Westerbeke BTG 8.5, BTGA 8.5, BTG 12.5, BTG 15.0, BTG 10.0 Operator's Manual

OPERATORS

. -

-

8~:5;!Kw.

..

BTG

·,

50Hz

MANUAL

·6.8Kw

BTG

50Hz

8.5Kw

12.5Kw

15.0Kw

MARINE

BTGA BTG BTG

GASOLINE

~,.._.

rWESTERBEKE

J

MYLES WEBSITE:

am.,_.

NAIHA

......

6,0Hz

60Hz

6.8Kw

10.0Kw

60Hz . 12.0Kw

GENERATORS

PUBLICATION

REVISIONS

-MARCH2018

WESTERBEKE

STANDISH

WWW.WESTERBEKE.COM

Member

CORPORATION

INDUSTRIAL

Ntditmal

.

#035909

•150JOHN PARK • TAUNTON

Marine

MllnufacturersAssoclaJion

HANCOCK

MA

02TBo

BTGA BTG BTG

ROAD

50Hz 50Hz 50Hz

CALIFORNIA

PROPOSITION

WARNING

Exhaust gasoline its the cancer, reproductive

Exhaust

colorless unconsciousness exposure

•Dizziness

gas

from

engines

constituents)

state

of

California

birth

defects,

harm.

gasses

gas. can

contain

carbon

and

include:

•NaiiSea.

•Headache

•

Weakness

IF

YOU SET seek

until

OR

ANYONE

OUT

INTO

medical

it

bas

and

Sleepiness

THE

attention.

been

inspected

65

diesel

and

(and

some

of

are

known

to

cause

and

other

A

WARNING:

Carbon

Monoxide

death.

ELSE

FRESH

Monoxide,

is

poisonoiiS

SympfDms

•

•Inability

EXPERIENCE

AIR

IMMEDIAmY.

Shut

down

and

repaired.

of

Throbbing

Muscular

Vomiting

ANY

the

unit

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptiJ!US

and

do

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

A

WARNING

should

be

generator.

WESTERBEKE

MONOXIDE

of

your

vessel.

obtainable

DECAL

is

provided

fixed

to a bulkhead

also

recommends

DETECTORS

They

at

your

in

are

local

by

WESTERBEKE

near

your

installing

the

living/sleeping inexpensive marine

store.

engine

CARBON

and

easily

and

or

quarters

Gasoline

with

an ETHANOL

content

higher

· and

than

may

10°/o (E10)

void

warranty.

is

not

allowed

AJ~

~

•WESTERBEKE™

Engines &

Generators

Blank

page

SAFETY

INSTRUCTIONS

'INTRODUCTION

Read

this

safety

manuol

caused by foilure

precautions.

. toke the

perso~eJ.~

As

the.dftmer

and

advisories

Is

in

·

stimdatd8;

in

the

potential

l'1lfiln1enarlce

to

the

:PREVENT

A

wblle

power.l.etha/

1111

Do not operate

enclosures and

111

Shut off electrical

equipment

111

Use ilisulated mats whenever working on electrical

equipment

111

Make

(particularly shoes) when

Ill

Remove wristwatch and all

electrlca1

PREVENT

A

exhallst

Know

necessary

your

or

ope(8toF,

provided

af1g11menfwitft

hovrevel;

followilg

E!rKI

ar;:tual

pages.

aCiMlies.

QWRef/operator.

ELECTRIC

WARNING:

engine

is

voltage

sure your clothing and skin are dry, not damp

equipment

BURNS-

WARNING:

system

hot!

111

Monitor engine antifreeze coolant level at the plastic coolant recovery location on the water jacketed exhaust manifold, but only

when the engine

A

WARNING:

1111

In case

before touching

of

an

engine overheat, allow the engine

carefully.

to

follow

fundamental

when

dangerous

precautions

machinBr!:

always~

for

your

the~

safety

riSks

The

responsNlyforthe

risks

for

comp(tanCe

and

other

Most

accidents

rules

conditions

to

protect

_

..

