER

MOTOR

MOUNT

SIDE

SERIAL

PUMP

CAP

BACKEND

PREHEAT

OIL

FILTER.

At

BREAKER

Engines & Generators

2

LIFT

PUMP

DRAIN

HOSE

This

WESTERBEKE WESTERBEKE's technology. dependable Thank

In

order

is important that

manual manual throughout. your nearest

This provided and a WESTERBEKE equipment contact

WESTERBEKE'S installation

We

perfonnance of

you

for selecting

to

get

is

designed

carefully

Should

WESTERBEKE

is

your

operators

WARRANTY

Your

WESTERBEKE

folder.

If, after

fonn

you

have

registering your

writing

with

model

number

Customer

and

commission

Identification

L~

Diesel

long

years

take

great

pride in

our

WESTERBEKE.

the

full

use

and

you

operate

to

help

you

and

observe

your

generator require

manual. A parts

technical

manual

dealer.

If

your

WESTERBEKE

you

PROCEDURES

Warranty

60

days

of submitting

not

received

warranty,

please contact the factory in

information,

date.

WESTERBEKE

J Engines & Generators

Customer Identification

MR.

GENERATOR

MAIN

STREET HOMETOWN, Model15BTDAR

Expires

7120/2008

OWNER

USA

Ser.

INTRODUCTION

Generator

of experience

engines

benefit

and maintain it

do

all

dealer for

are manual.

a customer identification

Card

#.

is

a product of

and

the

superior durability

and

from

your

this.

Please,

the

safety

precautions

servicing,

assistance.

catalog

is

available

planning

dealer for

is

included

the

Warranty

including

the

advanced

generators.

generator it

correctly.

read

is

also

from

your

to

install

in

a separate

Registry

unit's

and

thIS

this contact

this

card

serial

PRODUCT

Product software, (tech brochures WESTERBEKE

. WESTERBEKE CANNOT BE RESPONSIBLE

CONTENT WARRANTIES THERETO, COMPLETENESS THEREOF AND WILL IN BE LIABLE INCURRED IN CONNECTION OF

THE

WESTERBEKE

time

. software

WESTERBEKE provided WESTERBEKE be relied the respective product. but

is WESTERBEKE to

determine

product software

NOTES,

As

this

maintenance engine, critical infonnation

CAUTIONS,

NDTE:

A

observed, your

SOFTWARE

data,

parts lists,

and

catalogs), provided

are

not within WESTERBEKE's

OF

SUCH

SOFTWARE,

OR

REPRESENTATIONS

INCLUDING ACCURACY, TIMELINESS

FOR

ANY TYPE OF DAMAGE

FURNISHING

span

between printings of

and

the unavoidable existence of earlier

with

WESTERBEKE products, whether

upon

exclusively

imperative that appropriate representatives of

the

CAUTIONS

manual

An

takes

schedules,

and

operating procedure essential

CAUTION:

can

OR

USE

customers should

WESTERBEKE manuals. or

or

accuracy

being

WARNINGS.

In summation,

other suppliers, must

as

the

It

not

only

the

supplier in question

and

currentness of

consulted

AND

WARNINGS

you

through

and

troubleshooting

will

Procedures,

result

in

the

damage

engine.

manuals,

from

sources

MAKES

WITH

WIlli

OR

ARISING OUT

OF SUCH

also

keep

product

not

definitive

makes

by

the

be highlighted by

An explanation

which

authority

good

be

the

customer.

operating

to

note.

if

not

or

destruction

other

than

control.

FOR

THE

NO

RESPECT

OR

NO

EVENT

OR

INJURY

SOFTWARE.

in

mind

the

product

software from

and

cannot

on

sense consulted

the

procedures,

of

your

marine

NOTES,

follows:

strictly

of

The WESTERBEKE

alphanumeric

date

of

manufacture;A

the

end

of the engine

followed

characters. decade the Beginning in May represented 2008

by

E=2000s.

decade,

July,

three

2008

HG

number

numbers.

The

the

second

2008,

and

2008

engine

serial

that

can

assist

manufacturing

serial

number.

Today

date

code.

The character indicated

first

number represented

and

third,

the

two

the E the

July.

month

number

one

date

It

consists of a

it consists of

the

characters

of

is

an

in

determining

code

is

two

the

month

of

HE.

H

May

and

the

placed

at

character

the

year

in

that

year.

so

on

HF

Engines & Generators

3

A

WARNING:

followed,

can

Procedures,

result

in

personal

which

injury

if

not

or

properly

loss

of

life.

INTRODUCTION

SERIAL

The

are time plate

when

Parts.~~~~~~~~~~,.~~~

The engine block just above the injection

serial flat

NUMBER

engine

and generator

located

on

to

enter

shown

below,

seeking

MOOEL

--

RPM

___________

KVV

____________

KVA

___________

VOLTS AMPS

ENG,

ENG. GEN.

PF/PHASE

VVIRES RATING

INSUL

TEMP. BATIERY

C.I.O.

engine

serial

number

surface

on

LOCATION

serial

numbers

a decal

this

techuical information and/or

_________ _________

HP

SER. SER.

________

RISE

_________

is

on

information

as

this

________

______

_

NO. NO.

___

_

_______

CiJ\SS

_

__

__ __

____

__

number

staroped

the left

side

the

generator

on

the illustration of the

will

provide a

_ _

_

can

also be

found

pump.

into the generator housing

of the

generator.

and

model

housing.

quick

ordering

staroped

The

numbers

Take

the

narDe-

reference

repair

..

into the

generator

on

the

NOTE:

A carbon monoxide warning decal has been provided

by

WESTERBEKE. Affix this decal

engine

room.

UNDERSTANDING

The diesel

since the are the diesel conoecting

Therefore,

same

most important maintenance of the Replacement of fuel and lubricating filter time periods contamination (that tem the designed specifically for

The diesel however, carburetor component function of

engine

mechanism arranged SarDe

general

engine

rods

to

preventive

is

also

essential. Another important factor

SarDe

brand of high detergent diesel lubrication

engine

in

its method of handling and

and

both.

ORDERING

Whenever replacement

generator serial plate located this set. number for Parts List). Insist upon WESTERBEKE because

the

model

number

information so

In

addition,

each

will fit

SarDe

specifications

THE

DIESEL

closely resembles the

is

essentially the

above

a closed crankcase;the

type

as

that of a gasoline

has

the

SarDe

type

and lubricating

a great extent, a

maintepance

factors

are

proper ventilation

fuel,

lubricating and

specified

the

is a

is

water,

does

differ

iguition

systems

fuel injection

must,

diesel

PARTS

parts

number,

as

they

on

the generator

include a

part needed

or

appear

we

may

generic

as

engine

complete

parts

original equipment.

in

a visible position in the

ENGINE

gasoline

SarDe.

crankshaft

of

valves,

camshaft,

system.

diesel

engine

as a gasoline

cooliog

elements

and

frequent

sediment,

from

pump -which

are on

end.

properly

(see

etc.)

engines.

the

gasoline

firing

are

replaced

needed,

serial

the

are

always

number,

silver

and

You

must

identify

part description and part

the

separately

packaged

frequently

engine,

The

cylioders

engine,

requires

engine.

and

proper

systems.

checking

in

the

fuel

is

the

engine,

of

fuel.

by a single

performs

provide

and

black provide your

furuished

not

made

is

of

and

the

pistons,

the

The

at

the

for

sys-

use of

oil

The

the

generator

narDe-

us

with

generator

parts

to

An

identification plate

the

engine

model

ENGINE SERIAL NUMBER

and

on

the engine

serial

mauifold

number.

also

displays

GENERATOR

10

DECAL

--'GEIIERIITOR 'NUMBER

Engines & Generators

SPARES

Certain WESTERBEKE will assist See accessories,

INSTALLATION

Publication #43400 provides detailed information installing generators and a Also www.westerbeke.com

SERIAL

the

AND

spares

you

SPARE

see

manual

ACCESSORIES

will

be needed

engine.

in

preparing

PARTS page in

WESTERBEKE'S ACCESSORIES brochure.

Your

an

to

local

support

WESTERBEKE

inventory of

this

manual.

MANUAL

copy

is

supplied

is available

to

download

from

our

in a pdf

4

and

spare

For

with

website

format.

maintain

parts.

engine

for

each

at

your

dealer

unit.

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use fuel that meets the requirements or specification of Class

2-D

Care

Use only clean diesel in your particles these and keep it clean. The best unsatisfactory by careless handling or improper storage facilities. engine's daily use is clean advisable:

Purchase a well-known brand

ENGINE

Use a heavy duty diesel oil with an API classification CF, CG-4, CH-4 or CI-4. Change the engine oil and filter

after an initial the MAINTENANCE SCHEDULE in this manual. Westerbeke Corporation does not approve or disapprove of the use synthetic oils. be

must be section in this manual and not are used.

NOTE:

ments regarding synthetic

For recommended oil viscosity see the following chart· ,

FUEL

(ASTM),

finely

and has a cetane rating

Of

The

Fuel

fuel

injection pump

which

might pass through the filter can damage

finished parts.

To

assure that the

Supply

fuel!

The clearance

is

very critical; invisible dirt

It

is important

fuel

and

of

#45

or

better.

of

the components

to

buy

clean fuel,

can be rendered

going into the tank for your

pure, the following practice

of

fuel.

OIL

of

50 hours

oil

and

filter change intervals as specified in the

If

performed using conventional oil. Oil change intervals

as

listed in the MAINTENANCE SCHEDULE

The

information above supersedes all previous state-

Operating

Above

68'F

41'-68'F

Below

41'F

of

break-in operation. Then follow

synthetic

Temperature

(5-20'C)

oils

oil.

(20'C)

(5'C)

are

used, engine break-in must

to

be extended

Oil

SAE

30,

SAE

20,

SAE

10W-30

Viscosity

10W-30 10W-30

or

if

synthetic oils

or

15W-40

or

15W-40

of

is

ENGINE

WESTERBEKE recommends a mixture of and chemicals that can corrode internal engine surfaces.

The antifreeze performs double run at proper temperatures by transferring heat away the engine cooling circuit from rust and corrosion. Look for a quality antifreeze that contains Supplemental Cooling Additives anced, crucial

The distilled water and antifreeze should be premixed before

being poured into the cooling circuit.

NOTE:

antifreeze that is now available.

Antifreeze mixtures will protect against an unexpected freeze and they retard rust and

Antifreeze

Freezing

COOLANT

A coolant recovery tank kit is supplied with each WESTERBEKE diesel engine. The purpose of this recovery tank is during engine operation, without the loss of coolant without introducing air into the cooling system. This provided

NOTE:

located at can

particular

COOLANT

50%

antifreeze

50% distilled water. Distilled water is free from the

duty.

It

allows the engine

from

to

the coolant, and lubricates and protects

(SCAs) that keep the antifreeze chemically

to

long term protection.

Look

for

the new enviromnentallY1riendly long lasting

are

beneficial to the engine's cooling system. They

add

to the life

ANTIFREEZE

concentration

Temperature

RECOVERY

to

allow for engine coolant expansion and contraction

and

must be installed before operating the engine.

7his tank, with its short run

or

above the level

be

located below the level

~nstallation

of

the circulating pump

PROTECTION

23%

14'F

(-5'C)

30%

8'F

(-13'C)

TANK

of

plastic hose,

of

the

engine~

of

the engine ~ manifold

makes this necessary.

35%

-4'F

(-20'C)

manifold, but it

the

good

-40'F

(-40'C)

and

is

best

bal-

seal.

50%

kit

if

to

is

the

A

CAUTION:

engine

oil

additives

to

OIL

The engine's oil pressure, during operation, by

the oil pressure gauge on the instrument panel. During

normal operation, the oil pressure will range between

60 psi.

NOTE:

reading upwards have an oil pressure reading as low as These readings will vary depending upon the temperature the engine, the load placed on the engine, and the

of

produce

PRESSURE

A newly started, cold engine can have an oil pressure

00

to

mix.

Each

different

properties

of

60 psi (4.2 kg/cm". A warmed engine can

not

allow

brand

brands

harmful

two

or

contains

could

react

to

your

more

brands

of

its

own

additives;

in

the

mixture

engine.

is

indicated

30

25 psi (1.8 kg/cm".

RPM~.

and

of

Engines & Generators

5

GENERATOR

CONTROL

PANELS

DESCRIPTION

This

manualJy

diesel

generators

engine control panel and,

All

three

following

PREHEAT:

preheating engine oil pressure switch. The PREHEAT function closes

K2

relay.

the pull coil. .

When

the panel lights, solenoid.

START:

The energizes While the START

begins to

PREHEAT pressure reaches 5 -

STOP:

providing power opens flow To STOP switch noid The stops rotating

NOTE:

gauge and last temperature and oil

will

switch engages the start solenoid. When the engine

The the

of

fuel

stop

the

is

opened,

STOP

When

return

OF

SWITCHES

controlJed series of WES1ERBEKE marine

is

equipped

switches

functions:

The

the

PREHEAT

the

PREHEAT

fire,

STOP

power circuit

switch should

the

to

are

PREHEAT engine for

as

well

as

switch

gauges

and meters

START

switch should

engine, depress

toggle

starter solenoid

switch

the

START

10

toggle switch

to

the

to

the

engine and

is

depressed,

and the

the

engine is shut

oil pressure

zero once-electrical power

with

toggle switches on

optionally,

momentary contact type

toggle serves two

easy

supplies

is

switch

and

is

switch should be released. The not

be

psi.

K2

relay.

to

the

fuel

flow

be

depressed until

gauge

pressure

at

remote

purposes:

starting

fuel shuts

power feed

and

bypassing

current to

depressed,

and

closes

activates the

still depressed, depressing the

released until

is

a normally closed switch

Opening of

solenoid, stopping the

STOP switch.

to

down,

will continue

readings

the

fuel solenoid

the

voltmeter,

the hold coil

the

KI relay that

starter.

the

this

down the

the engine

the water temperature

engine. When

to

the

is

the

displayed.

is

restored.

the

panels.

and

serve the

the

of

the fuel

oil

switch

the

fuel

sole-

stopped.

generator

to

register

They

the

EMERGENCY

stop

switch

is

normally

will

open

panel

switch

performing

DESCRIPTION

Coolant

Engine coolant

175'

to

Engine

Oil

pressure

load but should range between between 30

DC

Voltmeter

Indicates

l3V

to

STOP:

on

the

closed.

the

DC circuit to the

and shut

is

the

not

toggled it

maintenance.

OF

Temperature

(water)

195' F (80'

Oil

Pressure

(psi)

may

the

amount

14V.

The

EMERGENCY

side

of

the

control

When

depressed, it

control

engine

down.

As

can

be used

GAUGES

temperature should

to

90' C).

fluctuate depending

the

battery

is

box,

the

when

being

charged

Hourmeter

Registers elapsed time perform scheduled maintenance.

REMOTE

For

switches connected serve switch serves WIRING

remote

are

the

same

is

in

the

PANEL

operation

used.

in

parallel with the

series

same

DIAGRAM

of

The

functions

with

function.

in

and

is

used

the

generator

PREHEAT

gauge

as

in

the

gauge

There

is

this

manual.

as

a guide

system,

and

START

panel's

gauge

panei.

panel's

a REM01E

GENERATOR

RELEASE

STARTER

PREHEAT

MUST

~

PRESS

Cf!))

1ST e

WESTERBEKE

NOTE:

For

additional infonnation on Control STARTING/STOPPING DIAGRAMS

and TROUBLESHOOTING

PROCEDURE,

f'li

STOP

START

I~~

\,fIiJ

'

normally

on

the

to

60

for

the

switches

The

STOP

switch

START/STOP

PRESS

2

NO

Panels.

DC

WIRING

GAUGES.

indicate

generator

psi.

should

when

to

same

and

STOP

and

Refer

show

three

are

to:

Engines & Generators

6

PREPARATIONS

PRESTARTINSPECTION

This section of ration, initial starting, break-in, starting (warm stopping procedures. Follow the procedures the conditions indicated set

will

Before starting your generator set

.prolonged layoff, check the following items:

o Check the engine oil level.

at

the

o Check the

tor bowls

o Check the

and tery negative (-) cable (this location

o Check the coolant level

and

o Visually examine the

parts,

threaded

o Check load leads

the wiring diagrams.

o Examine air inlet and outlet

o Be sure

to load lines.

o Be sure that

the neutral system requires, connected

3-phase ply the loads.

o Make sure the mounting installation is secure.

o Make sure that

the

manual provides the operator

and

your WESTERBEKE generator

give reliable performance

high

mark

on

the dipstick.

fuel

supply

and

for

contaminants.

DC

electrical

battery cable connections. Make

cable

is

connected

is

connected

is

tagged).

at

the

manifold.

unit.

disconnected

connections.

no

other generator or utility power

is

to

systemS

wrong

wires,

for

correct connection

in

power systems with a neutral line that

properly grounded (or ungrounded)

and

that the generator neutral

the load neutral.

an

incomplete

line-to-neutral voltage on unbalanced

the

generator

and for

the first time

Add

oil

examine the

system.

to

in

Inspect

the

starter solenoid

to

both

the plastic recovery tank

Look for loose

unattached

for

air

In

single phase

or

is

properly grounded.

long service

the engine ground stud

open neutral

as

to

maintain

fuel

wire

certain

hoses,

as

flow

obstructions.

or

with

prepa-

or

cold)

and

presented for

life. or

after a

the

level

filter/separa-

connections

the (+)

bat-

and

the

missing

and

check

specified in

is

connected

as

the

is

properly

and

some

can

sup-

FOR

INITIAL

GENERATOR

The however,

60

50Hz

The

however adjusted

VOLTAGE

actual load to authorized WESTERBEKE service

START-UP

A

CAUTION:

recommended be

switched

and,

in

will

preven{damage

of

the

stalling.

speed of

Hz

speed of

to

suitable

OFF

cold

climates,

AC

machinery

VOLTAGE

the

it

is

advisable

The At

rated

48.6 -59.0 The

rated

48.5 -49.0 the

it

is

advisable

to

optimum

ADJUSTMENTin this manual).

service

be used

values

or

in

When

starting

that

all

AC

loads,

until

the

engine

starts

to

caused

and

generator engine

engine

amperage hertz output

engine

amperage

generator engine

values

test

load

service.

arid

fault

by

will

prevent a cold

to

verify.

no-load speed

Hz.

no-load

Hz.

to

speed

hertz output

verify.

no-load

of the

same

If

the voltage cannot be

seems

the

generator,

especially

has

come

warm

up.

unanticipated

it

large

up

tii

This

precaution operation

is

motors,

speed

engine

is

adjusted

is

adjusted

The

voltages

and

evident, contact your

dealer.

at

the

is

set

at

61.5 -

may

decrease

is

set

at

61.5

may

decrease

at

the

are

full

load

If

possible,

power factor

Hz.

easily

(refer

as

adjusted

from

factory,

62

Hz.

to

At

to

factory,

to

apply

the

DIPSTICK

~

Oil

lEVEL

GLOW

PLUG

CONNECTION

\l\>

~PPROXIMATELY

ONE

QUART

SIDE

Oil

CAP

Y

-.rN'"

WESTERBEKE

Engines & Generators

7

Oil

Fill

CAP

STARTING/STOPPING

THE

STARTING

Westerbeke

glow

plugs illustration below cylinder.

ber

tbe glows is

This circuitry depressed for tbe while

button is depressed

NOTE:

PREHEAT switch switch activates the

plugs.

The

so

that its

glow

plug

red at !be

a rapid start witb

system

is

keeping tbe

The

PREHEAT intermittently to avoid overheating

GLOW

SYSTEM

diesel generators use electric starters assisted

for botb normal and cold

shows

a cross-sectional

glow

plug

is located in

tip

is

in tbe injector nozzle's

is

energized tip

is

common

desigued

time

by

and

assists in igniting

less

wear on tbe

to

WESTERBEKE diesels. The start

so

tbat tbe

specified in

PREHEAT

to

crank tbe engine.

START switch will not energize unless

is

depressed.

the

glow

plugs

weatber tbe

tbe

PREHEAT

starter.

PREHEAT

tbe

button

engaged,

Depressing in

the

preheat chatt.

cylinder head

starting.

view

of

one

combustion

spray

patb.

button,

tbe

fuel.