_ _

the

and

Yacht

limited

with

following

all

belong

c:onvenience.

Boat

are

not

conditions

SHOCK

Do

not.

trlllt:h

Ai:

electrical

ruDlling,

tbis

covers

components. A tullning

or

when

oolmecteil

is

present

machinery without electrical

in

,power

HOT

Do

llot-tDut:h

tank and periodically

is

COLD.

Steam

can

the

engine or checking the coolant.

at

th~

place.

before accessing electrical

handling electrical equipment

jewelry

when working on

ENGINE

hot

engl11e

cause

injury

and

exist

yourself,

,safe#¥

1his

safely

Cormcil

to

the

lnfonnation

ldenfilication

safety~~

eXClusiVely·

CtJIIIIectitms

tD

shore

titJDllections!

parts

or

engine

gets

at

the filler cap

or

death!

are

and

your

roles

information

(

ABYC)

of

very

to

cool

PREVENT

I A

111

Prevent sparks to pump, or other potential

vapors.

removing the fuel

111

Do not operate with the

Backfire can

Ill

Do

the fuel system. engine/generator clean and free of

chan~

1111

Be

PREVENT

. A

injury

1111

•Follow hatches closed when fueling. Open

after fueling.

running

before

111

All

when ventilated area away from spark-producing equipment and

-

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

111

Shut'·off the spill. DO NOT allow any

SQl.n"ceS

servicing. the fuel system.

Ill Do not alter

Ill

Be sure all fuel supplies have a positive shutoff

Ill

Be certain fuel line fittings are adequately tightened

free

1111

Make sure a fire extinguisher is installed nearby and is

properly maintained. Be Extinguishers rated ABC by for all applications encountered

BURNS-

WAJIIIIIIG:

:6ash

fires. Do not smoke or permit

occur near the carburetor, fuel line,

Use a suitable container to

cause

not smoke or permit flames or sparks to occur near

of

fire;

aware-

diesel fuel

BURNS-

WARNING:

or

death!

n>-fueling

Check

the

blower. Run

starting

fuel

vapors

handling and storing fuels. Store fuel in a well-

out

of

the reach

the

fuel

fue~

system.

of

fire near

Ensure proper ventilation

or

of leaks.

FIRE

F/rB

..........

line, carburetor, or fuel filters.

air

severe injury or death.

Keep

the

Wipe

up all spilled fuel and engine oil.

will

/tljtlry

Dr-

sources

of

spilled

catch

cleaner/silemcer

compamnent and the

debris

burn.

EXPLOSION

ExploslollS

safety

your engine. · ·

are

highly

service valve at the engine

Thke care

the

modify the fuel system.

from

fuel

'llllfJOI'S

instructi.OJ:!S.

below for fumes/vapor before

the

blow~

explosive.

of

children.

in

ca~b4J.g

smoKing,

fuel

system or

familiar with its

the

Keep the vessel's

and

for

Use

any fuel that

open

engine

exists

NFPA

in

~

flames

filter,

fuel

or fuel

all fuel when

removed.

to minimize

t:a11

t:aiiSII

ventilate

four minutes

extreme

are

environment

cabin

care

when

servicing

flames, or other

when

when servicing

valve.

proper

use.

apptopriate

or fuel

the

might

and

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

Thm

unit's

engine.

•

Make starting.

•

Make re-installed before starting the engine.

BAnERY

A

WARNING:

or

death!

• Do not smoke or being serviced. Lead highly explosive

arcing equipment in the during

• Never connect

positive ( +) connection terminal of the starter solenoi?. Do

not together. Ventilate accumulation of explosive disturb the battery charger connections is

being charged.

•

Avoid burns or sparks that could cause wristwatch, rings, the

battery.

•

Always

the

battery connections

and

BATTERY

A

WARNING:

severe

• When servicing level,

protection. Batteries contain sulfuric destructive. it off at once into the caps.

STARTING

Accidental

OFF

the

DC

breaker on the control panel or

battery

selector

certain all personnel

certain

all

covers,

switch

guards,

starting

to

are

can

OFF

before

clear of the engine before

and hatches

EXPLOSION

Battery

or

by

lit tobacco products. Shut off

servicing.

the

test the battery condition by shorting

Sparks could ignite battery any

compartment containing batteries

contacting

turn

the

reconnect it last

explosion

allow

an

acid

gas,

which can be ignited

vicinity

battery charger off before disconnecting

to

negative(-) battery cable

the

terminals with

and

any

..

Remove the

when

can

open

flame

batteries emit

prevent electrical

gases.

To

an

explosion. Remove

other jewelry before handling

servicing the

ACID

injury

or

death!

wear rubber

If

it

with

eyes

inadvertently when removing electrolyte

Sulfuric

the

acid

in

batteries

battery or checking the electrolyte

gloves,

comes

water.

a rubber

in

contact with your

Acid

may

apron,

splash

cause

servicing

are

cause

near the battery

hydrogen,

by

all

to

the

gases

or

avoid

sparks,

while

tools,

etc.,

negative

battery.

can

and

acid

which

skin,

on

injury

tum

the

the.

Injury

a

ele~cal

electncal

arcing

the

termmals

fuel

vapors.

to

prevent

do

not

the battery

to

prevent

lead

first

cause

eye

is

wash

the

skin or

TOXIC

• Ensure that the exhaust system

•

EXHAUST

A

WARNING:

discharged from regularly

water-injected Be

sure

the

Run

blowers when running

Do

not

run the generator set or engine unless the boat equipped with a functioning marine carbon detector that complies boat builder or dealer detectors.

• For additional information, refer (educational information

A

WARNING:

odorless nausea

•

• Do

•

AVOID

A

or

•

gas.

or

Do

not

use

Diesel

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

not

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

the

flow

of exhaust.

Although

exhaust

gas

is

present in symptoms poisoning

Vomiting Dizziness Headache Nausea

MOVING

WARNING:

death!

Do

not

service situation arises in make

operating adjustments, use extreme care

touching moving parts

components.

GASES

Carbon

the

for

leaks and

elbow

unit

and

Carbon

Inhalation

monoxide

engine.

make

is

securely

its surroundings

with

for

installation of

on

monoxide produces

(CO}

Is a deadly

is

adequate to

Check

the

exhaust

sure

the exhaust manifold/

attached.

are

the

generator set or

ABYC

A-24.

to

ABYC

Carbon

Monoxide).

(CD}

is

flu·llke

death!

copper tubing in diesel exhaust

can

rapidly

destroy

Exhaust sulfur causes rapid deterioration of

is

exhaust

fumes

discharge

Avoid

overloading

diesel engine exhaust

from

gasoline

diesel

exhaust

or

signs

of

carbon

are:

Inability Throbbing in temples Muscular twitching Weakness

copper

near the waterline, water outlet and

engines, monoXlde

close

the

gases

are

carbon

fume~.

S?me

to

think coherently

and sleepiness

PARTS

Rotating

the

engine

which

parts

can

cause

while

it

is

it

is

absolutely necessary

and

hot exhaust system

running.

gas!

expel

system

well

ventilated.

engine.

monoxide

Consult

approved

an

your

TH-22

invisible

symptoms,

systems.

tubing

in

exhaust

If

the

or restrict

craft.

not

as

toxic

monoxide

of.

the

mhalation

injury

If

a

to

avoid

gases

is

drawn engine

could

the

as

or

to

Engines & Generators

ii

1!11

Do

not

wear

loose

clothing equipment; jackets, could

1:1

Make Keep places

19

Do

not

the

engine

!1il

Do

not

the

exhaust generator death

4kW:«\RNING:

I(J~!

II

Never

1'1

Do

not

flame

1!11

Do

not open

A

WARNING:

mentally

tie

shirts,

be

caught

sure

all

protective

at

all

times.

check

is

operating.

allow

any

discharge

is

operating.

can

occur.

operate

run

the

arrester

run

engines

{when

installed).

or

physically

back

sleeves,

in

moving

attaching

shields

fluid

levels

swimming

High

an

engine

removed.