The result

button must be

tbe

START

the

PREHEAT

the

The

cham-

When

the

Then,

so

use

glow

by

plug

PROCEDURE

Should

tbe engine not start when tbe

for

10

to

20

depressed wait

30

seconds;

longer.

Never

Remote

The

start guages. lights rpm.

since A.

Starting

remote statt panel

panel except tbat it

When

when

tbe generator

This

indicates

tbe starting of

When

tbe start/stop panel START engine tbe START

LED

switch

this

light

switch.

depressed for a

which

up tbe

series

green

LED

is

engine

B.

After

tbe

run

starting

PREHEAT

LED

closes tbe

patb for

will

running. generator

seconds,

repeat

tbe

procedure

the

starter for more

Procedure

is

tbe

has a green

at

a remote location,

is

runrrlng

when

tbe

generator

switch

tbe

LED

light will

is

depressed

light

will

brighten sigualing

Continue

few

seconds oil

pressure safety switch that

12V

B+

remain

brightly illuminated while tbe

is

statted and

same

to

released, tbe generator's starter will not crank uuless tbe PREHEAT

supplies voltage

Once

tbe proper light load temperature applying

switch

engine statts,

oil pressure

to

tbe generator

to

come

heavy

loads.

is

operated first because tltis switch

to

tbe

START

check

and

battery charging

and

up-to

l40-lS0oP

START

switch is

release botb switches

above

and

preheat

than

30 seconds.

as

tbe

engine-mounted

LED

light and no

tbe

green

at

approximately

START

switch

may

is

depressed

illuminate.

can

be released

not be audible.

at

tbe remote

When tbe

and tbe starter cranks tbe

dim.

When

tbe engine statts

to

release tbe

hold tbe

to

allow

tbe fuel

tbe

PREHEAT

oil pressure

run

solenoid. The

START

switch

switch.

tbe engine's insttnments

voltage.

allow

tbe engine's operating

(60-66°C)

Apply a

before

and

LED

600

to

build

is

for

in

is

PREHEAT:

panel PREHEAT

Depress tbe

lights,

switch

gauges

PREHEAT

and

meters will

shouW

be depressed in accordance

tbe following chatt:

Temperature/Preheat

Almospherlc

+41°F(+5°G)

+23°F(-5°G)

Limit

START:

While

tbe

START

Upon

engine

release tbe

15

psi.

Then oil pressure protective circuits remain energized

Temperalure

or

higher

to

23°F or

lower

01

continuous

still

depressing tbe

switch.

This

starting,

PREHEAT

as

long

and

(-5°G)

use

will

release

switch until

as

tbe high

continue

NOTE:

A voltage

when is

switch.

be

30

PREHEAT

engage

tbe

START

the

water

do

not

to

run.

When

the

depressed.

The volttneter

activated. The

Preheallng Approx. Approx. Approx.

seconds

Time

10

seconds

15

seconds

20

seconds

before

switch,

tbe

starter

solenoid.

switch.

Do

oil pressure

temperature

activate, tbe

starting:

drop

will occur

preheat switch

and

witb

cranking

depress

not reaches and

low

engine

will

NOTE:

Some Depressing will

help

stabilize temperature the

engine.

unstable

the PREHEAT switch for 10-15 second intervals

reaches

the

running engine

140-150°F

may

occur

RPM until

and

in

a cold

the

operating

a load

engine.

is

applied

to

~

WESTERBEKE

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

STARTING

Make the

prevailiog

OIL

The

drop. Use a sufficient

sure

the lubricating

section battery

UNDER

temperatore. Check the table in

in

this

manual.

should

be

amount

Temperature/Preheat

STOPPING

1.

Remove

allow

stabilize

2.

Depress is

completely

3.

Now

SAFETY

The engine switches. Should

PROCEDURE

the

AC

electrical

the generator

its operating temperatures. the

STOP

stopped.

release the

SHUTDOWN

is

protected

shutdown

wilhont finding and

heading ''Engine

section

The following switches:

of

this

Stops"

manual.

is a description

COLD

CONDITIONS

oil

conforms with

fully

of preheat

chart

to

switch

STOP

charged

elsewhere

run

switch.

to

load

from

for three

and hold it

SWITCHES

by

three automatic shutdown

occur,

do

correcting

the

cause.

in

the

TROUBLESHOOTING

of these

the

minimize

aid

in

starting.

in

this

section.

the

generator and

to

five

minutes

until

the

not ottempt

Refer

automatic

ratings

ENGINE

voltage

See

to

generator

to

restart

to

the

shutdown

for

the

Remote

To the circuit.

generator comes goes

Low

A

low

engine's

switch's sensor engine's oil pressure interrupting the

off

Stopping

stop the

normally closed

the

generator, depress

The STOP switch

to

out.

Oil

Pressure

oil pressure

oil

gallery.

mouitors DC

engine.

Procedure

the

STOP

B+

path for voltage

must

be

held

a complete stop

Switch

shutdown

Normally open in a

fall

voltage

switch

the

engine's oil

to 5-10 psi,

to

the

K2

switch to

the engine's

open

until the

and

the

green

is

located off the

static

state,

pressure.

this

switch

relay,

thereby

which

LED light

this

Should

will

open,

shutting

opens

run

the

Coolant

A housing. coolant's operating temperatore reach approximately

(99'C), will

relay,

195'F (107'C).

COOLANT TEMPERATURE SWITCH

Temperature

high

water temperatore switch i.located

Normal1y

open

and

thereby

shutting

Switch

closed,

this

intermpt the

off the engine.

switch, should the fresh

DC

This

on

the thermostat

voltage

switch resets

to

the

water

21O'F

K2

at

SENSOR

OIL

PRESSURE

OIL

PREilSUFIE-,L

SENOOR

Engine

The generator's

manual reset circuit breaker draw wiring event relay source of the breaker and restart

Circuit

or electrical overload anywhere in

or

the

is terminated. If

.w""""

engine

wiring

generator

problem.

Breaker

is

protected

will

shut down

this

should

After

the

generator.

(20

amps

cause

occur,

repairing

by

an

DC).

the

breaker

and

the voltage

the

engine

mounted

Excessive current

the

instrument panel

to

trip.

to

check

and

repair the

fault,

reset the

In

the

this

K2

"'"

WESTERBEKE

Engines & Generators

9

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine hour of test operations

assembly operated life of operated

Breaking-in a piston and scored, the break-in period.

Your conditioning operation to Perform

following: Start

section. (water

AFTER

Once the generator operation and then encourage a fast generator between hours.

procedures

properly,

your

and

rings

smoky

which

new

engine

maximize

this

the

engine

Run

pump,

START-UP

engine

serviced

new

to

operation indicate that the cylinder

is

the conditioning

the

oil

has

at

were

a break-in time

is

dependent

during

engine

the

cylinder

caused

by

requires

to

performance

according

engine

while

pressure,

has

been started, check

20%

experienced a

the

factory

followed and that

upon

its

initial

basically

walls. overloading

approximately 50

break in each

and

carefully,

to

the

STARTING

checking that

battery charging)

and

60%

minimum

to

make

is

required.

how

hours

involves

Excessive

the

moving

service

life

keeping

warm-up.

of

full

load for the

of

sure

accurate

the

engine

The service

the

engine

of

use.

seating

the

oil

consumption

walls

are

generator

hours

in

PROCEDURE

all

are

for

during

of initial

part in order

of

the

engine.

mind the

systems

functioning.

proper

Run

the

first

one

is

10

CHECK

D Monitor

D Check for

D Check

D Confirm exhaust

To the breaker that

NOTE:

draw required for staning draw can

GENERAIDR

GENERATOR

Once be engine's break-in period A no-load conjunction

GENERATOR

THE

FOLLOWING

the

control panel

leaks

of fuel

for

abnormal noise

vibration

When

protect

generator's output leads

and

blow-back

smoke:

the

engine is cold - White

the

engine is warm - almost Smokeless.

the

engine is overloaded - some

against

unintentional overloading of the

is

rated

at

the

Be

aware

of

motor staning loads and

be 3 to

5 times normal running

INFORMATION

ADJUSTMENTS

the

generator has been placed in operation,

adjustments

required

voltage

adjustment

with

the engine's

INFORMATION in

for

gauges.

and

sounds.

should

rated

motors.

engine

(first

engine oil.

such

as

knocking,

Smoke.

be routed

output of the

This staning

in

this

speed

50 hours)

may

also be

speed

adjustment.

this

Black

the

amperage.

manual.

(hertz)

or

after

required

manual.

friction,

Smoke.

generator, through generator.

a circuit

high

current

amperage

See

there

during

this

period.

in

See

may

the

A

CAUTION:

generator

After the first

can

be

periodically vary

by

10

increased

00

running

hours

of

to

the

full-load rated output,

the

load.

not

attempt

to

break-in

without a load.

the

generator's operation, the load

then

your

"""

WESTERBEKE

Engines & Generators

10

THE

DAILY

OPERATION

CHECK

Follow

D D

D

D D

LIST

this

Record relate

to

Visually

Check

tanklradiator. Check

Look

for clean fuel in the fuel/separator transparent

Check

Check Check

chdck list each

the

hourmeter

the maintenance

inspect

the

oil

level

the coolant level in

your

diesel fuel

for

loose wires

the

starting batteries

drive

belts

reading

the

generator

(dipstick).

for

wear

day

supply.

at

before starting

in

your

schedule.)

for

fuel,

the

coolant recovery

the

alternator.

(weekly).

and proper

your

log

(engine

oil,

or

tension

generator.

hours

water

leaks.

bowl.

(weekly).

START

(See Allow operating temperatures' of applying generator Check temperature,

NOTE:

This temperature

STOPPING

Remove time. stabilize the operating temperature and switch. als).

THE

GENERATOR

STARTING

the

Some

condition should lessen

A

CAUTION:

.

long

periods

on

the

generator.

Allow

(See

PROCEDURES

engine

to

AC

loads.

to

adjust

to

gauges

for proper

and

DC

unstable running is

reached and loads

of

time

THE

GENERATOR

the

major

AC

the

generator

STOPPING PROCEDURES

on

warm

up

for 5 to

140°

to

150°F

Apply

loads systematically

each load before applying

oil

pressure,

voltage.

may

occur

as

normal operating

are

Do

not

operate

without a load

loads

from

the generator

to

run

for a

minutes

(60°-66°C)

operating

in

applied.

the

generator

being

few

minutes

depress

on

pages).

to

allowing

the

a cold

placed

one

the

before

the

next.

engine.

for

at

a

to

stop

manu-

an

~

WESTERBEKE

Engines & Generators

11

MAINTENANCE

A

WARNING:

running. use servicing

NOTE:

difficult and may require the expert knowledge

Wear,theproper

the

correct

Many

Never

attempt

tools

for

any

of

the

engine's

of

the following maintenance jobs are simple but others are more

safety

each

job.

DC

to

perform

equipment

Disconnect

electrical

SCHEDULE

any

service

such

the

equipment.

of

a service mechanic.

as

goggles

battery

while

terminals

the

and

engine

gloves,

is

and

when

SCHEDULED MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel

Sfarting

Engine

Generator

Heat

Fuel

Electronic

(if

applicable)

Exhaust

Engine

Inlet

Separator

Oil

Level

Belts

Inspection

Filler

Batteries

Oil

(and

Exchanger

Filter/Water

Governor

System

Hoses

Fuel

Filter

of

Engine

filter)

Zinc

Anode

Separator

Control

CHECK

EACH

DAY

0 0

0

weekly

0

weekly

HOURS

OF

OPERATION

50

100

NOTE:

Please

and

oil

will

remain

cool,

250

keep

inhibit

the

500

engine

engine's

750

surface

ability

1000

clean.

to

0 0 0 0 0 0

0

0 0

0

0 0 0 0 0

0

0 0

0 0 0

0

0 0

0

0 0 0 0

0 0

0

0 0

1250

Dirt

0

EXPLANATION

Diesel

No, 2 rating

Check

for

water

if

necessary),

Oil

level

should

dipstick, Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

fuel,

and

electrical

Check

for

loose

Initial

change

Every

50

operating

and

make

excessive

Initial change

Check with for

Inspect exchanger

Inspect

hours

drain

Check required

as

NOTE:

adjustment

Initial the manifold. and dilion.

Hose spongy.

Replace or

corrosion.

engine

both

that

no

chafing.

additional

zinc

daily,

of

use

separator

and

(hertz)

needed.

These

check

system

other

No

should

Check initially

as

needed.

MAINTENANCE

of

45

and

dirt

indicate

tank;

if

needed,

proper

tension

if

needed,

Check

oil

and

water

connections,

belt

tension,

at

50

hrs,

hours

sure

connections

oil & filter

every

100

AC

connections

See

GENERATOR

information,

anode,

replace

end

of

zinc

Replace

filter

or

as

found

bowl

as

or

adjust

the

and

the

adjustment

during

or

after

at

50

hrs.,

is

securely

System

is

properly

components

leaks,

be

hard & tight

and

tighten

at

50

hours

OF

SCHEDULED

cetane

or

in

fuel

(drain/replace

between

if

then

change

hours.

anode

then

fastened

are

MAX,

empty,

check

(3/8"

to

bett

edges

leaks,

Keep

bolts & nuts

change

check

electrolyte

are

very

at

are

clean

if

needed,

debris,

element

to

be

needed,

needed, no·load

speed

regulator

are

not a warrantable

the

unit's

every

to

supported

in

good

Replace

all

hose

and

then

higher,

and

LOW

at

manifold,

1/2"

deflection)

for

wear,

Inspect

wiring

every

250 levels

tight

Clean

50

hrs"

then

and

secure

SECTION

clear

the

every

250

Clean

in

the

board

adjustment

break-in.

250

hrs,

Ensure

the

exhaust

and

serviceable

if

soft

clamps.

once a year

filter

on

tight

hrs,

off

heat

and

panel,

muffler

con-

or

Engines & Generators

12

MAINTENANCE

NOTE:

Use the engine hour meter gauge to log your engine hours

engine hours by running time.

SCHEDULE

or

record your

SCHEDULED MAINTENANCE

Coolant

System

Air

Intake

Filler

Electric

FuelliH

Pump DC

Alternator

"Fuelln]ectors

"Starter

"Preheat

"Engine

"Torque

"Radiator

Motor

Circuit

Cylinder

Compression

Cylinder

Hold-down

"Adjust

the

bolts

Valve

Head

Clearances

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

1000

1250

0 0

0

0 0 0 0 0 0

0 0 0

0

0 0

0

0 0

0

0 0

0

Drain, appropriate

Clean

0

every

Periodically

Check bracket;

Check

spray

condition

Check and

lubricate.

pinion Check

clean

glow

Reinstall Check

ENGINE

At

first

ENGINE

Adjust

ADJUSTMENTS).

Remove,

tested.

EXPLANATION

MAINTENANCE

flush,

and

refill

cooling

antifreeze

100 check

DC

charge

tighten

and

adjust

solenoid

drive. operation

plugs;

with

compression

ADJUSTMENTS).

50

hours,

ADJUSTMENTS).

Valve

Clearances

have

mix.

hours.

Replace

the

wiring

from

alternator.

electrical

injection

(see

ENGINE

and

motor

Clean

and

of

preheat

check

anti-seize

pressure

then

every

(see

professionally

OF

SCHEDULED

system

with

as

needed.

connections

Check

connections.

opening

pressure

ADJUSTMENTS).

for

corrosion.

lubricate

resistance

compound

the

solenoid.

(4-6 on

and

timing

500

hours

ENGINE

cleaned

starter

Remove

threads.

and

..

mounting

and

Remove

motor

and

ohms).

(see

pressure

"WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

13

mechanic.

DESCRIPTION

Westerbeke fresh water combustion which water coolant parts

Fresh water circulating coolant to

the

block via

FRESH

NOTE:

r~commended

fresh water coolant.

diesel

cooling.

and

circulates

and

the

coolant

pump,

then

radiator

the

WATER

Refer

engines

friction

throughout

cools

engine

absorbing

passes

where

suction

COOLING

to

ENGINE COOLANT section/or the

antifreeze and water

COOLING

are designed and equipped for

Heat produced in the engine

is

transferred

the engine.

the

engine block and its internal

oil.

is

pumped through

heat from

through

the thermostat into it is cooled, and returned to the engine side

of the circulating

to

the

fresh

This

the

CIRCUIT

mixture

by

water

circulating

engine

engine.

the

pump.

to

be

used as

OIL FILTER

coolant moving

by

a

The

manifold,

fresh

the

SYSTEM

When

the

engine

is

started cold, external coolant prevented flow manifold thermostat coolant cooling

Coolant

A

coolant and significant

the

CHANGING

The

MAINTENANCE SCHEDULE.

become

A

critical; a substantial traced

by

the closed thermostat (although some coolant

is

bypassed

to

system.

contraction during engine operation, without any

cooling engine

around

the

thermostat

from

overheating).

gradually

flow

unrestricted

Recovery

recovery

loss

system.

manifold

tank

of coolant and without introducing air into

This

level

As

opens,

allowing

to

Tank

allows

tank should be

and

the engine

full

the external portion of

for engine coolant expansion

should be

COOLANT

engine's coolant

contaminated, it

CAUTION:

back

Proper

to

cooling

must

can

cooling

number

system

be changed

lead

according

If

the coolant is allowed

to

overheating

system

of

engine

corrosion.

flow

to

prevent the

warms

up,

flow

of the engine's

located

at or

easily

accessible.

to

problems.

maintenance

failures

is

engine

the

above

the

can

to

is

be

,

Drain

the

engine

coolant

\'

engine

block

and

,.

system

with

fresh

NOTE:

The petcock

engine

coolant.

•

\

COOLANT

DRAIN'

A

WARNING:

Wear

protective

by

loosening

opening

water,

the

radiator

then start the

on

the radiator can also be used to drain

Beware

of

the

hot

the

drain pressure refill

process.

engine

plug

cap.

coolant

gloves.

on

Flush

•

the

~

WESTERBEKE

Engines & Generators

14

COOLING

SYSTEM

Refilling

After replacing the engine block drain coolant petcock. then pour clean, premixed coolant radiator

Monitor the coolant the radiator

Remove

coolant mix the

into

After checking for leaks, Coolant should engine needed.

RECOVERY

MAKE

CERTAIN

PASSAGES

and

the

cap.

Run

the

recovery

cools

Clean

TO

GUULAN.r

THESE

ARE

the

when

to

cap on to

KEPT

Coolant

the coolant is visible, start the

in

the radiator and

the

filler

neck and install

the

coolant recovery tank

halfway

the

down.

up

1

between

engine,

draw

observe

tank.

back into the cooling system

Add'

coolant

any

spilled coolant.

stop

LOW

the

the engine

(0

the recovery tank if

plug,

add

the

and

coolant expansion

close

as pressure

MAX

and

allow

the

into

engine.

needed.

and

fill

and

it

as

radiator

the

Fill

cap.

with

replace

flow

to

cool.

the

Replacing

Remove housing

gasket, gasket

cap

screws.

Run

the

there

COOLANT TEMPERATURE SWITCH

the

cap

as

shown.

apply

before

engine and check

are

no

leaks at the thermostat housing.

THERMOSTAT

ASSEMBLY

Thermostat

screws

and

disassemble the thermostat

When installing the a thin coat of sealant on both pressing it into

place.

for

normal temperatures

new

Do not over-tighten the

thermostat and

sides

of the

and

that

,

BLEED

PETCOCK

SENDOR [OPTIONALI

NOTE:

Periodically check the condition o!the'radiator

pressure cap. Ensure that the upper and lower rubber seals

are in good condition and

closes tightly. Carry a spare cap.

and

check that the vacuum valve opens

THERMOSTAT

A thermostat, located near engino, continuously the engine coolant from hole in the thermostat warms accessible Carry a spare thermostat and

controls the coolant temperature

flows

is

first

started, the closed thermostat prevents

flowing

up,

the thermostat gradually

and

can be checked, cleaned,

the

manifold

through the closed cooling circuit.

(some coolant

to

prevent overheating).

gasket.

at

the front of the

as

is

by-passed

opens.

The thermostat

or

the coolant

through

As

the

replaced

When

engine

easily.

AIR

FILTER

The

air

filter from quiets

cartridge prevents engine room dust

entering

the

engine.

engine,

it

also

extends engine

and

life,

dirt

and

MAINTENANCE

The

filter

should

be

cleaned

the

cartridge

off

with

or

oily,

a

is

on a flat

compressed

replace

it.

surface

air.