Do

not

or

jewelry when servicing

long

hair

and

rings,

necklaces

parts.

hardware and

guards

or

the

drive

or

activity

opening

Carbon

noise

with

for long

work

for Monoxide

levels

without

the

periods

on

air

machinery

incapacitated

SAFETY

avoid

wearing

or bracelets

is

properly tightened.

in

their respective

belt's tension

around or

the

generator

can

cause

its

muffler installed.

intake (silencer)

with their enclosures

by

fatigue!

loose

while

poisoning

hearing

when

you

INSTRUCTIONS

that

while

near

or

ABYC,

INSTALLING

Read for

tions AB:YC

"Standards

Craft"

Order

the

Order

are

NFPA

the

following ABYC, NFPA and

safety codes

.when

installing your engine.

(American Boat and Yacht

and

from:

ABYC

613 Third Street,

Aprtapolis, www.abycinc.org

NFPA-

"Pleasure and Commercial Motor Craft"

National Fire Protection Association Battery Match Quincy,

USCfl(Uritted

"regulatedions

Code of Regulations"

U.S. Government Printing Office Washington,

No.302 (National Fire Protection

from:

MA 02269

from:

AND

USCG

PUBLICATIONS

ENGINES

and

Technical Information

MD

Park

are under titles

D.C.

AND

GENERATORS

standards. Follow their

St1ite

10

21403

States Coast Guard)

CFR33

20404

USCG

Council)

Reports

and

FOR

publications

recommenda-

for

Small

Association)

CFR46

of

the

OPERATORS

Many

of

in

your

notes

to carefully, procedures.

GASOLINE

Preparations begin

with

Yacht

Council's

a

combination

Sections H-2

Ventilation

·

H-24

Gasoline

P-1

Installation for

P-4

;M:arine

EllAC All

installations

Regulations

www.abycinc.org

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

install

a

thorough

(ABYC)

of

of the

ABYC

.for

Fuel'

of

Propulsion

Inboard

and

DC

Electrical must

(FCR).

critical

sources

safety

tips

and

warnings are repeated

Manual

along

with

other

<;autions

information. Read

your

equipment, and follow

AND

GENERATOR

a gasoline

examination of the American Boat

standards of particular interest

Boats

Systems

Exhaust

and

Auxiliary Engines

Engines

comply

engine

standards. These standards

tnc~uding

using Gasoline

Systems

the

and

Transmissions

on

with

the

yoU:r

INSTALLATIONS

or generator should

USCG and

Boats Federal Code of

manual

all

safety

and

are·

the

and

from

NFPA.

are:

Engines

iii

& Generators

When

installing

attention be paid to the

WESTERBEKE

INSTALLATION

following

engines

information:

and

generators

it

is

important that strict

CODES

Strict when

AND

federal

installing

REGULATIONS

regulations,

engines

and

SIPHON-BREAK

For installations or

will

be below the vessel's break in the minimum

the exhaust manifold raw

water

If

you

have

to

the

vessel's waterline under

siphon-break.

NOTE:

A

siphon-break operation. engine

damage.

EXHAUST

The exhaust system's hose Exhaust and and system under

Hose

turns turns.

MUST

any

where

the

raw

water supply hose

of

20"

above

the

injection

damage

Failure

any

doubt about

Consult

to

the

requires

to

properly

SYSTEM

is

recommended.

without

the

Iieed

In

this

regard, a single length of corrugated exhaust hose

be

designed

sea conditions

ABYC

guidelines,

generators

exhaust manifold/water injected exhaust

waterline,

to

vessel's waterline.

port

is

engine

and

the

position of

the

vessel's various operating conditions,

periodic inspection and

maintain a siphon-break

the

siphon-break

MUST of additional

and

to

prevent

at

The

any

be

use

angle of

and

in

a marine

provisions

the

exhaust

Failure

at or

below

possible

certified for

the

flooding

the

water-injected exhaust elbow relative ·

manufacturer

of

this

type

fitting

and

entry of

vessels

safety

codes

environment.

must

be

elbow.