If

every

100 operating hours.

to

dislodge loose dirt

the cartridge

Tap

or

clean

is

badly contaminated

CARTRIDGE

~

WESTERBEKE

Engines & Generators

15

INTAKE

SILEN.CER

FUEL

SYSTEM

DIESEL

Use No.2 diesel fuel with a cetane rating of

not

FUEL

A primary fuel filter of the water separating type must be installed between the fuel tank and the engine water be carried to the fuel system on the engine.

The owner/operator is responsible for making certain the fuel reaching the engine's injection equipment is free of

impurities. This process is accomplished by installing and , maintaining a proper fuel filter/water separator betwen'the , fuel tank and the generator/engine. Westerbeke recommends

a

FUEL

The

the diesel engine, requiring the utmost care in handling. The

fuel injection pump has been thoroughly bench-tested and the

owner-operator is cautioned not to attempt

requires servicing, remove it and take it

injection pump service facility. Do not attempt

ble

The only adjustment the servicing mechanic should make

the fuel injection pump is the adjustment for engine idle

speed (see

ADJUSTMENTS).

FUEL

use

kerosene or home heating fuel.

FILTERJWATER

and

other contaminants from the fuel before they can

10

micron filter be used.

INJECTION

fuel

injection pump is a very important component

and

repair it.

IDLE SPEED

SEPARATOR

PUMP

ADJUSTMENT

45

or higher.

to

remove

to

service

to

an authorized fuel

under ENGINE

to

disassem-

it.

Do

of

If

it

to

FUEL

FILTERS

The fuel injection pump and the fuel injectors are precisely manufactured and they must receive clean diesel from water

must pass through at least two fueLfilters, a fuel filter/water separator clean, and change these filters according to the maintenance schedule in this manual.

A

when

any

open

system

when

and

dirt.

To

ensure this

and

the engine's spin-on fuel

WARNING:

servicing

fuel

that

flames

whenservicin~.

servicing

Shut

off

the

fuel

system.

may

spill.

DO

NOT

or

othe~-sources

Ensure

the

fuel

system.

flow

fuel

valve

Take

allow

of

fire

proper

FUEL

of

filter.

care

any

near

FILTER

fuel,

clean

fuel,

Visually inspect,

at

the

tank

in

catching

smoking,

the

fuel

lientilation

exists

free

the

O·RING

fuel

FUEL

LIFT

PUMP

Periodically check the fuel connections

no

pump and make sure that

fittings

are

tight and secure. The DC ground connection at

one of

the

pumps mounting bolts should be clean and well

secured

tions.

When energized thru the preheat circuit, the fuel lift pump

will purge air from the fuel system and provide a continuous

flow

FUEL

To help ensure clean fuel

filter connected

replaced initially at

by

the mounting bolt

of

fuel

as

the engine

LIFT

PUMP

INLET

to

the fuel pump. This filter should be

50 hours then once a year or

leakage is present and that the

to

is

running.

FILTER

to

the lift pump, there is small inlet

to

and out

ensure proper pump opera-

of

as

needed.

the

ENGINE

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

Changing/cleaning

1. Shut off the fuel supply.

2. Unscrew the retainer ring that holds the

3. Remove and replace the filter element

4. Replace the sealing

FUEL

FILTER

50

hours

MAINTENANCE SCHEDULE.

the

filter

element

filter

bowl

housing and allow the bowl to come away

housing,

"0"

ring and reassemble the bowl

, the housing. Thread the retainer ting on carefully so as not

to

cross

thread.

When

tighten

114

- 1/2 tums by hand. Open the

run the engine

retainer

to

inspect for leaks.

contacts

from

and

clean the bowl.

the

"0"

ring,

fuel

supply and

the

to

the

to

~ngine~ ~ ~~nerators

16

ENGINE

LUBRICATING

OIL

LUBRICATlliN

OIL

PRESSURE

SWITCH

OIL

ENGINE

1.

OIL

Draining

the

sump drain hose (attached while the replace the hose in

securely.

DIAGRAM

PRESSURE

----..-"ffilfin,,;:;;..

OIL

DRAIN-----'

CHANGE

the

Oil Sump. Discharge the

eugine

to

the

front of

is

still

warm.

Drain

the

its

bracket. and replace the end

used

OIL

SCREEN

oillhrough

the

engine)

oil

completely.

cap

2. Replacing the

filter,

you

in

the

upper

oil

from

to

lessen spillage. A small style automotive filter

should be helpful

NOTE:

Do

filter

to

Place some paper towels filter

when unscrewing it to catch

(Oil or

cooling

old

oil

sealing gasket carne off with rubber sealing gasket remains sealed against block, gently remove

NOTE:

The engine oil

flowing through passages in the oil filter bracket

housing assembly.

011

Fl1ter.

When removing the

may

find it helpful

and

lower portion of

it

into

a container before removing it.

in

removing

not punch this hole without first loosening the

make

certain

any

other fluid on

ability.

Please keep your engine clean.) Inspect

filter

as

it

is

removed

and

cleaner

to

the

old filter

the

old

oil

it

can

be

removed!

and

a plastic bag around

any

oil left in

the

engine reduces the engine's

to

make sure that

the

old oil

filter.

it.

is

cooled by engine coolant

/

OIL

FILTER

ASSEMBLY

•.

.

(i

used

punch a hole

to

drain

This

wrench

filter.

the

If

this

the

engine

oil

the

helps

the

filter.

the

rubber

OIL

NOTE:

i/4

DRAIN

Thread size fo,- the lube Qil drain hose capped end is

NPT.-

..

HOSE

SEALING

APPLY

WHEN

When installing the new oil filter element, gasket's apply a thin coat

on

the

filter

nipple,

NOTE:

material standards generic parts might be entirely different from genuine

parts. immediately after an oil filter change

run

the

that there are

3. Filling

cap

on the top of the engine or After refilling, run the engine for a few checking around

stop

the

oil

lube the

dipstick, should the engine require additional

GASKET

CLEAN

ENGINE

INSTALLING

·sealing

new

oil

and then tighten the

Generic filters are not recommended, as the

OIL

surface on

of

clean engine

filter.

Screw

o'r

diameters

TURN

the

ON

HANO

TIGHT

engine block

oil

to the rubber gasket

filter onto

filter

of

the

finnly

important items on

wipe

free

and

engine

to

make

sure

the

oil

pressure

no

oil leaks around the new oil

the

Oil Sump.

the

oil pressure. Make sure there

the

new oil filter or from

engine. Then check the quantity of

dipstick. Fill to, but not over

Add

new

Ihrough

oillhrough

the

oil drain

the moments

the

high mark

is

the

side

is

oil

the

filter

of

oil

and

Ihreaded oil by

hand.

oil fill,

normal

and

filter.

oil

filler

oil

filL

while

no

leakage

system,

and

with the

on

oil.

Engines

17

& Generators

INSTALLATION

This popular ter

from

engine

NOTE:

instructions

APPLY A THIN INSTALLING TIGHTEN CONTACTS

accessory

the engine.to a

room

bulkhead.

Refer

to

ENGINE

on

removing

COAT

OF

CLEAN

KIT.

THREAD

ADDITIONAL

BASE.

AN

THIS

THE

3/4

OIL THE

TURN

REMOTE

is

used

to

relocate the engine's oil

more

convenient location such

OIL

the

TO

THE

KIT

ON,

AFTER

CHANGE

oil

filter.

O·RING

THEN

THE

NOTE ON

THE

REMOVED

,

WILL

in

WHEN

HAND

O-RING

THE

"IN"

ADAPTER

FOR

BE

RECONNECTED

this

manual

AND

"OUT"

MARKINGS

WHEN

THE

INSTAlLATION

HOSES

SO

CORRECTLY.

OIL

FILTER

fil-

as

an

for

ARE

THEY

(OPTIONAL)

To

install,

'llimply

remove WESTERBEKE'S remote install

this

kit

with

the

oil

Contact your

NOTE:

incorrect

A

correctly. by-pass from

failure.

immedialetyand

WESTERBEKE

Westerbeke

installation

CAUTION:

valve

reaching

If

the

in

the

there

is

not

of

It

is

oil

flows

the

engine

is

no

check

responsible

the

vital

filter

oil

the

engine oil

oil

filter

facing

dealer

Remote

to

install

in

the

reverse assembly causing

pressure

the

hose

filter

and

kit

as

shown.

down

as

illustrated.

for more

for

Oil

the

engine

Filter.

oil

information.

failure

lines

direction,

will

prevent

an

internal

reading,

engine

shutdown

connections

thread

Always

due

the

on

to

011

THE

MUST

ATTACH

OIL

TO

AT

FILTER.

CONNECTION

REMOTE

THE

HOSE

IN

CONNECTION

·MUST

ATTACH CONNECTION REMOTE

OIL

ATTHE

FILTER.

TO

HOSE

THE

OUT

APPLY A COAT TER

GASKET FILTER ADDITIONAL

WHEN

CONTACTS

3/4

THE

TURN

OF

CLEAN

BASE,

•

OlllO

TIGHTEN

INSTAlLiNG.

THEFIL-

AFTER

IT

THE

AN

...v:

WESTERBEKE

Engines & Generators

18

OIL

PRESSURE

DESCRIPTION

The

lubricating

oil

pump.

an the

oil

pump,

oil

filter,

the engine. continuous cycle. fied pump

. within

The engine's oil pressure, the

NOTE:

reading an oil pressure

The

pressure,

and

its

OIL

PRESSURE

oil

pressure gauge

mal

operation, the oil

60

psi

(2.1

A newly

readings engine

and

system

The engine

which

oil

cooler

oil

then

When

the

oil

returns

specified range.

up

will vary

and

to

the

to

4.2

started,

60

psi

reading rpms.

kg/cm').

depending

drives

returns

pushes

the

(4.2

is a pressure

oil

is

drawn

the

oil,

and

various

to

the

oil

pressure exceeds

open

oil

sump,

during

on

the

instrument panel.

pressure

cold

kg/em').

as

low

engine

will

as 35 psi (2.5

upon

feeding

under

lubricating

oil

the relief

keeping the

operation, is indicated by

range between 30 and

can have

A warmed

the temperature ojthe

from

sump

system

the

oil

pressure,

points

to

repeat

valve

oil

During

an

engine·

kg!cm').

using

sump

by

through

in

the

speci-

in

the

all

pressure

nor-

oil pressure

can

have

These

TESTING

To

test

install a mechanical warming and

Oil

Pressure

Sender

OIL

PRESSURE

MECHANICAL

PRESSURE

OIL

the

oil

up

read

the

and

Swlteh

TESTING

PRESSURE

OIL

GAUGE

pressure,

the

oil

35.0 Torgue

FROM BLOCK

PRESSURE

remove

oil

pressure engine, pressure

IbM

ENGINE

DlL

(3.8

set

the

gauge.

kg/em') 9 ·13

engine

or

ff-Ib

the

oil

gauge

more

(1.2

pressure

in

it's

speed

at

1800

-1.8 m -

place.

at

1800

rpm.

kg).

sender,

After

rpm

then

OIL

PRESSURE

[NORMALLY

OIL

PREiISURE-,.,:':

SENDDR

OWITrl

OPENI

"

•.

LOW

OIL

PRESSURE

The

specified

+

0.1

kgicm'). A gradual

a

worn

sure readings, see

.

OIL

PRESSURE

An

oil

just

below

appoximately

LOCATED UNDER

.

fUEL

P[jMPONTHE ENGINE

safe

bearings.

pressure

the injection

50

JUST

THE

INJECTION

BLOCK.

minimum

loss

For

additional

the

ENGINE

RELIEF

relief valve

pump.

psi

[343

oil

pressure

of

oil

information

TROUBLESHOOTING

is

pressure

VALVE

is

located

kpa]

on

the engine

1bis valve opens

and

maintains that

4.3 + 1.4 usually

on

low

at

pressure.

psi

(0.3

indicates

oil

pres-

chart .

block

Engines

19

&.

Generators

ALTERNATOR

The charging system consists of a

with

a voltage

mounted

cables. electronic voltage regulator

internally or on the back of the

50

#14

VIOLEET1~~;;~;~

TO

FUEL

FUEL TO

S'

PUMP,

T82111

AND

regulator,

DC

circuit breaker

Because of

AMP

ALTERNATOR

~~~;:.,

ill

an

engine

and

the

use of iutegrated circuits (IC's),

is

DC

ELECTRICAL

DC

belt driven alternator

DC

wiring harness, a

a battery with connecting

very

compact and

alternator.

is

mounted

the

SYSTEM

1.

Start the

2.

After the engine

starting battery

multimeter set

a.

b.Ifthe

engine.

If

the voltage

alternator

voltage

with

exists continue

has

rnn for a

voltage

on

DC

is

increasing toward

is

working.

remains around

either

the

with

Steps

MULTI

METER

few

minutes, measure

at

the

battery terminals

volts.

14

volts,

12

volts,

a problem

alternator or the charging

3 through

~

COM

8.

mID

G

using

the

a

circuit;

ALTERNATOR

A

WARNING:

hot.

00

Use this troubleshooting section exists with detennined that the alternator or voltage regulator have a qualified technician check

The alternator charging circnit charges the starting battery and any accessory solenoid or a battery selector switch is usually mounted in the circnit to isolate discharged along is charging the problem not

with

Testing

A

CAUTION:

that

everyone

sheaves

TROUBLESHOOTING

A

failed

alternator

not

touch

until

the

alternator

the

charging circuit

battery.

with

the

starting battery but

is

in the service battery's charging circuit

the

alternator.

the

Alternator

Before

is

clear

and

belts

An isolator with a diode, a

the

batteries

the accessory battery.

starting

of

moving

during

test

can

has

to

determine

or

with the

it.

so

the starting battery

not

the accessory battery,

the

engine

parts!

procedures.

become

cooled

if

a problem

alternator.

If

the

make

Keep

away

very

down.

If

it is

is

faulty,

is

alternator

and

certain

from

not

e

TESTING BATTERY (ENGINE

3.

Thrn off the engine: Inspect all wiring and connections. Ensure that the battery tenninals connections

A

CAUTION:

alternator,

when

4.

Tum on the ignition switch, but

5.

Check condition,

THE

IALTERNAT

RUNNING)

are

tight and clean.

never

the

engine

the

battery voltage. the

reading should be

STAR

To

avoid shut is

running!

liNG

OR

-

damage

off

the

If

~

0

coM

I""

~

L

-=

GROUND

and

engine

do

the battery

12

+

g~~~

gg9

"<-

the engine

to

the

DC

battery

not start

is

in

to

13

volts.

STARTING

charging

the

good

MULT

.J

BATTERY

ground

switch

engine.

IMETER

A

WARNING:

DC

and

AC

Always

engine

be

made

isolate

before

without a proper

When

circuits

DC

and

performing

are

often

AC

testing

with a multimeter;

mixed

converters,

DC

testing.

knowledge

together.

and No of

shut

AC

circuits.

down

tests

,.

TESTING

the

should

ALTERNATOR

(IGNITION

WESTERBEKE

Engines

&.

Generators

20

THE

VOLTAGE

ON • ENGINE

OFF

)"1'"

.

e

999999

~r

'<"-

-=-

GROUND

~=']

~

STARTIN

~

G

--~

...

BATTERY

6.

Now tenninal age isolator

If

cuit connections

STARTING

check the

(B+) and ground

at

the

alternator will

is

in

the circuit

neither of the

betWeen

888

8

the

-look

BATIERY

88

ALTERNATOR

voltage

above

is

alternator

for

between

be

the

an

the

alternator output

If

the

circuit is

the

same

alternator

Ime,

and opeuing

voltage will

a problem exists in

the

battery.

in the

MUlTI

8

.

l'<1il-'I\\W~1

DC

as

the

ELECTRICAL

good.

the

volt·

battery,

or

if

an

be

zero.

the

cir-

Check

all

the

charging

METER

circuit.

[]bID

..

·'·

·

;~

~

e

COM

SYSTEM

12

VOLT

DC

CONTROL

The

engine has a

shown

on the wiring diagrams that diagrams electrical

A

circuit, the however, engine's

when troubleshooting or system.

CAUTION:

never

engine

12

To

shut

is

running.

to

avoid

electrical

BATTERY

The

ntiuimum recommended capacity of

the

engine's

Cranking

12

volt DC control circuit

Amps

(CCA).

CIRCUIT

volt DC electrical control circuit that

avoid

damage

off

the

engine

Shut

off

electrical

circuit.

follow.

When

to

battery

the

engine

shorts

Refer to

servicing the

the

battery

switch

battery

when

working

the

battery used

is

600

- 900

is

these

DC

charging

while

switch, on

the

in

Cold

TESTING

BATTERY/ALTERNATOR (ENGINE

7. Start alternator output

The should be between is

over·

service facility.

NOTE:

voltmeter

at the tery voltage at the B output terminal.

If

12 volts is not present at the

wiring and look

A

CAUTION:

do

not

performing

THE

STARTING

RUNNING)

the

engine

again.

Check

and

ground.

voltage reading for a properly operating alternator

13.5

and

or

under-charging,

Before removing the alternator

to

ensure that

EXC

terminal

To

use a high

tests

for

voltage

on

12

if

the previous test showed only bat-

breaks

avoid

damaging

tester

the

alternator

..

the

voltage between

14.5

volts.

have

it repaired

for

volts

DC

excitation is present

EXC

terminal, trace the

and

poor

connections.

the

alternator

(i.e. a megger)

charging

=--'

If

ENGINE GROUND

your altemator

at

a reliable

repair,

use a

diodes,

when

circuit.

the

Battery

Review

establish engine's starting batteries.

o Monitor your voltmeter

Care

the

manufacturer's

a systematic maintenance

engine

operation.

reconnnendations

for

o Check the electrolyte level

hydrometer.

o

Use

only distilled water

level.

o

Make

tight

to

o

Keep

your batteries clean and

A

WARNING:

cause

severe

protective

certain that battery. cable connections are clean and

the battery posts (and to your engine).

Sulfuric

burns

gear.

on

to

acid

skin

and

then

schedule

proper

and

specific

bring electrolytes to a proper

free

in

lead

and

damage

for your

charging

of corrosion.

during

gravity with a

batteries

clothing.

can

Wear

-.v

WESTERBEKE

Engines &

21

Generators

STARTER

MOTOR

DESCRIPTION

The

starting

system

and

starter

button.

When

the

starter

button

current

flows

and

energizes energized into

~

to serves flywheel.

To pinion is engine motor

Once ping contact flow

magnetic plunger fi·om

the

coil,

reach

the

to

prevent

gear

spJined

may

itself.

the

activation

with

of

electricity

is

its

engagement

coil

becomes

and

closes a set

starter

push

that

damage

incorporates

to

the

starter

speed

started

button

tlle

battery-to-start

fields

and

released,

motor. starter

the

of

is

includes

on

the

an

electromagnet,

At

pinion

to

the

starter

an

over-running.Cone-way)

armature

rotation

is

released,

the

solenoid.

interrupted

tlle

starter

its

movement

with

the

battery,

instrument

starter's

of

contacts

the

same to

mesh

motor shaft.

of

the

tlle

The.plunger cables to

the

ceases

also

engule

starter

panel

solenoid

which

time,

the

with

when

The

rotation

pinion

but

CUlTent

by a coil starter.

its

rotation.

pulls

the

flywheel.

SOLENOID

motor,

is

coil. pulls

allow

plunger

the

not

flow

is spring,

This

starter

engine

solenoid,

depressed,

The

the

high

also'

teeth

on

starts,

clutch

of

the

starter

ceases,

pulled

out

and

weakens

As

the

solenoid

drive

plunger

cunent

the

which

numing

stop-

of

the

.

gear

SOLENOID

IGNITION TERMINAL

To

test

the

ignition

ofthe

smaIl Use a screwdriver, ignition

terminal

the

solenoid.

If

the starter cranks, the fault

If

the

solenoid

motor

is

probably

tenninal

don't

to

clicks

circuit,

studs

touch

the

positive

but nothlng

faulty.

locate

and

is

the

')-:l~---(M)

TERMINAL

n

the

ignition(s)

wired

blade,

battery

lies

with

else

terminal

to

the

ignition

to

imup

from

cOllileetion

the

ignition

happens,

the starter

(it

circuit).

tlmt

tenninsl

circuit.

is

on

one

MOTOR

TYPICAL

STARTER

REFER DIAGRAM

MOTOR

TO

THE

IN

WIRING

THIS

MANUAL

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

and

that

the

starting

system

wiring

clean

and

tight.

Pay

cmIDections To

check

never

the

wires

resistance. Using a multimeter,

stud

If

you

more

on

read

the

and

the

on

the

wiring,

than

tenninals

Repair

slalt

solenoid

12

volts,

10

or

particular

engine

try

seconds

replace

test

the starter

attention

block.

cranking

at a

lookhlg

any

the

voltage

and

the

for

ships

batteries

cOllilections

to

the

.

the

starter

time,

then

wann

spots

trouble

spots.

between

engine

block

is

faulty.

are (terminals)

ground

for a few

nul

your

that

the

positive

(ground).

at

full

wh'e

seconds, hand indicate

tem1inal

charge

are

along

SOLENOID.

IGNITION

If

nothing Check collilections.

A

fly space

at

the

battery

WARNING:

when

is

gasoline.

all

happens

isolation

It

is

also

jumping

treeot

pofl!ntially

the

solenoid

switch

possible

There

that

will

terminals.

POSITIVE

').::~--'fll.nTERMINAL

~

isn't

getting

current.

and

inspect

the

wiring

the

solenoid

be

arching

Be

certain·the

explosive

is

defective.

and

sparks engine

fumes,

will

especially

Engines & Generators

22

IGNITION TERMINAL

Test

again screwdriver screwdriver would

cause a short.

A

WARNING:

starting screwdriver.

by

jumping blade blade

current

~V_;o---~IM)

the

two

large

firmly

between

to

touch

the

solenoid

There

will

should

be

terminal

the

studs.

be

arching

flowing

or

starter

thru

studs.

Do

as

the

STARTER

POSITIVE

TERMINAL

Hold

the

not

allow

the

casing,

this

the

full

blade

of

the

MOTOR

SERVICE

Westerbeke servieed

If

replacing eertified standards.

TO

1.

Disconnect

2.

If

starter

3.

Label wires

4.

Remove

5.

Remove will

uses a standard

or

rebuilt

at

the

starter

for

marine

If

in

doubt,

REMOVE

necessary,

have

motor.

and

disconnect

to

touch,

the the

to

FOR

the

negative

remove

tape starter starter

be

turned

marine

any

starter

motor,

make

use.

Automotive

contant

your

SERVICE

battery

any

components

the

wiring

over

the mounting from

the

to

a

different

starter

motor

automotive

certain

the

starters

do

WESTERBEKE

cable.

to

gain

from

the

terminals).

bolts.

engine.

ill

some

angle

which

service

new

not

full

starter.

cases

to

clear

can

be

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

allow

the

starter

obstructions.

the

If

the starter

If

the starter

If

no

arching occurred. There

NOTE:

the

pre-engaged

engages

screwdriver motor provide

magnetic the

solenoid

Starter

the

starter to

without

the

power

field

are

spins, fails

motors

model,

bypass

engaging

for

bad.

the

to

motor

to

the

solenoid

spin,

are

the

solenoid.

arm

is

faulty.

the

motor is probably

is

no

juice

either

inertia

solenoid

to

solenoid

flywheel.

to

the

flywheel

move

also

on

Tum

Hopefolly

even

reaching the

type

or

pre-engaged.

moves

an

of

the

engine.

such a starter

the

starter

it

will

though

the

faulty.

solenoid.

arm

that

Using

will

run

switch

create

contacts

In

a

the

on

to

enough

inside

-.y'

WESTERBEKE

Engines & Generators

23

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are

wired through When should

PREHEAT

"click"

is

pressed at the control

on

and

INSPECTION

To

inspect

the

plug,

remove

tions,

then

head.

soft

oil

deposits.

bum

unscrew

Thoroughly

brush

and

erosion;

or

clean each plug's tip

cleaning solution to remove

While

clearring,

if it

has

TESTING

An

accurate Touch other plug used an

ammeter

A

to

thB

testing

way

to

test

one

prod

to

the

to

the

body

of

the

will

have

a 0.4 -0.6 ohm resistance.

with

the

plug

in

to

test

the

WARNING:

touch.

the

Be

careful

plugs.

These

the

preheat

the

glow plug should

the

electrical tenninal

unclamp each plug

examine the

eroded

too

much, replace

glow

plugs

is

with

glow

plug's

wire

glow

plug,

as

shown.

or

out of the engine.

power drain

glow

not

(5

plugs

to

burn

- 6

will

your

solenoid.

panel

this

begin

from

the

and

threads

all

the

tip

for

wear

the

an

ohmmeter.

connection,

A good

This

method

You

can

amps

per plug).

become

fingers

solenoid

to

get

connec-

cylinder

with

carbon

and

plug.

and

glow

can

also

very

when

hot.

a

and

the

use

hot·

be

Re-install plugs should seconds. circuit. pound

A

than

Glow

the

If

When

on

the

WARNING:

30

seconds.

Plug

Tighlening

plugs

get

very

the

plugs

reinstalling

threads.

Torque

in

the

engine and test

hot

(at

the

terminal end)

don't

heat

up

the

glow

Do

not

keep a glow

7

-11

n-Ib

TESTING A GLOW WITH

AN

OHMMETER

them

again.

within 7 to

quickly, check

plugs,

use

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WESTERBEKE

. E'!gines & Generators

27,A

ENGINE

The

following troubleshooting table describes certain problems

to

relating

engine service, the probable causes

of

TROUBLESHOOTING

these prob-

lems. aud the reconnnendations to overcome these problems.

Note:

The

manual

of

the engine.

engine's electrical system

reset

circuit

breaker located

is

protected by a

on

a bracket at

20

the

amp

rear

Key

switch

depressed:

fuel

START

engagement.

START indications

fuel

Generator start,

Engine Battery

Battery

Generator

on,

n.o

solenoid

or

SWITCH

switch

OK;

solenoid

engine

fuel

solenoid

can't

be

runs

down.

not

charging

engine

Problem

PREHEAT

panel

is

not

switch

indications;

electrical

fuel

DEPRESSED,

depressed;

starter

solenoid

functioning.

cranks,

energized.

stopped.

stops.

but

pump

no

panel

OK

does

starter

not

1.

Battery

2.

Emergency

20-Amp

3.

K2

relay

4.

5.

Loose

Preheat

6.

1.

Connection

Faulty

2.

Faulty

3.

4.

Loose

Low

5.

K1

relay.

6.

Poor

1.

2.

Defective

3.

Current

1.

Faulty

2.

Preheat Low

3.

Faulty

1.

Oil

Pressure

1.

2.

High

Low

3.

Poor

4.

5.

DC

1.

DC

2.

Alternator

Fuel

1.

Switches

2.

or

disconnected.

3.

Fuel

20

4.

Exhaust

5.

6.

Water

Air

7.

Probable

Switch

not

stop

circuit

breaker

battery

connections.

solenoid

t.o

solenoid

switch. solenoid.

battery

connections.

battery.

connections

fuel

solenoid.

limiter.

1ueling

system.

solenoid

battery.

DC

alternator.

switch.

resistance

battery

connections.

alternator

charge

Amp

intake

not

circuit

drive.

feed

pump

and/or

starvation.

circuit

system

in

fuel.

obstruction.

Cause

on.

switch

tripped.

not

.operating.

faulty.

to

fuel

faulty.

leak

to

leak.

charging

faulty.

strainer

wiring

breaker

is

restricted.

off.

solenoid.

ground.

..

is

dirty.

loose

tripping.

1.

Check

2.

Check

3.

Reset

Circuit

4.

Check

5.

Check engine

6.

Check

1.

Check

2.

3.

Check

4.

Check

5.

Check

6.

Check

1.

Check Check

2.

fuel

3.

Check

1.

Check

1a.

Switch

lb.

Replace

le.

Check

2.

Check

3.

Replace

1.

Remove

1.

Observe

is

2.

Check

lines. after

Check

3.

4.

Check corrosion.

Check

5.

DC

Perform

1.

DC

Check

2.

for

volts

1.

Clean

2.

Inspect Inspect

3.

Check

4.

Check

Ensure cause

5.

Check

exhaust

6.

Pump

bleed

7.

Check

Verilicalion}Remedy

switch

and/or

emergency

breaker;

and

K2

(+)

ground

solenoid

connection.

switch

that

battery battery

K1 connections.

that

run

limiter.

that

to

fuel

solenoid.

not

running.

wiring.

(Do

short

all cable

connections,

ELECTRICAL

drive

loose

are

strainer.

fuel for

breaker

tripping.

for water

fuel

air

stop

if

breaker

check

circuit

relay. connection

stud.

"S"

terminal

with

ohmmeter.

12

volts

are

connections.

charge

relay.

12

volts

solenoid.

batteries.

Exc.

if

wires

D.C.

connections.

present

wiring switches

elbow.

are

fuel

valves

combine

house

lift

pump.

connection

gauges

and

Test

the

Insert

not

start

engine.)

is

located.

for

temperature

connections

SYSTEM/ALTERNATOR.

voltage

SYSTEM/ALTERNATOR

belt

tension.

at

for

short

for

supply,

1uel

high

DC

amperage

is

not

blockage,

from

1uel

system.

intake

filter

battery

connections.

switch

trips

for

shorts

to

starter

Check

battery

for

present

state.

present

are

open.

and

at

alternator,

panel

oil

pressure

sensitive

Remove

at

battery

check

belt

check

of

Alternator

Check

the

Exc.

terminal.

circuits

proper

operation.

valves,

overly

collapsed

tank(s);

cartridge.

position.

again,

check

t.o

ground.

solenoid

cable

voltage.

at

the

solenoid

at

the

(+)

start

batteries.

lights

are

switch.

(0 -.25

amp)

connections

rise

to

for

tension,

generator

should

output

with

and

loose

fuel

feed

draw

during

sensitive

hose,

carbon

change

preheat

and

(-)

connection

connections.

connection.

connection

repair

alternator.

activated

when

meter

locate

the

fault.

loose

connections,

test

alternator.

challling in

this

manual.

turn

1reely.

voltmeter.

connections.

strainer

..

operation.

to

heat

which

buildup

filters

and

solenoid

on

the

engine

in

battery

and

replace

See

circuit.

Check

Ensure

would

at

to

See

12

I~/WESTERBEKE

I Engines & Generators

28

ENGINE

TROUBLESHOOTING

Generator

Low

Exhaust

engine

oil

pressure,

smoking

Problem

overheats/shuts

shuts

down,

problems

down.

1.

2.

1.

2.

3.

Probable

Coolant

not

Loss

of

oil.

Oil

pressure

Blue

smoke.

White

smoke.

Black

smoke.

Causu

circulating.

swilch.

VerilicalionJRemedy

Thermostat -remove

1.

Replace

thermoslat.

Loss

of

2. 2c.

2d.

1.

2.

1.

1a.

2.

23.

3.

3a.

ab.

3c, 3d.

coolant -check

for

leaks.

Broken

or

loose

Air

leak

in

system;

bleed

air.

Add

Check

dipstick,

oil

drain

hose

Replace

oil

Incorrect

grade

Crankcase

through

Engine

Faulty

Improper

Fuel

insufficient

exhaust

Improperly

Lack

ventilation.

Overload

...

is

the

is

running

injector

grade

burn

incomplete

system;

of

air -check

.

coolant

connection.

pressure

overfilled

exhaust).

air

timed

and

test

in

hot

hoses,

hose

bells -tighten/replace.

run

engine

and

open

as

needed.

look

for

oil

leaks

at

oil

switch.

of

engine

oil.

with

engine

oil

cold.

or

incorrect

injector

timing.

of

fuel.

due

to

high

for

proper

check

injectors

air

inlake

back

combustion

intake.).

or

-valves

or

and

air

water.

clamps,

the

pressure

filter

and

(oil

is

blowing

pressure

(Check

for

poor

compression.

filter.

Check

drain

plug,

cap

at

out

in

exhaust

restrictions

for

proper

etc.

to

or

in

~

WESTERBEKE

Engines & Generators

29

ENGINE

NOTE:

WESTERBEKE recommends that the following engine

adjustments be performed by a competent engine mechanic.

ADJUSTMENTS

VALVE

Make the following adjustments when the engine is cold.

1. Remove the cylinder head cover.

2. Slightly loosen the cylinder head bolts and retighten them

CLEARANCE

to the specified torque in the number sequence

below.

ADJUSTMENT

Tightening

Torque

04

65 ± 41b·H

(BB±"5

(15

shown

Nm)

01

012

FOUR

FRONT

Oll

CYLINDER

01

010

THREE

CYLINDER

d. For 3 cylinder models, rotate the crankshaft 240

degrees to position the next cylinder in the firing order

TOe

at its Rotate the crankshaft another last cylinder in the firing order at cylinder valves. 240 degrees, it should put the #1 cylinder at its compression stroke with the

alignment with the timing gear case mark.

e. For 4 cylinder models, rotate the crankshaft

degrees to position the next cylinder in the firing order

. 'at its

the next two cylinders in the firing order.

When the crankshaft another cylinder back to its the with the timing gear case mark.

position and adjust the cylinder valves.

240 degrees to place the

TOe,

If

you rotate the crankshaft another

TOe

marl again in

TOe

position and adjust the valves and so on for

#2 cylinders are adjusted, rotating the

180 degrees will bring the

TOe

on

compression stroke and

TOe

mark

on

the crankshaft pulley should line up

then adjust the

TOe

180

#1

of

3.

Find top dead center compression position for No.1 piston

by using the procedure that follows. a. Rotate the crankshaft observing the valve opening and

closing on cylinder #1 to correctly position the piston on the Top Dead Center (TOC) compression stroke. crankshaft pulley should then timing gear case mark.

b.

Firing order 3 cylinder: I - 3 - 2

Firing order 4 cylinder: I - 3 - 4 - 2 Valves will

with each cylinder piston at TOC

stroke.

c. With

adjust the intake and exhaust valve for that cylinder.

the

#1

be

piston

The

TOC mark

be

adjusted in the firing order

at

TOe

of

its compression stroke,

INJECTION

~ARK(1T)

of

o~the

aligned with the

of

its compression

TIMING

its

front

of

the engine

#1

l

~

?

TIMING

GEAR

CASE

MARK

4. Loosen the lock nut for the adjusting screw. With a feeler gauge inserted between the rocker ann and valve cap, adjust the valve clearance by turning the adjusting screw.

Make certain to adjust all the valves.

---''£''''''''"'''''''~

5. Install the cylinder head cover.

Head

Cover

Bolt

Torque

2 -3

H-Ib

(0.3 -0.45

0.25mm (0.009B

INCHES)

INTAKE & EXHAUST

m-kg)

Engin'!s &

30

Ge,!_l!rators

"

ENGINE

NOTE:

WESTERBEKE adjustments information below

be

perfonned

recommends

is

provided

ADJUSTMENTS

that

the

following engine

by a competent

to

assist

engine

the

mechanic.

The

TESTING

Make certain and the air intake must

L

also

Warm

ENGINE

Ihe

oil

filter

be

in

good

Ihe

engine

COMPRESSION

level

(dipstick)

is

clean. The battery

condition. to

normal operating temperaiure.

is

at

the correct level

and

starter

2. Move the control lever to a position for shutting off

fuel.

(Disconnect

is

used).

3. Remove the compression gauge/adarter combination to cylinder

all

on

TESTING

the

glow

which

Ihe

ENGINE

wires if a

plugs from

compression

fuel

shutdown solenoid

Ihe

engine and install

Ihe

is

to be measured.

COMPRESSION

PRESSURE GAUGE

ADAPTER

c·

....

.'

~WPLUGHOlE

4.

Crank the engine maximum

5. Rereat

NOTE:

this

COMPRESSION MAXIMUM

42.7

psi

(3.0

If

the

repair.

6.

Re-instalilhe run

rosition.

PERMiSSIBLE

readings

and

reading,

Kgl/cm~

Ihen record

process

for each

PRESSURE

DIFFERENCE

are

glow

rlugs and reset the fuel shut-off

allow

427

below

Ihe

gauge

Ihat

cylinder.

psi

(30

BETWEEN

the

limit,

to reach a

reading.

Kgl/cm')

the

at

290

rpm.

CYLINDERS

engine

needs

motor

Ihe

to

the

FUEL

INJECTORS

In

case

of severe vibrations and detonation injectors injection service loss in clean injector

Before base falling

out

Ihe free

The

washer.

replaced

installed.

INJECTOR

40

DRIVE

Proper inspection, service and maintenance of the

,

is

,

Drive

not provide proper alternator charging

damage

'the alternator out of alignment and/or cause

wear out prematnrely. Excessive drive belt tension can

cause

fresh

on the belt can cause belt slipping, resulting

temperatnres.

The

no

(12mm)

point between the

, A

checked

of positive

injector faults. Since fuel injectors must

room environment, it is best to carry

asa

removing the old injector, clean

of

Ihe

down

easily

injector side-to-side wilh the

it,

and

injector

This washer should be removed

with a new

TO

±4

ft-Ib

(5.5 ± 0.5

BELT

important for the efficient operation of

Belts

belts must be prorerly tensioned. Loose drive belts

Ihe

rapid

water pumps bearing. A slack belt

drive

less

Ihan

as

spare

belt or belts should always be carried on

and

center.

fuel

spare

injector

into

the

and

is

held in

then

lift

seats

CYLINDER

overhauled

Poor fuel

pressure to the injection

should a problem

to

help prevent

injector hole.

by

it

out.

in

Ihe

cylinder head

washer when

'

HEAD

TIGHTENiNG

kgl-m)

by quality,

any

If

carbon build-up

aid

Ihe

ADJUSTMENTCFANBELT)

under MAINTENANCE

alternator. Drive belts that

wear of the belt and reduce the service life of

belt

is

properly adjusted

3/8

inch (lOmm) and no

the belt

is

depressed with

two

pulleys on the longest span of

if

noise,

have

an

au!horized fuel

contaminant's

pump

be

serviced

at

least

one

occur.

the

area

around

rust

or

debris

Ihe

injector will

or

the

like,

of

Ihe

socket

wrench

on

a copper sealing

wilh

the injector

new

injector

TORQUE

your

engine

SCHEDULE).

and

will

eventnally

are

too

tight will pull

Ihe

alternator to

or

Ihe

presence of

in

high operating

Ihe

belt can be deflected

more

Ihan

112

Ihe

Ihumb

at

board.

can result

drive

the

is

inch

Ihe

in

extra

Ihe

from

not

work

belts

(see

also

mid-

the

and

a

lift

to

and

will

the

oil

belt.

LOW

COMPRESSION

When low compression applying a small plug hole. Allow

Install the pressure compression reading rises dramatically, rings.

If

Ihe

compression valve does uot

the valves.

A slight rise

bolh the rings and

in

compression would indicate a problem

amount

Ihe

oil

gauge

Ihe

valves.

is

fonnd, determine the cause

of oil in

to settle.

the

cylinder thru the

and repeat the above

rise,

test.

Ihe

fault is

with

the problem is

~

A

drive

If

by

glow

Ihe

wilh

WESTERBEKE

Engines &

Gene-,at~rs

3.1

WARNING:

belt's

Adjustin~

1.

Loosen mounting

2.

With

edges.

3.

Pivot or

right

4.

Tighten bolt.

5:

Run recheck

tension

Belt

Ihe

bolt.

Ihe

belt

the

alternator

as

required,

the

,lhe

engine the

Never

attempt

while

Tension

alternator

loose,

inspect

base

mounting

for

belt

tensions.

to

check

the

engine

adjusting

on

the

to

loosen

about 5 minutes,

for

base

bolt

is

strap

wear,

mounting

or

tighten.

and

or

adjust

in

operation_

bolt

and

cracks

and

bolt

Ihe

adjusting

Ihen

shut

the

Ihe

base

frayed

to.the

strap

down

left

and

CONTROL

MANUAL

NDTE:

The engine control system is protected by a

located on the engine as close

STARTER

PANEL

as

possible

TROUBLESHOOTING

DISCONNECT

to

the

(TOGGLE

20

amp manual reset circuit breaker

power

source.

SWITCHES)

PREHEAT

fuel

preheat

START

engagement.

NO

depressed,

solenoid,

solenoid

SWITCH

IGNITION,

NOT

CHARGING

BATTERY

RUNS

Problem

no

electric

panel

fuel

not

energized.

DEPRESSED,

cranks,

does

BATTERY

DOWN

indications

pump

no

not

start.

and

starter

1.

Oil

Pressure

2.

20

amp

K2

relay

3.

Connection

1.

2.

Faulty

3

..

Faulty

4.

Loose

5

Low

K1

relay.

6.

Faulty

1.

2.

Check

Faulty

3.

Faulty

1.

Oil

pressure

High

2.

Low

3. Faulty

4.

Probable

switch.

circuit

breaker

faulty.

to

solenoid

switch.

solenoid.

battery

connections.

battery.

fueling

system.

for

air

in

the

fuel

lift

pump.

alternator

switch.

resistance

leak

alternator.

Cause

fuel

drive.

leak

to

ground.

tripped.

faulty.

system.

ground.

1.

Check

2.

Reset

circuit

3.

Check

1.

Check

2.

Check

3.

Check

4.

Check

5.

Check

6.

Check

1.

Check

2.

Allow

3.

Replace

1.

Check turns

output

regulator

1.

Observe

engine

2.

Check lines after

3.

Check

4.

After a good If

leakage

replace.

VerilicalionJRemedy

switches breaker.

system

freely.

(Do

short

and/or

If

it

run

circuit

with

12

volts

connections.

charge

fuel.

to

bleed.

lift

pump.

drive

belt

Check

a

voltmeter.

terminal.

the

gauges

not

running.

wiring.

Insert

NOT

start

is

located.

wires

for

battery

stops.

Remove

opens

ohmmeter.

temperature

and

relay.

connection. switch

that

battery

relay.

for

fuel

the

with

if

is

the

all

battery

for

are

present

state.

and

for

loose

and

Test

sensitive

engine).

charging,

connections.

again,

check

shorts

to

at

its

tension.

connections.

Ensure

12V

panel

lights

the

oil

pressure

(0·.25

Remove

rise

disconnect

alternator

preheat

ground.

the

solenoid

Be

sure

Check

are

present

are

activated

switch.

amp)

connections

to

locate

alternator

and

bench

solenoid

connection.

the

alternator

the

at

the

when

meter

in

and

the

fault.

at

test.

Repair

the

battery

replace

output.

or

TROUBLESHOOTING

If

the

gauge reading

by

the

gauge

step

is

to

check for

and

the

Negative

Assuming that there instrument panel energized and perform

1.

Disconnect the sender gauge

reads

situation.

2.

Remove gauge scale,

the

and

which

is

other than what

when

the

instrument panel

12

volts DC between

(B-)

terminals of the

is

12

volts

as

required, leave

wire

at