This

to

use

the load

of

cleaning

can

for proper

marine

use.

of hose

clamps

water

into

heel.

must be complied

made

a siphon-break

waterline

the

result

allows

to

the

elbow

is

close to

to

install a siphon-

hose

must

be looped a

when

wiU

result in

boat.

instaU

to

ensure

proper

in

catastrophic

maintenance.

Corrugated Marine

for

extreme bends

accomplish these

can

be

used.

exhaust system

with

a

bends

The

•.

AVAILABLE

YOUR

WESTERBEKE

'DEALER

:·s/PHON4fREAiWirif

LOOP'

FROM

STAINLESS

A

detailed

engines

to

and

download

Marine

Installation generators, from

our

Manual

is

supplied

website

Engines & Generators

with

at

www.westerbeke.com.

iv

covering

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

Parts

Identification Introduction Fuel,

Engine Control Operating Generator The

Alarms Maintenance Fuel

Cooling

Engine Remote

Carburetor

Engine

Alternator Engine

Lay-up Wiring

Generator BT

12

BT Voltage BT BTGJBTGA

Panels

Dally

Routine

and

System

Fuel Lift Pumps .....................................................

Gasoline/Water Separator ...................................... 12

System

Changing Coolant .................................................. 13

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

Replacing the Thermostat ...................................... 14

Raw Water Intake Strainer .................................... 15

Raw Water Pump ................................................... 15

Lubricating

Changing the Oil Filter .......................................... 16

011

Adjustments

Electric Choke ....................................................... 19

Engine Compression .............................................. 19

Ignition Wires ........................................................ 19

Valve Clearance ..................................................... 20

Pressure ........................................................... 20

Oil

Spark Plugs ............................................................ 21

Drive Belt Adjustment. .......................................... 21

Govemor ................................................................

12

Volt

Troubleshooting and Diagrams

Generator Stud

Internal

Single

Regulator

Generator

BTG

12.5Kw

BTG

15.0Kw

Metric

Conversion

OF

CONTENTS

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

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

011,

and

Engine

Coolant

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

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

Instructions

Break·ln

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

Procedure

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

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

Circuit

Breakers

Schedule

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

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

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

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

Oil

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

Filter

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

Adjustments

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

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

Testing

DC

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

Circuit .................................................

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

Recommissioning

and

Schematics

Information

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

Description

Wiring

Phase

Wiring

Adjustments

Troubleshooting

8.5Kw

Speclfications Specifications Speclficatlons

Data

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

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

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

Schematic

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

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

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

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

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

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

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

2 4

s

6 7 8 8 9

10 12

12

13

t6

17 18

19

22 23

23 25

.27

28-3S

36 37 38 39

40

41-50

S1

53

ss

57

Engines & Generators

1

J.D.

RAW

WATER

FRONT

PLATE

PUMP

STARTER

PARTS

IDENTIFICATION

LUBE

OIL

FILL

SIPHON

BREAK

CONNECTION

DISTRIBUTOR

BT

20A

CIRCUIT

BREAKER

WATER

INJECTED

ELBOW

GENERATOR

REAR

12.5KW

BTG

GASOLINE

AC

CONNECTIONS

15.0KW

BTG

GENERATOR

PORT

AIR

INTAKE

FLAME

LH

SIDE

LUBE

OIL

FILL

RH

SIDE

OIL

FILTER

Engines & Generators

2

HEAT

EXCHANGER

ANODE

FRONT

HEAT

EXCHANGER

PARTS

OIL

DIPSTICK

IDENTIFICATION

SIPHON

BREAK

CONNECTION

WATER

INJECTED

DISTRIBUTOR

GENERATOR

COMPONENTS

.20A

CIRCUIT

BREAKER

REAR

AC

CONNECTIONS

PORT

STARTER

MOTOR

LH

SIDE

AIR

INTAKE

FLAME

ARRESTER

8,5KWBTG GASOLINE

OIL

GENERATOR

FILL

ANODE

FUEL

LIFT

PUMP

LUBE

OIL

DRAIN

RHSIDE

INTRODUCTION

ORDERING

Whenever generator include a complete part

needed

insist

or

generic

cations

NOTES,

As

this

maintenance

tor,

critical

CAUTIONS,

NOTE:

A

observed,

tile

A

followed,

NOTE:

.

by

WESfERBEKE.

the

engine

SPARES

Certain

your

SUGGESTED

as

proper

the

way. spares on-board

PARTS

replacement

and

engine

(see

upon

WESTERBEKE

parts

are

as

original equipment

CAUTIONS

manual

An

takes

schedules,

information

and

operating

CAUTION:

can

engine

01

WARNING:

can

A carbon

room.

AND

spare parts will be

WESTERBEKE

SPARE

fuel

and

WESTERBEKE

and

accessories

inventory of

parts

are

needed,

model

and

serial

part

description

the

separately

frequently

AND

you

through

and

will be

WARNINGS.

procedure

Prot:edures,

teSUif

in

the

generator.

Procedures,

result

in

personal

monoxide

Affix

this

and

furnished

packaged

not

made

WARNINGS

the

troubleshooting

highlighted

An

explanation

essential

which

damage

·

which

injury

warning

decal

in a visable

ACCESSORIES

needed

to

generator

PARTS).

oil

filter

the

brochure

or

Often

can

be

difficult

will

provide

to

proper

WESTERBEKE

engine

assist

always

numbers.

part

number

Parts

Catalog).

parts

because

to

the

same

operating

of your

by

NOTES,

to

note.

U

not

strictly

01

destruction

if

not

01loss

has

support

and

when

even

simple

to

obtain

you

with a suggested

you

in

provide In

addition,

for

each

will

specifi-

procedures,

genera-

follows:

of

properly

of

life.

been

provided

location

maintain

cruising

items

along

preparing

parts.

the

Also

fit

in

(see

such

an

PROTECnNG

Care

at

the

have

resulted

many

thousands

manufacturer

installed

operated

buyer/owner-operator.

NOTE:

Six

•

Proper

• An

ejJicient

an anti-siphon break to prevent water from entering the

engine.

•

Changing

ing hours. Proper

•

nents according manuol.

•

Use

clean,

•

Winterize

Recommissioning" section in this manual.

UNDERSTANDING

The

gasoline

ways

similar

are

verticle overhead a

solid-state camshaft-driven. lubrication

which

is

generator's

that is

required important ventilation, cooling

CARBON MONOXIDE DETECTOR

YOUR

factory

in a

cannot

in

the

vessel

and

serviced

important engine

weU-designed

the engine oil

maintenance

filtered

your engine according

engine

to a gasoline

in-line,

GamShaft

distributor

system,

thennostatically-controlled.

engine

factors

maintenance

system

INVESTMENT

during

assembly

WES1ERBEKE

of hours of

and

to

and which

The

and a fresh

requires

of a

to

and

dependable

control

how

or

the

manner

in

the

field.

steps

to

ensure

generator installation

exhaust system that

and

oil

of

all engine

the maintenance schedule in

unleaiJed

THE

driving

the which

engine

gasoline

the

fueL

GASOLINE

an

AC

automobile

engine's

is

chain-driven.

is

horizontally

incorporates

water-cooled

the

same

automobile

generator's

of

the

fuel

generator

and

thorough

generator

or

where in

This

long

filters every 100

capable

service.

the

generator

which

the

is

up

to

generator

and

generator

to

the "Lay-up and

GENERATOR

generator

cylinder

preventive

longevity

system,

backend.

engine.

The

a

To

a large engine.

is

The

head mounted

pressure

engine

are

ignition

testing

However

unit

the

olignment.

includes

in

many

cylinders

has

engine

degree,

maintenance

The

proper

of

the

is

life:

operat-

compo•

this

an

utilizes

and

type

block

the

most

system,

WESTERBEKE monoxide

quarters. Carbon

ean

be

deadly.