the

gauge

zero,

which

is

the normal reading

wire

attached to

the

sender tenninal

connect it to ground. See if

is

the

normal reading for

WATER

is

normally indicated

is

energized, the

the

ignition

gauge.

the

following

and

see if

for

at

the

gauge reads

this

situation.

"'"

TEMPERATURE

If

both of

first

(B+)

undoubtedly OK and the problem lies either conductor

If

either of

probably defective and should be replaced.

steps:

the

this

Assuming

sender Check that the engine block

Some

the

full

battery

terminals), the ground side to

the

WESTERBEKE

E.I1JJ.ines

&

Gener~~t?rs

AND

the

from

the

to

the

starters

is

connected

block.

DlL

PRESSURE

above

gauge

the sender

GAUGES

tests

are

positive,

to

the gauge

or

above gauge tests are negative,

gauge

is

OK,

check the conductor from the

sender terminal

at

the gauge

is

connected to

have isolated ground tenninals

to

the starter (both plus

will

not necessarily

the with

with

the

for

continuity.

the

and

be

gauge

the

sender.

gauge

ground.

if

the

minus

connected

is

32

ELECTRIC

GOVERNOR

(OPTIONAL)

DESCRIPTION

The system

1.

Controller. A solid state component mounted in the

control box on the generator

2. MPU (Speed Sensor). Installed on the bellhousing over

the

3. Linear Actuator. Threaded into the engine block

behind and below the fuel iniection pump

is

composed

flywheel ring gear teeth.

CONTROLLER.

•

PNI04960lf"

(12

AND

of

three basic components:

1-::::"--1--,----,

24

VDC)

I

ri===ib.!"".-L~

..

just

•

ADJUSTMENTS

TO

ElECTROHIC

CONTROLlER

'ro1l:IIJII!1I

IIDNlIlU

,

TO

Ili!HSD

(TOUHEAIlAC

ru~TOR

(Cn1"t411~

flUlACr

"

n

:~ro(

vlOm

lllOlfT

TERMINAL

REFER

1 .

",,2

TO

WIRING

,~

3

4~

.;:,

5

.

6~

BOARD

DIAGRAM

,m

"".

BLAtKIWM

VIOLrT

,lIlom

TB·3

"',.

J

TeODVtllHOIi

f"

SENSOR_

LOCKNur--

;t

FLYWHEEL--....

TEETH

,VV\

MAGNETIC

CONTROLLER

1. Speed. This adjustment is used to raise or lower the

2.

Calibration

1. With no power to the governor, adjust the GAIN to

2. Start the engine and adjust the speed by either turning the

3. At no-load,

4. Tum the GAIN potentiometer counterclockwise

"

_ '

~

,,-r=::

-

engine's speed to the desired hertz.

Gain.

This adjustment affects the reaction time

actuator to the generator/engine load changes.

NOTE:

A high gain adjustment can induce an oscillating

of

the actuator producing a hunting mode. In such

cases,

lessen the gain adjustment.

9:00 o'clock.

speed potentiometer clockwise INC (increase) pad until the desire speed is obtained.

NOTE:

Controllers are factory adjusted However. the engine

the engine begins to hunt. physically upset the governor linkage.

until stable.

D,Or

n

'!

---

PICK-UP

SENSOR PNilD39172

ADJUSTMENT

for

safety, one should

, I

12

VDc

. - - ,

or

if an overspeed should exist.

tum

the GAIN potentiometer clockwise until

if

the engine does not hunt,

~

SUPPl

....

rrliTp;;~ll

LINEAR

ACTUATOR

depress and hold the

to

be

capable

•

PN!303007

'PN1I39745

of

minimum rpm.

of

disabling

the

12'

24V

INSPECTION

The system has two styles

early version (black encapsulated components) with 2 adjustments, a speed potentiometer and a GAIN adjust-

ment. This controller is NLA. The current electronic

controller (aluminum housing with components inside) has

two push pads for speed adjustment.

speed (INC) and one has the GAIN adjustment,

These two

When

page. sent to the controller to function with.

The engine is started, the new controller will operate the

engine in the depressing and holding the INC pad until the speed reaches the desired rpm (hertz) as possible.

The GAIN adjustment has been discussed earlier under CALIBRATION. and note its reaction react and maintain higher. The electronic governor system will maintain a set speed at rated amperage load for the generator.

NOTE:

When stopping the unit, the engine only goes

idle and does not shut down fully, the actuator will need a slight adjustment to provide complete stopping Thread the actuator in stopping

AND

ADJUSTMENT

of

electronic controllers. The

One

pad

to

increase

pad

to decrease speed (DEC).

,electronic controllers are illustrated on this

you press

800-1000 range. Adjust the engine speed by

+ or - 0.5 hertz from no an1perage load

of

the engine is

the

preheat button, DC voltage is

Place an amperage load on the generator

to

the load.

the

set speed, adjust the GAIN slightly

114

obitai',

tum-

If

the system is slow to

112

tum

until complete

!eq/)""

to

of

the unit.

It

full

to

also

a low

NOTE:

The controller operates

range is ± 20% (9.6VDC

varies above

not operate proper voltage is supplied

or

below these ranges, the controller

and

the engine will run in an idle mode until

on

I2VDC. The voltage

I2VDC

to the controller.

I4.4VDC). Ifvoltage

will

-..y'

WESTERBEKE

Engines & Generators

33

ADJUSTMENT

Problem

System

(No

actuator

Engine

Actuator

Unit

hunts

appears

movement)

runs,

but

(removed)

during

dead.

at

idle

operation.

speed

LINEAR

1.

Check

the

battery

with

the

2.

3.

1.

2.

Preheat

If

there

is

MPU,

measure

MPU

while

and

black/white

While

cranking

should

be

NOTE:

The

5000

ohms/volts

NOTE:

When

preheat

solenoid

so

as

not

Check

the

This

provides

DC

voltage controller on

the

controller

have

battery

a

Purple

b.

Purple

NOTE:

Continue

voltage

is

c.

The

following connections on

the is a break connection leads

themselves.

1}

Low

2)

Battery

3)

Battery

not

Check

the

one

at a time

terminal

block.

prehea'Von a.

Actuator

b.

Shorted/open

Improper Inadequate

a.

Connect a DC at

the

b.

Disconnect controller

c.

Connect

on

the

Black

d.

Momentarily

should Measure while of

the

9.0

VDC

30.0

VDC

NOTE:

Reconnect

e.

MPU teeth

giving

no

signal

cranking

2.0-3.0

AC

to

damage

actuator

between

block

voltage lead lead/purple/white

not

controller

in

voltage

at

the

controller

switch.

does

governor

power

controller

one

terminal

fullY

the

J:,!erforming

DC

minimum

positioned

ACTUATOR

Tesl/Check

voltage

at

the

controlier

switch

or a weak

the

AC

the

wire

leads

the

engine

volts

input

impedance

or

greater.

making

by

disconnecting

the

with

DC

voltage

the

and

the

terminal

+0.00

to

Black

this

test

present.

checks

at

the

actuator

terminal

the

line

and

the

(1.0-2.0

voltage

at

voltage

at

second.

by

that

come

lift

one

Reconnect

not

coil

in

adjustment.

supply

voltmeter

terminal

both

leads

terminal

lead

from

block

(-)on

the

energize retract

DC

voltage

this

voltage

measured

maximum

the

marginally

erratic

depressed.

signal

voltage

engine.

on

the

or

it

AC.

this

test

glow

the

Preheat

to

the

actuator

black

block.

or

-0.75

DC

(-).

lead

(ONLY)

are

performed

block.

between

actuator

VDC)

both

actuator

one

actuator

removing

from

the

actuator

retract

(Diesel).

actuator.

voltage.

to

block.

coming

block.

the

and

terminal

the

start

as

long

across

test.

actuator

AC

input

terminal

from

being

produced

Measure

controller

is

funning

of

meter

in

diesel

units,

the

"S"

plugs.

switch

controller.

connections

DC

(-)

power

Both

connections

VDC.

to

Black

if

the

baffery

between

and

the

Black

This

is

the

controllers

connections

at

either

connections.

connection

the

two.

actuator

lead

and

do

the

Red

(+)

and

from

actuator

to

the

other

actuator

block.

switch.

as

the

switch

the

Red

DC

voltage

across

the

leads

properly

too

far

away

to

controller.

the

between

at

must

DC

to

actuator

depress same

the

TROUBLESHOOTING

Correct

1.

Inspect

the

DC

circuit

back

to

or

improper

replace

VDC)

if

lead,

repair.

lead,

repair

winding

actuator it

should

fuel

when

of

actuator

ohm

fully

retract

than

the

K2

of

value

the

or

re-adjust.

at

either

battery

or

for

open.

lead.

not

the

coil.

leads.

specified,

in

the

relay

the

MPU.

950

-1000

and

block

by

the

terminal

strip.

idle,

the

voltage

be

disable

terminal

connection

depresssed

Measure

the

on

the

connection

should

(-).

the

DC

(-)

connection

determine

terminal

or

the

actuator

connections.

but

purple

leads

off

the

controller

the

with

the

Black

(-)

leads

from

Red

(+)

lead

to

The

actuator

is

depressed.

(+)

and

Black

must

be

greater

battery

supply.

after

completing

from

f~wheel

white

the

if

block

second.

there

(-lleads

han

this

2.

3.

1.

80%

Check

magnetic

Low

b.

Replace

both

1)

Broken

2)

Broken

3)

Check

controller lever

a.

Replace

b.

Check

12 24

1.

Re-adjust

2.

If

actuator (then If

the loose the

test.

e.

Check

f.

Check

for

damage pick-up.

voltage

(1.0-2.0

the

controller

the

Purple

actuator

for a shorted

because

to

go

to

controller.

resistance

Volt

3.0 -3.1

volt

to.7 -10.8

the

calibration.

doesn't

check

the

voltage

is

or

poor

battery,

check

the

position

resistance

to

leads.

full

actuator less

connections

starting

battery.

adjustment

actuator

voltage

is

replace

actuator.

Replace

cause

the

engine

is

check

DC

circuit

its

connections.

ohm

of

connections.

not

present

actuator.

the

actuator

not

running.

for

back

to

at

If

problems

continue

to

persist,

contact

your

WESTERBEKE

~

WESTERBEKE

Engines & Generators

34

dealer

for

additional

assistance.

GenRemote

CALIBRATION

NOTE:

.

THE

OPTIONAL

THIS

DATA

APPLIES

GenRemote

ONLY

TO

CONTROLS

The unit consists

Cable. The shielded cable links the display to the module and can display panels can be daisy chained to one cable outputs allowing for a total

module, including both display cable outputs, is six-hundred

of a Power

Logic Module, Display

(I) module output. The module supports two display !

of

four (4) displays per module. Total allowed cable length per

Panel

and six conductor shielded Display

be

up

to

300 feet long. Two

(600') feet.

The logic module is powered directly from the generator's cranking battery and consumes less than

70

milli

amps (70/1000

12

or 24 volts. The AC generator output can

three

(3

0)

phase.

of

an amp) when the generator is idle. DC operating voltage can

be

115V, 240V, 50/60

Hz,

single phase

(10)

or

Generator and Engine Monitoring

1.

2.

3.

4.

5.

6.

7.

DC

Voltage

Oil

Pressure Water AC

Voltage

AC

Current

AC

Current

Line

Frequency

.

Temperature

L-l

L-2

Hz

be

8.

9.

GenRemote digital mechanical

The assures package. mote

Electlical

Engine Exhaust

is

display

gauge

GenRemote

that

GenRemote

Electrical

be

accidentally

HooJv..Up

Hours

Over

Temperature

designed

is

easily

package.

circuitry

isolation

disconnected

Up

to

safely

calibrated

is

isolated

will

not

also

10,000 Alarm

interface

to

match

from

interfere

allows

from

the

Hours

with

the

generators

with

normal

generator.

the

existing

readings

the

manufacturers

generator

Electrical hookup includes interconnecting with both the generators

. TheAC wires Required: The ,

Line

-2 [L-2] isBlackwithaRedStripe.

1

to

the GenRemote.

j

The

220

VAC Generator Neutral

Color)

is connected

The

DC

Wire Harness Supplied Color

! Switch), WhitelBlack

. Temperature, Yellow

to

is

115

volt

Line

One

[L-l)

is

Black. Line Two [L-2) is White. The 220 volt

The

220 VAC Neutral connection

is

the

same

as Green Ground wire. The

the generator

is

the Stop Switch, Black is Preheat, Orange is Oil Pressure, Red is Water

frame.

Code

as follows: Green

is

Ground, White is ESS [Emergency Stop

the ExhaustHigh Temperature Alarm [marine applications ouly) andBlacklRed,

',is the Start Button. , IMPORTANT!

The

ExhaustHigh Temp terminal is connected

of

the

OEM

engine

sensors.

manufacturer

electrical

supplied

operation

AC

and DC systems .

is

115/220

to

the ESS terminal when it

should

White and is Not connected

VAC Neutral [White

The

supplied

system.

gauge

the

is

not used.

This

GenRe-

"""

WESTERBEKE

Engine!--,&'

35

Generators

GenRemote

CONTROL

STATION

IMPORTANT!

calibration mode can be accessed. Enter

the

indicated when the hundreds place decimal

The generator must be running and the system fully operational before the

Calibration

Mode: Press and holding the Mode Button for 10 seconds. Entry is

Calibration Button Functions

Mode

Bntton:

Preheat

Stop Start Mode

Firmware

Button:

Burton: Use the Start Button to increment

Button:

I.D. The firmware identification number will appearjn,the displaywhen the

Calibration Method

Calibrate the AutoGaugeScroll by using the values derived from

the mechanical gauge package supplied with the generator. 0

Calibrate the AC Volt and Current Meter with a standard Amp and Voltmeter normally carried by most service technicians.

No

calibration

calibrated to

± one (1)

Press and hold the mode button to enter the calibration mode. Use the Preheat Button to manually advance through the AutoGauge

Scroll functions until the desired gauge is reached. Use the Stop Button to decrement or reduce the gauge value.

Press the mode button to exit the calibration mode. Not pressing

any button for

calibration mode is exited. A typical firmware identification number is "A15".

~----

of

the Frequency Meter is required

Hz.

'

of

the 3-digit, 7 -segment display

or

increase the gauge value.

30 seconds will also exit the calibration mode.

f81Bi8~=P.~~"t~~'~""

turns

on.

IB\

I.

.

(J

=.

or

allowed. The Frequency Meter is factory

DI81

LI.

.

NOTE: The unit will automatically exit the Calibration Mode (30) seconds.

Firmware Identification

When calling for service or warranty repair identificiU;ion number. The unit's age, software revision level and the systems

hardware numberis also placed on the 28 pin microprocessor locatedinthe control module ass@mbly. mode is exited.

The fall:safe system is settings. This allows time for the operator to manually shut down the generator before serious damage occurs.

Failures are displayed by turning temperature alarm will appear at

The alarm LED will remain lit after the generator shuts down to provide indication as to why the unit stopped.

The alarm LED can be cleared by pressing the stop button The Fail-Safe Protocols include:

can

be

identified from this number. The firmware idel).tjfication • .

The flrmware.number appears in the display when the calibration

if

no buttons are pressed for thirty

it

is useful to have the firmware F"mw".IO

IB18101

,

FAIL

~etup

SAFE

to display potential failUres approximateiy 10% lower than the OEM

on

the appropriate' warning LED. For Example, the high coolant

195

0 F and the OEM safety switch will stop the generator

1 -

2 - Coolant Temperature

'3 - Exhaust Over temperature KLIXON

PROCEDURES

or

by restarting the

Oil Pressure

unit.

O.

at

210 0

F.

-..v-

WESTERBEKE

Engi~t!l!.

36

& Generators

GenRemote

WIRING

DIAGRAM

0 0

BlACK

WHrrEJRED

ORANGE

VElLOW/REO

0

--"

GROUND

STOP

OIL

START

Black

Whlte/Red

0 0 0

orange

RED/VIOlET

WHITE

YEllOW

R

ESS

PREHEAT

H20

'e

Gerllem"'"

TEHminalBbck

telmlnal$ 1 thru

Ground

•

ESS

.........

STOP

START

PreHeat

........

Exhaust

all

Press

Water

Temp

8

Figure -20

for

Westerbel<e

/

To

Westerbel<e Harness

LAND

BASED

UMP

ESS

TO

Westerbeke Wire

Hamess

UNITS

EXH

and

Plug

Wlnng

Plug

As<iry.

Notes: Follow

The

Required Federal Requirements

Important! Neutral Connection Not Recuired for 220

For

this

and

Local

115 Volt Is

usually the white

Eleotrical

for

Proper

systems

l2

OUfPUl'TO

Dls1r1butlon

State,

Wire

to

GenRe

Volt

Applications

l2

Is

Neutral,

wire.

LOAD

Panel

Code

Sizing.

mote

or

Is

l T

0

e

l2

INPUT

FROM

OZH

'10

0

PRE·HEAT

RELAY

Accessory

Jack

DISPLAY

JACK

1

DISPLAY JACK

2

FROM

GENERATOR

H~

RElAY

~,s

0

diS

HX3

0 0

EJ

PCB-7HHI0C

SS3

0 0

ON9

0

a

o

L 1

OUTPUT

TO

Distribution

LOAD

Ponel

or

Engines _ & Generators

37

D

'-----'

GenRemote

Westerbeke 8 Wire

IOO@i]

rul

-.l

'---'

.

--------

STOP/START-ROCKER

INSTALLATION

Harness

&

~

11

In

Black

12 m ';\'hIla

Westerbeke

Neutra[

Not

for

220

Volt

Applicat[ons

---

GenRemote

Electrical

Plug

aT

115

IJOO

.

AC

Output

Requ[red

Neulral

l1

~

I

~

"'

l

\i

& l2

DIAGRAM

Note: GenRemote

and

AC engine Without

Box'

and

GenRe Baftery, NoACread[ Run

[ndicato

lloutBlack

L20ut

While

SWITCH

vo[t

is

run

AC Wat

age

nput

[ mote

er

uses

engine

to

recognize

n[ng,

the

generator

will

only

Temp

and

ngs

will

be

r

will

not

turn

ToAC

load

AC

load

d[rectly

to

the

II

and

will

not

be

The

AC

signal

to

GenRemote,

oil

pressure

the

monttor

Oil

Pressure,

displayed

on,

can

be

connected

generator,

l2

current

avallab[e,

MUST

will

run

the

and

however,

readings

be

wired

the

The

One

functions Startthe

the

generator

. Stop

Trouble

problem and

High

illuminated Button Start I

are

required

and

no

generator by

the

generator

Indicator:

is

developing.

Exhaust

is

starting,

by

Temperature

pressing

The

pressing

The

indicator lamp will

Possible

Stop

Rocker

will

the

flicker

include,

Switch

for

the

remain

lower

slowlywhile

High

space

is

available

andreJeasingtbe upperrocker

indicator lamp

and

rel~asing

problems

Safety

Switch.

START

STOP

6 conductor Dcto Coble

Maximum

Length

is

provided

standard

display

once.

on

and

steady

rocker

once.

Coolant

WaterTempemture,

150

'

for

The

while

the

generator

Press

Light Ge[1erala

Ugh\:

Whne

Operotng

Press

Slow

\ht! Genera!or

lndlcalm

areas

panel.

lamp

Once

Flashes

Is

Remains

Generator

Once

Bltnllng

Service

where

will

flicker

the

generator

is

operating

To

llopidlyWhiIe

Starling.

On

Is

to

Ugtt

\\!hila

~

lllXlnlng

Problem

remote

Low

start

Stop

start

rapidly

is

rurming

if

a

Oil

Pressure

stop

while

.

service

"""

Accessory

Display Display

.... :-__

2

1

WESTERBEKE

En.g~l1es

& Generators

38

_

GenRemote

DC

OPERATING VOLTAGES

DC

CURRENT REQUIREMENT--MoDULE

.

DC

CURRENT REQUIREMENT--DISPLAY

DC

CURRENT

AC

VOLTAGES PHASE STANDARD CURRENT METER REMOTE CURRENT

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

EACH

ADDITIONAL

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

METER

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

SPECIFICATIONS'

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

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

DiSPLAy

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

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

12

OR

24

120/240

10

OR

60 AMPS

200 AMPS

VDC

50 MA .

20 MA .

15 MA

VAC

3 0

START RELAY STOP RELAY PREHEAT RELAY

MAXIMUM MAXIMUM # MAXIMUM DISPLAY TOTAL ALLOWED

TEMPERATURE RANGE

NOTE: should output lines.

Each

be

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

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

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

#

OF

DISPLAYS

OF

DISPLAYS DAISY CHAINED

CABLE

DISPLAY CABLE LENGTH

module will support a maximum

daisy chained

PER

MODULE

LENGTH (ONE

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

to

one module output. The module supports two (2) separate display

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

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

DIRECTION)

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

OffOUT

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

0 0 F

displays.

No

more than two (2) displays

THROUGH

7 AMPS

4

2

300 FT.

600 FT.

180 0 F

"""

WESTERBEKE

Eng/lle.1!

39

~

Generators

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The power required

than

more

Some motors require much more current to start others. Split-phase

under similar circumstances, than other types.

monly used machines, or started, such

7

times

avoided, whenever possible, ven by a small motors require to

run. load connected compressor, motor

In

general, to

medium

"NOTE:

more

for

mode in larger sizes.

is required

on

where

as

much

The current required to start

for

to

which no load

the

current

starting

MOTOR

SIZE

(HP)

1/6

114

113

1/2

314

1

In the above table the maximum Amps

for some small motors

this is that the hardest starting types (split-phase) are not

MOTORS

to

start

an

electric motor is considerably

to

keep it running after it

(AC)

motors require more current

easy-starting loads, such

loads are applied after the motor

small

power tools. Because they require 5 to

current

to

start

as

to

run,

if

the electric motor is generator. from 2 to

Capacitor

4 times

and

as

much current

any

to

it.

Au

electric motor connected

example, will require more current

is

connected.

required

loads

to

start

will

be

approxiruately

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

than

115-

for larger

is

They

as

washing

their

use

repulsion-induction

motor varies

Volt

motors as

follows:

AMPS

(~TARTING

AMPERES)

6.4

9.2

10.4

14.4

20.4 26

for

ones.

started.

them

are

should

to to to

than

connected

FOR

to

22.4'

to

32.2'

to

72.S'

to

29.2'

to

40.S'

to

52

Starting is

The

Because the heavy surge of current needed for starting

for

only

an

motors is required

can

be daruaged if it seconds. off on

REQUIRED

Run

If

difficulty

all

other electrical loads

the

electric

OPERATING

the

generator

bring the motor is

motor.

first generators capacity, and finally loaded to indicted on

the

generators data plate. The output voltage

should be checked periodically

instant, the generator

up

to speed

in a few

experienced in starting motors,

and,

if possible, reduce

SPEED

with

no

load applied, then at half the

its

full capacity

to

ensure proper operation of

the generating plant and the appliances it supplies. If

is

voltmeter or arupmeter load, check

NOTE:

contains that the generators provide one 120 volt

This will ensure good motor starting response from the

it

with a portable meter

When the area in which the generator is installed

AC

equipment

not installed to monitor voltage

and

arup probe.

of

120 volts only, it is recommended

AC

terminal block

AC

hot leg

be

configured

for

the distribution panel.

generator.

than

to

is

be

start

with

an

reason

will

the

an

to

start,

com-

dri-

as

air

a

not

tum

load

as

AC

be

the

and

Generator

• Maintaining reasonable cleanliness Connections of terminal boards

corroded, and insulation surfaces salts, build excessive heating

Maintenance

and

dust, engine exhaust, carbon,

up.

Clogged ventilation openings

and

reduced life of windings.

is

irnportaut.

rectifiers

may

start conducting if

etc.

are

allowed

may

cause

may

become

to

• For unusually severe conditions, thin rust-inhibiting petroleum-base coatings, should be sprayed or brushed

over

all

•

In

addition

surfaces

to

reduce

to

periodic cleaning,

rusting

and

corrosion.

the

generator should

be inspected for tightness of all connections, evidence of overheated terminals

• The drive discs

loose or

on

single bearing generators should be

daruaged

wires.

and

checked periodically if possible for tightness of screws and

for

any

evidence of incipient cracking failure. Discs

to

should not be allowed accelerate cracking. to

the

generator shaft must be hardened steel SAE grade

8,

identified by 6 radial marks, one at each of the 6

comers of the head

• The rear armature bearing maintenance

is

required. However,

become rusty because rust

The

bolts which

fasten

..

is

lubricated

if

the

the drive disc

and

sealed;

bearing becomes

may

no

noisy or rough-sounding, have it replaced.

• Examine bearing at periodic intervals. of shaft should be detected when force

is

motion wear.

detectable, inspect the bearing

Repair must

be

made qnickly or major components

will rub and cause major damage to

CARBON

MONOXIDE

DETECTOR

No

side movement

is

applied.lf side

and

generator.

shaft for

WESTERBEKE recommends mounting a carbon monoxide detector in the living quarters. Carbon Monoxide, even in small amounts

The

presence of carbon monoxide indicates

the

from

is deadly.

engine or generator or from

the

an

exhaust leak

exhaust elbow/exhaust hose, or that fumes from a nearby generator are

leaking in your

If

carbon monoxide

and

correct the problem immediately!

air

area.

is

present, ventilate

the

area with clean

Englnes

40

& .Generators

POWER

TAKE

OFF

SYSTEMS

POWER

A power take off adapter

backend. This adapter allows access enwe

Contact your WESTERBEKE COMMERCIAL GENERATOR

SUPPUER

XRT

The XRT power system combined with a Westerbeke

generator provides electrical and hydraulic power for fire/emergency apparatus

power

operation of

TAKE

OFF

ADAPTER

can

be attached to

to

the full

for a variety of hydraulic

for additional infonnation.

POWER

for

SYSTEM

auxiliary lighting and provides continuous

up

to three extrication tools at

and

electrical accessories. \

The

system generates electrical

the

generator I

Rower

the

sarne

of

time.

the

SPECIFICATIONS

Components

System

Availability

Dimensions

Dual

stage

high

with

block

5.000 fluid

COMBI

L:l0" x W:15" x H:14" x 42

Reservoir:

Open

L:

continuous pressure filter,

pump

assemblies.

psi

phosphate

systems

pump

H:

Center

3.75" x W:

fittings,

enclosure

ester

up

to

10,500psi.

in

shroud.

12" x W:

Valves:

2.75" x H"

duty

three

12" x D:

4.0."

pump,

gallon

with

fluid

Ib,

stainless

reselVoir

integral

and

mineral

6.5"

control

GENERATOR

\

END

POWER

HYDRAULIC

(OWNER

PUMP

I

TAKE

OFF

ADAPTER

For additional information, contact SYSTEMS

XRT 321ioga Marblehead, MA 01945

at

www.xrtcombi.comorcall (800) 343-0480.

POWER SYSTEMS

Way

XRT

POWER

XRT

COMBI

POWER

SYSTEM

""""

WESTERBEKE

Engines & Generators

41

BT

GENERATOR

This generator

requires

which duce

AC

are

stator erator.

The

be

induced

tion.

Diodes

DC

and

.creates

an windings supplied

parallel produced main

stator

tifier.

The

exciter

the

rated

AC

a available produce a

AVR

is a four-pole,

only

output.

The copper

responsible

magnetic

the

for

field

brushIess,

driving

and

the self-exciting feature of

produced

into the related exciter rotor

located

supply

electromagnetic

of

the

to

a load A

to

tl)e

in

the

and

rectifier produces a

in

it

to

the

main

AC

output of the

auxiliary

is,

in

the exciter rotor rectify

windings of

field

stator,

inducing

step

down

windings

tum,

supplied

DC

stator windings, enabling

output.

An

optional solid-state voltage regulator

to

work

in

more

tandem

stable

AC

output.

/

with

OIPTICINAL

self-excited generator

force

of

the

engine

to

laminated iron in

the

this

causes

an

AC

voltage

windings

the

rotating

which

rotates

an

AC

transformer

main

stator.

of

the

to a full-wave

voltage

the

generator

transformer

during

this

voltage

field.

throngh the

voltage which

is

connected

An

AC

voltage

bridge

to

further excite

to

produce

the transformer regulator

VOLTAGE

AVR

ADJUSTMENT

/,,<L',.

"In

SWITCH

A circuit

pro-

exciter

gen-

to

rota-

to

This

tors.'This circuit breaker ator breaker

tor

NOTE:

add-on

WESTERBEKE

is

in

is

and

the

rec-

is

to

/AUIJUSTINGSHIMS

power

to

ensure

This

breaker

in

can

be

no

circuit

kit

for earlier

is

installed

case

of

manually

power

breaker

dealer.

on

all

will

automatically

an

electrical overload.

shut

off

when

is

coming

model

CIRCUIT

PART

into

is

available

generations;

BREAKER

NUMBERS

WESTERBEKE

disconnect

The

circuit

servicing

the

boat.

as a WESTERBEKE

contact

your

genera-

gener-

genera-

'

AC

TERMINAL

BOARD

AC TERMINAL BOARD (12

STUD)

/COMPO,UND

TRANSFORMER

BT

GENERATOR SINGLE [6

STUD]

PHASE

COMPOUND

TRANSFORMER

BREAKER

BRIDGE

-.yo

WESTERBEKE

Engines & Generators

42

.

BT

GENERATOR

SINGLE

[12

PHASE

STUD]

BT

GENERATOR

I

SINGLE

PHASE

[SIX

STUDI

r-------------------l

: B :

A I I

I a a I

+:

II

:

I 1 2 I

L

_______________

I"m

aRlaEN

,,,,---

I \

00:

:*

-,

"""....""--4'--++-.,

YElLOW

I

BLACK

... / YELLON

"'-"CK

4 i

,b

~_J

c

~~~==t=====~====:

I

D

50

_-+

___

Hz

TERMINAL

.s

.2

\

8

\6

VI

OJ

W2

'7

'8

60

Hz

TERMINAL

:·~rn~-7

A.v.R.

BLUE

{TO

SLUE tWHITe (TO

HERTZNOI.TS

AVR

PLUG

{WHITe

#8TERM.

BAR)

REDfWHtTE

(TO

HERTZNOLTS

-t~~i-~:jt-

BLACK/WHITe

(TO

BRIDGE

SAR)

RECTIFIER)

,

YE"

_ ..

'WH'"

(TO~EZECTOR

50cyc;

SWITCH)

INTERNAL

A.

EXCITER STATOR WINDINGS 1& 2

A-I

and

A - 2 Exciter Stator

(Selector

B.

EXCiTER ROTOR

1.

2.

.

3.

4.

C.

MAIN STATOR

1.

2.

3.

in

COMP position)

Auxiliary Windings Diodes

(6) Rotating Field Windings Suppr\",sor •

Main Stator Windings Main Stator Windings Main Stator Auxiliary Windings

and

.

(A

Windings

FIELD

- B - C)

WIRING

W/OPTIONAL

SCHEMATIC

VOLTAGE

Engines & Generators

(SIX

STUD)

REGULATOR

D.

COMPOUND TRANSFORMER

1.

Compound Transfonner Windings

2.

Compound Transfonner Windings

3.

Compound Transfonner Auxiliary

Resistance readings

for

easily D-3 points winding resistance component's electrical connections.

G. BRIDGE RECTIFIER A.V.R.

the components

by

locating the color coded wires at

shown

Optional Automatic

on

the

and

above

values

voltage checks

in

the exciter circuit

schematic. When checking

be

sure

Voltage

Regulator

to

lift

can

both

Windings

be

accessed A,

the

connection

of the

Plug

(6

G,

C-3

Prong).

and

43

BT

GENERATOR·

SINGLE

PHASE

(12

STUD)

r----

I 1 B :

r-

I

I I I I

-

I

L

_____________

--

-------...,

A

B

1>1-

c

ORANGE

GREEN

A.

EXCITER Resistance Value 10.0 Ohms

,

B.

EXCITER

1. Auxiliary Wiudiugs (A - B - C)

2.

Diodes

3. Rotating Field Windiugs

4. Suppressor

C.

MAIN

1. Main Stator Wmdiugs

2. Main Stator Windings

3. Main Stator Auxiliary Windiugs

~

~4

2

+

DC

-

STATOR

ROTOR

(6)

STATOR

r-------..,

1 C I I D I

: I

I

L

31

J

I

I 1

1

I

~

1

~

I

I 1

I

~

I

3

1

L

f-------

G

BLACK

AC

-K1-

AC

YELLOW

INTERNAL

WINDINGS

and

FIELD

J

WIRING

DIAGRAM

D.

COMPOUND

1.

Compound Transformer Wiudiugs

2. Compound Transformer Windiugs

3. Compound Transformer Auxiliary Windings

G.

BRIDGE

r-------,

! 4 !

•

!

:

!

•

I

w

L~l-ll--I--~J·

z

. I

"

a:

""

0

TRANSFORMER

RECTIFIER

AC

11111ijr--~1-~-

•

2~

=?'~

3..

I I

!

I

WHT/BLK

i

~.

1

aN

2 A

7 L

8 B

L

o

C

K

•

@

WHT

IGREEN •

I

-

T

S

U

D

OPTIONAL BT 6 STUD

An

optional solid-state voltage regulator (board #34410) is available for nse with the installed, and the regulation switch is moved position, the regulator works together with the standard com-

. pound transfonner regulator to regulate

age

output. In the

excitation former provides excitation to the group 2 exciter windings.

AUTOMATIC

MODELS

ELEC

to

the group 1 exciter windings, and the trans-

VOLTAGE

REGULATOR

ONLY

BT

series generators. When

to

the ELEC

the generator's volt-

mode, the regulator provides

(AVR)

Installation

1.

The

regulator is mounted using existing tapped holes in the generator's case. each ISmm long, with lock washers to mount the regulator board.

2. Connect the 6-prong generator plug to the receptacle on the regulator board.

Use two (2)

M4

x 0.7mm screws,

"""

WESTERBEKE

Engines &

NOTE:

The

plug

is

keyed

to

engage

one

direction.

3. Before moving the selector switch to the ELEC position, the NO-Load voltage produced the COMP position will have to Load voltage should

volts

procedures as explained earlier in tbis manual.

4.

With the generators no load voltage properly adjusted, move the selection switch iuto the ELEC position. Adjust the regulator board potentiometer to set at

120 - 122 volts SI.S allel with the compound transformer and should maintain voltage output witbin FULL-Load.

NOTE:

'

down. the

regulator

exciter circuit power. This leaves less exciter circuit

for

loacled

Generators

Check this

(60Hz) or 224 - 228 volts

S2.0 Hertz). Tbe regulator board is operating in par-

Do

not

use

Use

the

compound transformer for

to

perform this causes

conditions.

and

be

adjusted down between 114 - 118

at

61.S - 62.0 Hertz (230 - 234 volts at

±5

the

regulator

insert it

per

cent

to

the

regulatorreceptacle in

correctly.

by

the generator when in

be

adjusted. The NO-

(SOHz)

force

following the

NO-Load voltage

from NO-Load to

NO-Load

the

regulator

this

voltage

function.

to

Using

use

more

power

44

GENERATOR

NOTE:

WESTERBEKE

tests

and

adjustments

VOLTAGE

recommends

be

performed

ADJUSTMENT

tiull

the

by

a quai/ijied

following

generator

technician.

Generator

1.

Frequency is a direct result

1800 rpm = 60 hertz 1500 rpm = 50 hertz.

.2.

To change generator frequency follow the steps below.

a.

b.

If

installed, do uot change the wiring, Voltage/Hertz Connection Bar. Simply reconfigure AC

c. Start the engine, monitor voltage and adjust engine

Frequency

of

engine/generator speed:

Connect the following the illustrations on this page.

If

an lead to correspond to the hertz selected on the VoltageiHertz Connection Bar.

there is no automatic voltage regulator

terminal for

no-load speed. Adjust diesel units by the linkage between the throttle arm and fuel solenoid or the throttle lever on the injection pump

60 hertz: no-load speed, 61.5 - 62.0 hertz.

50 hertz: no-load speed, 51.5 - 52.0 heltZ.

AVR

AC

output leads to the

is

installed, reposition the blue

on

the

hertz

change.

..

AC

tenninal block,

or

(AVR

the

blue/white

the

d. After the no-load hertz adjustment

voltage may need generator was producing the correct no-load voltage at the previous hertz setting, it would be correct at the changed hertz setting.

In

the event it needs adjustment, adjust the shim thickness under the laminated steel bar 60 hertz: no-load voltage, 121-124 volts. 50 hertz: no-load voltage, 232-236 volts.

e.

Load the generator to the rated amperage output

corresponding to the hertz speed Rated Loaded Speed

60 hertz: loaded speed, 58.5 - 59.0 heltZ

50

hertz: loaded speed, 48,5 - 49.0 hertz The lowest acceptable voltage (amps) 60 hertz:

50 hertz:

to be readjusted. In most cases,

108 -11

205 - 210 volts

0 volts

is

made, the no-load

of

the transformer.

of

the generator,

at

full rated output

if

the

The

frame

be

moved from volts

50

hertz.

nections

block.

1/4

inch accept wire

sized rating nection. wire

is

.

green

between and

the

115V

@ ®

ground

when

115

volts

and

50

hertz.

to

From

making

to

the

AC

use

!enninal

studs

that

multl·strand

f0r

the

from'the

hot

The

frame

white

or

strip.