The presence exhaust

system,

or

If

Ventilate

locate the

Engines & Generators

leak from

from

a neighboring

the dectector

4

highly

recommends

detector in the vessels living and sleeping

monoxide even in small amounts,

of

carbon

monoxide

from

the

main

engfu.e

the

area,

source

exhaust

signals

of

discharge location on the

vessel.

the presence

move

into a fresh air location and

the

carbon

mounting a carbon

indicates a possible

or generator, it's

of

carbon

monoxide

and arrest it.

monoxide.

exhaust

vessel

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

rating

of

harm

to

your

Care

Of

The

Use

only

clean fuel! The clearance of the

your

fuel

iqjection pump is very critical; invisible dirt particles which might pass through the these

finely

and

keep

it clean. The best fuel unsatisfactory facilities.

engine's

advisable: Purchase a Install

metal bowl type filter/water separator

and

ENGINE

Use a heavy duty

Specificati~

eilgine

break~in

change

SCHEDULE in this

To

daily

and

tile

engine.

OIL

on

and filter after the

operation.

intervalS

Only

use

unleaded

89

or

higher.

engine

Fuel

finished

by

assure that the fuel going into the

use

well~known

regularly service a

Section

'as

Leaded

and

fuel

violate

your

Supply

parts. It is important

can

be

careless handling or improper

is

clean

and

pure,

the

brand

of

fuel.

good,

Coast

engine

on

as

called for in the

of

this manual.

initial-

50 hours

Then

follow the olland filter

specified in MAINTENANCE

manual.

fuel

with

will

cause

warranty.

components

fllter

can damage

to

buy

rendered

following

Guard

between

~the

of

an

octane

serious

clean

storage

tank

for your

practice

approved

the

fuel

in

fuel,

tank

is

ENGINE

WESTERBEKB 50% that

The to the cooling circuit antifreeze that that

term

The

poured into

NOTE:

ontij'ree~

A proper engine coolant to temperatures

COOLANT

A coolant

The

coolant

without the

COOLANT

recommends a mixture

distilled

can

antifreeze perfonns double

run at proper temperatures by transferring heat

engine

keep

protection.

water and antifreeze should

purpose

cooling

water.

corrode

Use

internal

to

the

coolant. It also

from

contains

the

antifreeze

the

cooling

the

new

that is now

50/50

mixture

environmentally-friendly~

RECOVERY

recovery

expansion

the

tank

of

this

and contraction

loss

of coolant and

system.

Distilled water is

engine

surfaces.

duty.

lubricates

rust and

corrosion.

supplemental

chemically

circuit

available.

as

recommended

of

be

TANK

kit

is

supplied with

recovery

tank

without

of

free

It

allows

Use a

cooling

balanced,

premixed

will protect

-40"F

is

to

allow

during

engine

introducing air

50%

antifreeze

from

the

chemicals

the

engine

away

and

protects

good

quality

additives

crucial

before

long

lasting~

each

generator.

for

engine

operation,

from the

{SCAs)

to

long

being

the

into

and

Westerbeke

disapprove the use

oils

are

using conveirtional

be

as listed in the MAINTENANCE SCHEDULE

section oils

are

NOTE: The previous statements regarding synthetic on.

Corporation does not approve

of

synthetic oils.

used, engine break-in ... ust

oil.

on

change

of

this

manua1

used.

information above supersedes all

and

not

extended

or

If

~thetic

be

perfor.tn!'d

~tervals

__

must

if

sYnthetic

Engines & Generators

5

CONTROL

PANELS

DESCRIPTION

The

generator mounted control_panelis equipped ON switch switch (red).