It

connects

the

neutral

generator

50Hz

Wlra

must

changing

1101220

230

volts

con·

tenninal

ends will

copper

ampemge

lead

con-

ground

white

with"a

stud

frame.

for

,,'

"~

115V

=

0

"

50Hz

7

0

t-

N

230V

@ ®

TWELVE

0'

!l

~

CIRCUIT

BREAKER

•

SIX

50Hz

•

L1

STUD

230V

=

.3

2

0

v

AC

VOLTAGE

A

STUD

AC

VOLTAGE

50Hz

0

;z,

!l

d::::1,

10 0

0

N Ll

II]

Engines & Generators

CONNECTIONS,

120V 60HZ

JUMPER

IS

,!p=PEU--J

CONNECTIONS

115/230V

1=0

=

.3

b' •

L\

7

0

5DHz

0

!lin",

8.

0

,2

N

r-

•

,,'

120V

0

N

6D

=

7

8

e,

Hz

"A

JUMPER

REQUIRED

12D/240V

12D/240V!6DHz

0

=

,S

"'~

0

7@:

6

0

<3

~1

~

• •

IS

60HZ

N

¢:PL

~

III

2

45

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator

tests and adjustments be

VOLTAGE

peifonned

ADJUSTMENT

by

a quailified technician.

NO-LOAD

Voltage being governed

1.

The

VOLTAGE

adjusttnent

ADJUSTMENT

is

made with the generator regulation

by

the

compound

transfOlmer.

selector switch, if installed, must

be

in

position.

2.

To

confinn no-load voltage, start a momentary (moderate) load The

voltage produced

tary

load

is

removed

from

output hertz). volts

NOTE:

The no-load voltage

produced

load should be applied removed. The voltage

momentary load is removed

3.

To

raise or lower the voltage, shims of varying thickness

the

The

no-load

at 61.5-62 hertz (232- 236

by

the generator

by

the generator after

is

no-load voltage. Note

generators

voltage should

should

once

to

excite the transformer

produced

is

the

generator

to

excite

the

120

volt

leges)

be

between

volts

at 51.5-52

be adjusted

started

and

a momentary

by

the generator after this·

no-load voltage.

(non-conductive material) are placed or removed under the steel laminated bar transformer.

The

material used soften at temperatures small times

reduction be

in

no-load voltage

accomplished

laminated steel bar to reduce the

shims

and

the

transfonner

on

top

of

the

for

shimming should not

in

the 176' F (80' C) range. A

(1

to 3 volts)

by

gently tapping the

gap

between the existing

core.

the COMP

and

apply

transfOlmer.

the

momen-

the

voltage

(230 volt

121-124

hertz).

to

the voltage

and

then

from

compound

can

top

of

the

50

some

FULL-LOAD

The

voltage hertz connection bar that

from

60Hz

the

generators full-load

Fine

voltage adjusttnents

wires A to progressively in that have

to

Should (210

volts-50Hz),

BLUE

WIRE

VOLTAGE

to

50Hz

can

leads

#1, #2,

order.

be

made

as

well.

full-load output

the

A

TWO

RED

WIRES

'.

6

AND

ADJUSTMENT

also

output.

can

and

fall

voltage

12

CONNECTION

is

used

when

changing

be

used

to

be

performed

#3

increasing

increase

or

by

repositioning

the

loaded

decrease

voltage

A no-load voltage adjusttnent

below

108

volts-60Hz

should

be

adjusted.

12

STUD

A

BLUE

WIRE

STUD

VOLTAGE

HERTZ

BARS

will

NOTE:

No-load voltage

with the compound transformer.

adjustments to compensate

on

placed Loss cause a drop in voltage output.

the generator/engine (inductive-motor type loads).

of

generator hertz/speed, the result

mny

be

for

Shim thickness of 0.001 inch voltage material raises

by

approximately 4 - 6

the

no-load voltage. Removing shim

material lowers no-load voltage.

effected needing readjustment

Do

not use these

overload conditions being

of

overload, will

will

change the no-load

volts.

Adding shim

NOTE:

When the optional voltage regulator is installed

and

if the Blue!White (Blue) lead is not correctly positioned

to correspond

regulator

to produce abnormally high output voltage.

to

the Hertz the unit is operating at, the

will

sense incorrect voltage

and

cause the generator

Engines &

46

,G~nerators

BT

GENERATOR

VOLTAGE

REGULATOR

ADJUSTMENTS

[THREE

PHASE]

Description

The voltage regulator

AC

optimum complete protection circuitry conditions that could

VOLTAGE

generator performance. It

IIttil~LIII

is

an

advanced desigu which ensures

is

equipped with

to

guard against operating

be

detrimental

to

the

AC generator:

PROTECTS FROM

THE

AN

ELECTRICAL

REGULATOR

Volts

is

used

to

This potentiometer engine operating speed the output voltage should ±1 % from and variations VOLT driver) until HERTZ himmers completely clockwise (Maximum) sarne normal speed, and possible that output voltage will oscillate. Slowly rotate VOLT stabilize. Increase

situation, only

a no-load condition

from

power factor

up

to

-6%.

and

STAB

trinuners (using a

fully

in a counter clockwise (Minimum) direction

you

feel them hit their stops.

manner.

With

the

with

adjust clockwise. The voltage output will increase

the

green

adjust output voltage. At proper

to a full

1.0

- 0.8 with engine drive speed

Prior to starting

generator running at no-load, at

VOLT

adjust at minimum, it

voltage to the desired value. In this

LED will

rated generator output

the

engine, turn the

mini

phillips

Tum

the AMP

stay

lit.

Stability

This potentiometer permits variation of

to

response

pensation

voltage output. In order

running at no-load Tum the

staJ.1s terclockwise until

volt.

a

~

-

--",,--'H"ertz

oS

E

c

:g

c

~

"

generator load changes

and

obtain a minimum

to

adjust

the

and

STAB

adjust slowly clockwise until the voltage

to

fluctuate. At

green

yellow

Amp

Slab

Volt

VOLTAGE

this

the

'-

REGULATOR

regulator stability

the output must

point rotate

voltage

is

DIAGRAM

the

regulator's

so

as

to

limit overcom-

recovery

stable within 1 or 2 tenths of

time

the

generator must

be

monitored.

the

STAB

to

adjust

be

held at

screw-

and

in

is

the

nonnal

BOARD

OVERLOAD

the

and

be

coun-

Amp-Hertz

These

two

adjustments protection circuits by

the illumination of colored LED lights.

1.

Delayed overload protection

2.

Low

speed protection

systems

Both adjusted

circuits

voltage overheating.

The

overload protection system temporary motor start-up or other similar load surge lator

also

tor

operation

with

the

Setting

In

order

be

must

1.

Load

the hertz

2.

Rotate its

stop.

put of

should come

3.

Slowly

output voltage increases age yellow

4.

Return and Should this not

NOTE:

remove

Setting

NOTE:

jumper strap is in place

two

60 setting,

1.

To lower

(54

2.

Rotate the Hertz adjusnnent counterclockwise the the

3.

Increase the engine The put

With

the

tion

normally.

have

using the respective potentiometer.

are

able

to

safeguard

overloading of

has

a third

to

generator.

the

Overload

to

set the

loaded to

the

generator

engine

by

on

50 hertz units).

the

AMP adjusnnent counterclockwise

Wait

the

generator

rotate the AMP adjusnnent clockwise until

output at the start of

LED light should come to

nominal

the

generator voltage will rise

When

changing

the

60 hertz jumper bar from

the

Underspeed

If

the

unit is operating

Hertz terminals.

the

generator shauld

adjust

the

engine

hertz

on

60

generator's sarne

time the red "LED" light comes

red "LED" light

will

return

above

are

used

in

conjunction

in

the

voltage

an

intervention threshold

to

cause

the

excitor windings

.

LED

indicate correct operation of

regulator that

(yellow

(red

LED).

an

adequate

has

the

generator

(green), that

LED).

reduction

a delay

during

glows

Protection

AMP

overload protection,

its

full output rating.

to

its

rating, then decrease

10.10%

about

on.

15-20

should

speed,

happen,

from

(54

Hertz

on

60

seconds after

drop

and

the

to

approximately

the

adjusnnent. At

on.

the

yellow

LED

to

its normal·value.

repeat the adjusnnent.

60

hertz

to

50

the

Protection

at

60

Hertz

on

the

regulator board between

In

order

to

adjust

be

running at no-load

underspeed

speed

hertz

AC

to

adjusnnents made, the regulator should

at

units,

output

speed

will

normal.

(low

frequency)

90%

of

its

45 hertz

voltage starts

to

its

normal

go

out

and

normal

on

the

with

are

which

Each

in

and

prevent their

which

times such

demands.

during

the

regulator

the

generator

hertz

units,

which

yellow

97%

this

will

hertz

operation,

regulator

ensure

that

the

underspeed

protection

running

50

hertz

to

decrease

on.

speed

AC

voltage

'.

the

two

indicated

can

be

of

the

two

excitor

permits

as

The

regu-

genera-

the

speed

45

until

it

hits

the

AC

out-

LED

light

the

of

the

volt-

point

the

tum

off

board.

the

circuit,

speed

units.

slowly

until

and

(frequency).

out-

func-

of

at

~

WESTERBEKE

Engines & Generators

47

BT

3

PHASE

r------------.,

I I

A

EXCITER

~--:-l

r---..J

_________

STATOR

r -

-:-

- - -

I I I

I B

I

EXCITER

I I

- I I

I I I

L-----r--

GENERATOR

TWELVE

I

I I I DSTATOR

~

- - - - - - - - -

II I I

.1

ell

ROTOR

FiElD

________

INTERNAL

WIRE

RECONNECTABLE

-,

12--' 10'

I -

8-

6_.

J

BUS

FUSE

WIRING

~~---+1--I----+----

----11-1-----+----

---+----1-1-----'5

1------

I

~..,l

____

Q

w

'"

1

.1

-.J

•.

11

'9

'7

I

red

~

green

-

yellow

~rIz

.;

Amp

§

Stab

~

.

Volt

>l

~

REGULATOR

BT

GENERATOR

THREE

PHASE

BRIDGE

•••

BLUE

TI.'.O

RED

TERMINAL

BOARD

GREEN

____ . FUSE

HOLDER

20A

Engines & Generators

48

REGULATOR

Description

The

regulator

(0

to

6)

arid

their related

shown

connection points

uration

of

the

#1

and

#2

and

#0

on

the

'NOTE:

Series

Delta

the

regulator

board between terminal B and

is

equipped

brass

and

generator.

#2

170 -270

The sensing

on

the

AC

voltage regulator

requires

V

SENSING 3 PHASE

NOTE:

WESTERBEKE

and adjustments

with

seven

numbered

jumpers. The illustrations

jumpers

tenninal

the installfltion

for

leads

block

board.

the 3 phase

connect

and

of

1.

,

4

•

,

I-

: ~ 180

.

~

+

I-

-

~::]60

recommends

be

performed

tenninals

config-

between

connection

a jumper on

-160

EXCITER

Hz

WYE·DELTA

that

by

a qualified technician.

V

the

follnwi{!g

CONFIGURATIONS

generator

SERIES

tests

WYE

~

(STAR)

9H_....JLbl!1

ru;j0

~

L-L L-N L-L L-N

460VAC

265VAC 380VAC 230VAC

SERIES

DELTA

30 10 30 10

60 60 50 50

Hertz Hertz Hertz Hertz

L3

N

3

PHASE

VOLTAGE

PARALLEL

L-L L-N L-L L-N

REGULATOR

WYE

(STAR)

208VAC 120VAC

190VAC 115VAC

0

30

10 30 10

60 Hertz

60

Hertz

50 Hertz 50

Hertz

L-L L2,L3,

L-L L2,

L3,

-N

- N

240VAC 120VAC 230'VAC 115VAC

5 l-+----'L

....

L3

N

30

60

Hertz

10

60

Hertz

30

50

Hertz

10

50

Hertz

2

~

WESTERBEKE

Engines & Generators

49

BT

'\

NOTE:

and adjustments

GENERATOR

WESTERBEKE

TROUBLESHOOTING

recommends

be

performed

that

by

a qualified

the

following

technician.

CHART

g~nerator

tests

REFER PERFORMING THE FOLLOWING TESTS.

TROUBLESHOOT THE COMPONENTS

1.

LOW

COMPONENT CHECKS:

VOLTAGE 60-100

TO

THE INTERNAL WIRING

VOLTS

F SELECTOR SWITCH B ROTOR COMPONENTS

B2. EXCITER ROTOR DIODES

B3. ROTOR FIELD WINDING

B1.

EXCITER ROTOR WINDING(S)

A 1-1+2 EXCITER STATOR WINDING(S).

2.

NO

AC VOLTAGE

MAIN

COMPONENT CHECKS:

STATOR,

ROTOR

OUTPUT

COMPONENTS,

C 1+2 MAIN STATOR WINDING

B 4 SUPPRESSOR

B 2 DIODES (4-6 OPEN/SHORTED)

D 1 +2 COMPOUND TRANSFORMER WINDING

B 3 ROTOR FIELD WINDING

DIAGRAMS

IN THE FOLLOWING ORDER:

WHEN

AC

a,b,c.

TRANSFORMER

3.

RESIDUAL

COMPONENT CHECKS:

VOLTAGE

A 1-1+2 EXCITER STATOR WINDING(S)

G BRIDGE RECTIFIER

D 3 TRANSFORMER AUX. WINDING

C 3 MAIN STATOR AUX. WINDING

F SELECTOR SWITCH (SIX STUD MODELS

(from

CIRCUIT CONNECTIONS connections

on

the Bridge Rectifier)

the

EXCITER

Transformer

CIRCUIT

Aux.

winding to the

FAULTY

-..v-

WESTERBEKE

Engines & Generators

50

SPECIFICATIONS

10.0KW/8.0KW

BTDAR

Engine

Type

Displacement

Aspiration

Combustion

Bore & Stroke Firing

Direction

Compression

Minimum

Valve

Spilled Valve Engine

Injector

Valve

(engine

General

Oil Sump

(not Operating

(engine Oil

Order

of

Rotation

liming

Seat

Angle

liming

Pressure

Seat

Angle

Clearance

cold)

Filter

Capacity

including

Oil

hot)

Grade

Chamber

Ratio

Pressure

(Static)

filter)

Pressure

GENERAL

Diesel,

four-cycle,

cooled,

vertical

mechanism.

80.4

cubic

inches

Naturally

aspirated.

Swirl

type.

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

TUNE-UP

427

384 Intake

Intake 170 (spill) 45 lJOBTDC 1991 + 71 Intake

Exhaust

0.25

when

SPECIFICATIONS

psi

(30

psi

(27

Opens Closes

0

-0

0

45

0

30

inches

LUBRICATION

Pressure

fed

Full

flow,

paper

3.9

U.S.

qts

50 -60

psi

API

Specification

SAE

30,

all

three-cylinder,

in-line

overhead

(1.318

inches

(78 x 92

viewed

kg/cm')

at

psi

(140

mm)

280

+ 5 - 0

kg/cm')

(0.009B

SYSTEM

system.

element,

(3.7

liters)

(3.5

-4.2

kg/cm')

CF,

CG-4,

season,

15W-40

liter)

mm)

from

the

rpm

spin-on

CH-4

fresh

water-

valve

front.

kgf/cm').

type.

or

CI-4

General

Fuel

Injection

Pump Nozzle Fuel

Filter

Air

cleaner

Air

Flow

(engine

combustion)

Fuel'Lift

Pump

Starting

Battery

Capacity

DC

Charging

Alternator

Starting

Aid

Starter

Engine

Combustion

Requirements @ 60Hz 1800

rpm

General

Operating

Fresh

Water

System

Capacity

(Fresh

Water)

Air

Temperature

Pump

FUEL

SYSTEM

Open

flow,

self

priming.

No.2

diesel

oil

(cetane

In-line

plunger

type

Throttle

type. Replaceable Replaceable 42cfm

12 solid

ELECTRICAL

12 600 -900 51

Glow 12 41

COOLING

Fresh

controlled

170

Centrifugal

7.0

cartridge. paper

(1.2

cmm)

volt

OC

lift

state

Volt,.(-)

negative

Cold

Amp

rated,

plugs,

Volt,

reduction

cim(I.16

SYSTEM

water-cooled

with

-1900 F type,

US

qts

(6.6

capacity

SYSTEM

Cranking

belt-driven

sheathed

cmm)

heat

(77

rating

(BOSCH).

filter

at

1800

of

ground

type

gear

block,

exchanger.

o

-8B

metal

liters)

of

45

or

cartridge.

rpm.

5'

wet(1.5

mm)

Amps

(CCA)

thermostatically-

C)

impeller,

belt-driven.

higher).

.

Engines & Generators

51

SPECIFICATIONS

GENERAL

Engine

Type

Displacement Aspiration

Combustion

Bore & Stroke

Firing

Direction

Compression

HP@1800RPM

Compression

Order

of

Chamber

Rotation

Ratio

Pressure

Minimum

Spilled

Timing

(Static)

Valve

Seat

Angle

Engine

Speed

Valve

Seat

Angle

Valve

Clearance

Injector

Pressure

Engine

liming

Starting

Battery

Capacity

DC

Charging

Alternator

Starting

Aid

Starter

TUNE-UP

Diesel,

four-cycle,

coated,

vertical

mechanism.

107.3

cubic

Naturally

aspirated.

Swirl

type.

3.07 x 3.62 1-3-4-2

Clockwise,

22:1 25

HP

SPECIFICATIONS

427

psi

(30

384

psi

(27

17·

(spill)

Intake

45·

Exhaust

30·

1800

rpm

1500 Intake

Exhaust

0.25 1991 + 71 17"BTDC

(60Hz)

rpm

(50Hz)

45·

30·

inches

ELECTRICAL

12

Volt,

(-)

600 -800

51

Amp

rated,

Glow

plugs,

12

Volt,

reduction

15KW

four-cylinder,

in-line

overhead

inches

(1.758

inches

(78 x 92

when

viewed

kg/cm')

at

kg/cm')

(0.0098

-0

negative

Cold

280

mm)

psi

(140

+ 5 -0

SYSTEM

ground

Cranking

belt-driven

sheathed

type

gear

BTOCR/14.0KW

fresh

water-

valve

liter)

mm)

from

the

front

rpm

kgflcm~.

Amps

(CCA)

General

Fuel Fuel

Injection Nozzle Fuel

Filter

Air

cleaner

Fuel

Lift

Pump

General

Operating

Fresh

Water

System

Capacity

(Fresh

Water)

General Oil

Filter

Sump

Capacity

(not

including

Operating

(engine

hot)

Oil

Grade

BTOCR/12.5KW

FUEL

SYSTEM

Open

flow,

self

No.2

diesel

Pump

Temperature

Pump

filter)

Oil

Pressure

In-line

plunger

Throttle

type. Replaceable Replaceable 12

volt

DC

solid

COOLING

Fresh

controlled

170

Centrifugal

12.0

lift

state

SYSTEM

water-cooled

with

-190· F type,

US

qts

LUBRICATION

Pressure

fed

Full

flow,

paper

5.5

U.S.

qts

50 -60

psi

API

Specification

SAE

30

15W-40

BTOBR

priming.

oil

(eetane

type

(BOSCH).

cartridge. paper

filter

capacity

block,

heat

exchanger.

(77

-88·

metal

(11.3

liters)

SYSTEM

system.

element,

(5.2

liters)

(3.5 -4.2

CF,

CG-4,

all

season

rating

of

45

or

cartrtdge.

of

5'

wet

(1.5

thermostatically-

C)

impeller,

belt-driven.

spin-on

type.

kg/cm')

CH-4

or

higher).

mm)

CI-4

-...v'

WESTERBEKE

Engines & Generators

52

AC

GENERATOR

Single

Phase

Voltage

Voll8ge

regulation:

Frequency

Rating 60

10.0KW 50

7.5'{N1

Generator

Air

(60

Engine

Air

.

Generator

Ambient

Recommendations

regulation:

(Volts

Hertz Hertz

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

rpm

Combustion

Requirements

Compartment

Temperature

SPECIFICATION

(Single

Brushless, Pre-lubricated, Reconnectable,

regulation regulation).

120

220

±

±3

120

120/240

220

225 -250

NOTE:

operation

42elm (60Hz

122'f

(optional

or

120/240

Volts -50

5%

no

load

Hertz

(5%)

Volts

efm

Increase

(1500

(1.2cmm)

at

1800

(50'CI

four-pole,

single

Volts -60

Hertz

to

no

83.3

83.3/41.6

34.1

(5.66 -6.37

air

rpm)

maximum

Phase)

revolving

bearing

phase

solid-sl8te

full

load.

load

to

Amps

supply

field.

design.

transformer

voll8ge

Hertz

full

load.