The ON switch provides power to the start circuit switch by-passes until the oil pressure reaches

The

cranks

switch The

switch must The panel also has two

• A 15 amp slow bluw fuse protects

•An

any optional

REMOTE

An optional remote start/stop panel is available

controlling the generator from a remote location. This panel

previously described. Also included is a green which glows once the engine/generator rpm's. The purpose release the START switch. It is also engine/generator

(black),

START switch energizes the start solenoid/starter which

the

engine.

is

depressed and held at the

STOP

switch

8 amp fuse protects the

START/STOP

has

a START switch(white)

the

protective

This

switch

will

turn off the engine/generator,

be

depressed until the stop sequence

fuses

rembte

start/stop

the same ON, START, and STOP

of

the LED is

is running. ·

oil

pressure

5 - I 0 psi.

will

not operate

same

to protect

engine

or

instrument

PANR

to

time.

the

start

operating

(OPTIONAL)

has

alert the

an

indication that the

and

a

shutdown

unless

DC

circUit:

circuit.

circuit panel.

for

LED

reached

operator

with

an

STOP

This

switch

the on

.This

is

complete.

·

Ond

functions

light

600

to

..

REMOTE

An includes

DC charging voltmeter, operating

switches.

INSTRUMENT

optiol)al

remote instrument

a water temperature gauge,

·

REMOTE

The

installed

an

oil pressure

located installed in the thermostat housing is

adjace~~

on

the-thi:eads

each

wiring The

is

for the water temperature between removed. Refer

DIAGRAM

NOTE:

installers standards

INSTRUMENT

remote instrument

on

the engine

gauge

on

the engine.

to the oil pressure switch.

of

sender

are

tied off

harD.ess),

blue wire

iS

tenninal board connections

in this

When

installing

responsibility

33

CFR

both

PANEL

panel

block,

sender.

The

water temperature sender is

senders.

panel

is

available

oil

pressure

hourmeter,

and

INSTALLAnON

has two sending units to

a water

Plugged ports for each

to

temperature

and

the oil pressure sender

Use

sealing

Electrical connections

the senders location ( in

· · · . . .

.'for

the

oil

to.

the.

manual.

part

j»:essure

sender.

REMOTE

the

optional

to

comply

183.

sender

and.

If

there

is a jumper

T-1

and

T-2,

INSTRUMENT

rembte

panels,

with

the

U.S.

which

gauge,

start/stop

be

sender

are

compound

for

the tan

it

should

WIRING

it

is

Coast

Guard

and

the

wire

be

the

. Engines & Generators

6

OPERATING

INSTRUCTIONS

PRESTART

Before starting your generator for the first time longed layoff, check the following items:

a Check the engine oil level:

the full mark on the dipstick.

INSPECTION

add

or

after a pro-

oil to maintain the level at

a Check the fuel supply and examine the fuel filter/separator

bowls for contaminants.

a Check the

and battery cable connections.

DC

electrical system. Inspect wire connections

a Check the coolant level in both the plastic recovery tank

and at the manifold.

NOTE:

After the

the

engine's cooling recovery the

cooling system after

the tank will be replace

Before subsequent manifold should

tank

the purged

may

tank.

engine

drawn

need

initial

Open

has

be

to

be

running

system

will

the

air bleed petcock

is

purged

of

cooled, into air.

operation

topped

the

filled

the

engine's

off,

to

of

the

generator,

be

purged

air.

After shutdown and

coolant

of

the

and

the

cooling

generator, the

MAX

level.

from

coolant

to

the

to

ensure the

system

the

air

coolant

that

recovery

to

engine's

recovery

.

in

a Check load leads for correct connections as specified in

the wiring diagrams.

a Examine the air inlet and outlet for air flow obstructions. a Be sure no other generator or utility power

the load lines.

is

connected to

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

neutral is properly grounded (or ungrounded) as the system requires, and that generator neutral is properly connected to the load neutral. or open neutral can supply the wrong line-to-neutral volt-

age on unbalanced loads.

A

CAUTION:

recommended motors,

to

speed

be

switched

and,

precaution

pated

operation

cold

engine

In single phase systems

When

starting

that all

In

will

from

AC

OFF

cold

climates,

prevent

of

the

stalling.

until

damage

AC

the

loads,

especially

the

engine

starts

caused

machinery

an

incomplete

generator,

large

has

to

warm

by

unanticl·

and

will

it

Is

come

up