Amps

emm)

15%

for

50

Hertz

10.0KW

General

-3

10.0

7.5

Voll8ge

(60

Voll8ge

(50

Amperage

(60

Amperage (50

Engine

Air

(60

Generator

Ambient

Recommendations

Phase

'{NI

-

60

-3

Hertz)

-3

Hertz)

50

Hertz

Phase

-3

Hertz

'{NI-

Combustion

Requirements

Hertz)

at

1800

Compartment

Temperature

BTDAR

AC

GENERATOR

Brushless

lubrica1ed

reeonnecl8ble

voll8ge

with

Low High DELTA

High DELTA

Phase

rpm

Low High DELTA

High DELTA

42

efm

122'f

(3

six

pole,

single

for

Delta.

Solid

protection

voltage

voll8ge

voltage

voll8ge

(1.2

(50'C)

circuitry.

WYE

cmm)

maximum

Phase)

revolving

bearing

design.

low

voll8ge

Sl8te

voll8ge

field.

12

WYE,

208 480 240

380 220

35

Amps

15

Amps

30

Amps

14

Amps

24

Amps

Sealed

Lead high

regulator

volts volts volts

volts volts

SPECIFICATION

AC

GENERATOR

Single

Phase

Voll8ge

regulation:

Voll8ge

frequency

Rating

60

8.0'{NI

50

6.0KW

Generator

Air

(60

Engine

Air

(60Hertz)

Engine

Generator

Ambient Recommendations

regulation:

(Volts

Hertz

AC)

(1800

rpm)

Hertz

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Combustion

Requirements

at

1800

Compartments

Compartment

Temperature

rpm

Brushless, Pre-lubricated,

Reconnectable,

regulation regulation).

120 220

±

±3

120

1201240

220

175·200

NOTE:

operation

42

100-200 122'f

8.0KW

(Single

four-pole,

(optional

or

120/240

Volts -50

5%

no

load

Hertz

(5%)

Volts

elm

Increase

(1500

elm

(1.2

clm

(50'C)

revolving

single

solid-s1ate

Volts -60

Hertz

to

full

no

load

66

Amps 66/33 27

Amps

(4.95 -5.66

air

supply

rpm)

cmm)

(2.83 -5.66

maximum

BTDAR

Phase)

field.

bearing

design.

phase

transformer

vol18ge

Hertz

load.

to

lull

load.

Amps

cmm)

15%

for

cmm)

50

Hertz

Engines & Generators

53

AC

GENERATOR

Single

Phase

Voltage

regulation:

Frequency

Rating 60

50

Generator

Air

(60

Engine Air

Generator

.

Ambient

,

Recommendations

regulation:

(Volts

Hertz

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Combustion

Requirements

Compartment

Temperature

rpm

SPECIFICATIONS

(Single

Brushless,

Pre-lubricated,

Reconnectable,

regulation regulation).

120

220

±

±3

120

120/240

230 225 -250

NOTE:

operation

41

(60Hzat

122'F

(optional

or

120/240

Volts -50

5%

no

Hertz

(5%)

Volts

Increase

(1500

efm

(1.16

1800

(50'C)

four-pole,

single

Volts -60

Hertz

load

to

no

125

125/62.5

60

cfm

(5.66 -7.08cmm)

air

rpm)

emm)

rpm)

maximum

Phase)

revolving

bearing

phase

solid-state

full

load.

load

to

Amps

supply

field.

design.

transformer

voltage

Hertz

full

load.

Amps

15%

for

50

Hertz

15.0KW

General

15.0

KW -60

12.0

KW -50

Voltage (60

Hertz)

Voltage

(50

Hertz)

Amperage (60.Hertz)

Amperage

(50

Hertz)

I

Generator Ambient

I

Recommimdations

BTOCR

-3

Phase

Hertz Hertz

-3

Phase

-3

Phase

-3

Phase

-3

Phase

Compartment

Temperature

AC

GENERATOR

Brushless lubricated reconnectable voltage

with

protection

Low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA High

voltage

DELTA 122'F

six single

Delta.

(50'C)

(3

Phase)

pole,

revolving

bearing

for

low

Solid

State

circuitry.

WYE

maximum

design.

voltage

field.

12

WYE,

208 480 240

380 230

52

Amps

22

Amps

45

Amps

28

Amps

47

Amps

Sealed

Lead high

regulator

volts

volts volts

AC

GENERATOR

Single

Phase

Voltage

regulation:

Frequency Rating

60

12.5KW 50

9.3KW

Generator Air

(60

Generator

Ambient

Recommendations

regulation:

(Volts

AC)

Hertz

(1800

rpm)

Hertz

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Compartment

Temperature

rpm

SPECIFICATIONS

(Single

Brushless, Pre-lubricated, Reconnectable,

regulation regulation).

120 220

±

±3

120

120/240

230

200 -225 NOTE:

operation

122'f

(optional

or

120/240

Volts -50

5%

no

load

Hertz

(5%)

Volts

efm

Increase

(1500

(50'C)

four-pole,

single

Volts -60

Hertz

to

no

104

104/52

60

(6.37 -7.08

air

rpm)

maximum

Phase)

revolving

bearing

phase

solid-state

full

load.

load

to

Amps

supply

field.

design.

transformer

voltage

Hertz

full

load.

emm)

15%

for

50

Hertz

12.5KW

Single

12.5KW -60

9.3KW -50

Voltage

(60

Hertz)

Voltage

(50

Hertz)

Amperage (60

Hertz)

Amperage

(50

Hertz)

Engine

Air

Requirements

I

Generator

.

Ambient

'

Recommendations

BTOBR

Phase

Hertz

-3

Phase

-3

Phase

-3

Phase

-3

Phase

Combustion

Compartment

Temperature

AC

GENERATOR

Brushless,

Pre-lubricated, Reconnectable,

regulation regulation)

Low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA High

voltage

DELTA

41

efm

(60Hzat

122'f

four-pole,

(optional ..

WYE

(1.16

1800

(50'C)

(3

Phase)

revolving

single

bearing

single

solid-state

WYE

emm)

rpm)

maximum

phase

field.

design.

transformer

voltage

208

volts 480volts 240

volts 380

volts 230

volts

43

Amps

18

Amps

37

Amps

23

Amps

39

Amps

~

WESTERBEKE

Engines & Generators

54

AC

GENERATOR

Single

Phase

Voltage

regulation:

Frequency

Rating 60

50

Generator Air

(60

Engine Air

Generator

Ambient

.

Recommendations

regulation:

(Vols

Hertz Hertz

Requirements

AC)

(1800

rpm)

(1500

rpm)

Cooling

Hertz)

at

1800

Combustion

Requirements

Compartment

Temperature

rpm

SPECIFICATIONS

(Single

Brushless, Pre-lubricated,

Reconnectable,

regulation regulation).

120

220

±

±3

120 120/240

230 225 -250

NOTE:

operation

4t (60Hzat

t

or

120/240

Volts -50

5%

no

Hertz

Volts Volts

Increase

efm

22°F

(50°C)

four-pole,

(optional

load

(5%)

Volts

cfm

(1500

(1.t6

cmm)

1800

maximum

single

Volts -60

Hertz

to

full

no

116.7

116.7/58.3

52.2

(6.37 -7.08

air

rpm)

Phase)

revolving

bearing

phase

transformer

solid-state

Hertz

load.

load

to

full

Amps

emm)

supply

15%

14.0KW

field.

design.

voltage voltage

General

15.0

KW -60

12.0

KW -50

BTDCR

AC

-3

Phase

Hertz Hertz

GENERATOR

Brushless lubricated

reconnectable

with

Low High DELTA

High DELTA

Low High DELTA

High DELTA

122°F

load.

for

50

Hertz

Voltage

-3

(60

Voltage (50

Amperage (60

Amperage (50

Generator

Ambient Recommendations

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Compartment

Temperature

Phase

(3

six

pole,

single

for

Delta.

Solid

protection

voltage

(50°C)

circuitry.

WYE

maximum

Phase)

revolving

bearing

design.

low

voltage

State

voltage

field.

12

WYE,

regulator

208 480 240

380 230

48

Amps

21

Amps

42

Amps

25

Amps

43

Amps

Sealed

Lead high

volts

volts volts

"Y'

WESTERBEKE

Engines & Generators

..

ENGINE

TORQUE

SPECIFICATIONS

Bolt

or

Alternator

Back Connecting Coolant

Coolant Coolant Coolant Crankshaft Cylinder Delivery Engine Exhaust

Flywheel Fuel Fuel Fuel Fuel Fuel Glow Glow Intake Main Oil Oil Oil Oil Oil Pressure Rear Rear

Retaining

Valve

Rocker

Rocker Sliding Special

Torque

Starter B Terminal Stop Thermostat Thermoswitch

Bracket

Plate

Pump

Pump Temperature Temperature

Head

Valve

Mounts

Manifold

Bolt

Filter

Assembly Injection Injection Leak-Off Solenoid

Plug Plug

Connection

Manifold

Bearing Filter Pan

Bolt

Pan

Drain

Pressure

Refief

Plate

Bolt

Plate

Bolt

Nut

Holder

Cover Shaft

Sleeve

Nut

Spring

Solenoid

Rod

Cap

Pulley

Bolt

Holder

Nozzle Pipe

Pipe

Locknut

Cap

Plug Sender Switch

Valve (stamping) (standard)

for

Body

Bolt

Bracket

Shaft

for

Set

Housing

Nut

Sender Switch

Nut

Holder

Nut

Plate

Bolt

Delivery

Bolt

MAJOR

Diameter Pitch

M9

M18 M10

M12

M20 M12

M12

M10 M4

M10 M20 M8

M14

PT1I8

M22

M8

M12

M16

M8

M10

M12

M8

M30

M16

1.0

1.5

1.25

---

1.25

1.5

1.25

0.7

1.25

1.5

1.25

1.5

1.25

0.75

1.25

1.0

1.25

1.5

BOLTS

across

AND

Width

flats

14

27 14 19

19

21

18

12

8

17

12

22

26 22 12 17 19

12 12

14. 17

12 36

17

NUTS

Clamp

length

87

29

60

81

25 10

11 33 16 28

40 581

29.5

31.5

TORQUE

kg-m

3.8-5.3

3.3-4.8

3.55±0.25

1.6±2.4

1.2 ± 1.8

1.2±1.8

17.5±2.5 9±0.5

4.5±0.5

3.2±4.7

1.6±2.4

13.5±0.5 98±4 132±5

4.6±6.8

5.5±0.5 3±0.5 22±4 29±5

2.75±0.25 20± 2 27±2.5

4.0±5.0

1.75±0.25

0.125±0.0250.9±0.2 1.2±0.2

1.6 ± 2.4

5.25±0.25

1.2±0.1 8.7±

2.8±0.3 20.3±2.2 27±5.3 40±5

1.2±1.8 1±0.2 50±5

1.15±0.15

6.5±1 47±7

3.75±0.25

1.15±0.15 8.3±1.1

1.5±0.5

3.6±0.6 26±4 35±6 2±0.5

1.1

±0.1

4.5±0.5

0.3-0.45

2.3

±0.4

ft

- Ib

27-38 24-35 27±72 12-17 12-17 9-13 9-13 127±18 65

± 4 88± 5 32±54 23-34 12-17

33-49 40±44

28.9±36.2

12±72

12-17 38±2

29±4 9-13

7.2±1.4 36±4

8.3±1.1

27±2 37±2.5

11

±4

14±4

80±7 32±54.

2-3

16.6

0.7

± 3

N-m

36.6

32.5

34.8±2.5

17.2

12.2

12.2 172±25

44± 5

31.1

7.2

44.7 54±5

39.18

17.2±2.5

16.2

51.5

±2.5

12±1

39±5

12.2 10±2 49±5

11.3±1.5 64±10

11.3±1.5

14.7±5

20±5

10.8

± 1

44±5

2.7

22.6

± 4

.

-.v:

WESTERBEKE

Engi~es ~ G'~meratqrs

55

BOLT

HEAD

MARKINGS

STANDARD

HARDWARE

Metric

strongest.

bolt

class

numbers

identify

bolts

by

their

strength

with

10.9

the

NOTES:

1.

2.

3.·

STANDARD

Capsrew

Body

(Inches)'

(Thread)

1/4

-

20

-

28

5116-18

-

24

.318-16

-

24

7/16

-14

-

20

1/2

-13

-20

9116

-12

-18

5/8-11

-18

314

-10

-16

7/8-

9

-14

1 - B

-14

Use

the

torque

These

torques

Reduce

torques

BOLT & NUT

SAE

Size

FHb(Nm)

values

listed

below

are

based

on

clean,

by

30%

or

more,

TORQUE

Grade

5

Torque Torque

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)

SPECIFICATIONS

SAE

Grade

FHb(Nm)

10

(14)

19(26)

34(46)

55

(75)

85(115)

120

(163)

167(226)

280

(3BO)

440

(597)

660

(B95)

when

dry

when

6·7

specific

threads.

threading

SAE

Torque

FHb(Nm)

12(16) 14

24 27(37)

44 49(66)

70 78(106)

105 120

155(210) 170

210 240

375 421f(569)

605(820) 675(915)

910 990

torque

Reduce

capscrews

Grade

8

(19) (33)

(60)

(95)

(142) (163)

(231)

(285) (325)

(SOB)

(1234) (1342)

values

torque

into

are

not

available.

by

10%

when

aluminum.

METRIC

Bolt

Wrench

Dla.

5.5mm . 0.3(0.5)

M3

7mm

M4

Bmm

M5

10mm

MB

13

M9

Ml0

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

mm

16mm

lB

mm

21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

engine

oil

BOLT & NUT

Grade

Size

FI·Lb

(Nm)

0'

O.B

(1.1)

1.5(2.5

3(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(BO)

81

(110)

118(160)

159(215)

203

(275) 295(400) 402

(545)

546

(740)

700

(950)

is

used.

TORQUE

4.6

Grade

4.8

FI·Lb

(Nm)

0.5

(0.7)

1

(1.5)

2(3)

4

(5.5)

10

(13)

lB

(25)

33

(45)

55(75)

85

(115)

118

(160) 166(225) 225

(305)

288

(390)

417

(565)

568

(770)

774

(1050)

992(1345)

SPECIFICATIONS

Grade

B.B -9.B

Grade

FHb(Nm)

1(1.3)

2(3)

4.5(6)

7.5

(10)

lB

(25)

37

(50)

63

(B5)

103

(140)

159

(215)

225(305) 321

(435)

435(590)

553

(750)

811

(1100)

1103

(1495)

1500

(2035)

1925

(2610)

10.9

Ft-Lb

(Nm)

1.5(2) 3(4.5)

6.5(9)

11

(15) 35(26) 55

(75)

97(130)

151

(205)

232(315)

321

(435)

457

(620)

620

(840)

7B9

(1070)

1154

(1565)

1571(2130)

2139

(2900)

2744

(3720)

GASKETS/SEAlANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surtaces

When

instelling

sides

w;th

WHITE

High-copper

ing

assembly,

Specialized ing copper

gasket

non·hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

red

sealant

Of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers properties.

gaskets

and

it's

effective

fuel.

LIQUID

should

oil

pan seal

grease.

such

HYLOMAR

as

HIGH

TACK

in

just

TEFLON

be

gasket

with

around

are

useful

as

HYLOMAR

it

resists

equivalent

about

can

be

used

on

high

water

for

work

is

particlarly

fuel,

oil

any

(coolant)

holding

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

sealing

used

oil

temp

well

and

are

joint

in

on

rubber

adapter

RED

passages,

gaskets

in

effective

water.

excellent

all

contact

with

gaskets

hoses

and

SILICONE

coat

in

position

applications

on

~

WESTERBEKE

"Engines & Generators

the

oil

sealer.

both

dur-

requir-

passages.

BOLTS & FASTENERS/ASSEMBLIES

Lightly plugs HIGH

When Anti-seize

threaded

LOCTITE LITHIUM

ing Heavily

use

Do

oil

head

that

penetrate

TACK.

assembling

compounds

components

offers based

boxes.

oil

all

ctean

engine

not

use

bolts

the

levels

grease

sliding

oil!

tape

sealants!

and

other

the

water

flywheel,

and

thread

yet

allows

of

locking

is

waterproof,

and

reCiprocating

56

pipe

plugs

fasteners

jacket

should

coat

the

locking

them

according

ideal

and

fillings

as

you

assemble

be

sealed

bolt

threads

adhesives

to

came

apart

to

the

job.

for

water

components

that

with

such

when

pump

wrien

connect

coolant

them.

Bolts

PERMATEX

LOCTITE

blue.

as

LOCTITE

necessary.

bearings

and

assembling.

and

#2

or

protect

stuff-

Always

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(fI) x .305 = Meters

Miles x 1.609 = Kilometers

VOLUME

Cubic

Inches

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

Pints

(IMP

pt) x .568 = Liters

Quarts

(IMP

qt) x 1.137 = Liters

Gallons

Quarts

Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces'

Pints

(US

Quarts

Gallons

(IMP

gal) x 4.546 = Liters

(IMP

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

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

(US

qt) x .946 = Liters

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces Pounds

(oz) x 28.35 = Grams

(I

b) x .454=

Kilograms

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

Cubic

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

CONVERSION

Centimeters x .061

(L) x 1.76 = IMP

(L)

(L) x .22 = IMP

Quarts

Gallons

(L) x 1.057 = Quarts

(L) x .264 = Gallons

x.88 = IMP

(US

qt) x .833 = IMP

(US

gal) x .833 = IMP

DATA

=in'

pt

qt

gal

qt

gal

PRESSURE

Pounds Inches Inches

Inches

PerSq

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

TORQUE

Pounds-Force

VELOCITY

Miles

Per

Hour

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Per

Hour Kilometers Miles

Per

Gallons

Kilometers

In

(psi) x 6.895 = Kilopascals

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

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

(H20) x .248 = Kilopascals

Inches

(in-Ib) x .113 = Newton

Feet

(fI-lb) x 1.356 = Newton

(MPH) x 1.609 = Kilometers

(Hp) x .745 = Kilowatts

IMP

(MPG) x .354 = Kil9meters

Per

Liter

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

Per

Liter

(Km/L) x 2.352 = US

of

(Kw) x 1.34 = MPH

MPG

(kPa) x .145 = psi

(kPa) x .2961 = Hg

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = fI-lb

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

TEMPERATURE

Degree Degree

Fahrenheit Celsius

(OF) = (OC X 1.8) + 32

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

-.v

WESTERBEKE

Engines &

57

Genera_tors

CONTACT

YOUR

SUGGESTED

WESTERBEKE

DEALER

•

FUEL

.

(OWNER

LINE

SPARE

FOR

FilTERS

INSTALLED)

- -

PARTS

SUGGESTIONS

FUEL

AND

FilTERS

ADDITIONAL

INFORMATION

~

-

Q

'.

WESTERBEKE ENGINE AND A GALLON

WESTERBEKE

each packaged in a rugged hinged toolbox. Kit

"A" includes

Kit

"B"

is,

KIT

DRIVE OIL FUEL FUEL FUEl

also

the

more

extensive.

A

BELTS

FilTER

FIlTER SYSTEM

PUMP

offers

two

basic spares.

HARDWARE

INLET

FilTER

Spare Parts

KIT

RECOMMENDS

OIL

(YOUR

OF

SPARE

Kits,

i Oil

,

CARRYING

BRAND)

PREMIXED

FOR

COOLANT.

PARTS

FilTERS

--

AN

OIL

KITS·

ENOUGH

CHANGE

SPARE

U

HARDWARE

•

KIT

B

DRIVE

BELTS

OIL

FIlTER

FUEL

FilTER

INJECTOR

OVERHAUL

AIR

GLOW

FUEl FUEl

GASKET

FilTER

PLUG

SYSTEM PUMP

_~.

KIT

MOLDED

_

HOSE

liN A

CARRYING

KIT

HARDWARE

INLET

FilTER

' .

KIT

CANVAS

BAG!

KIT

-..v-

WESTERBEKE

Engines & Generators

58

~

WESTERBEKE

Engines & Generators

1151-4/2010

Westerbeke 8.0KW BTDAR, 12.5KW BTDBR, 10.0KW BTDAR, 15.0KW BTDCR, 14.0KW BTDCR Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual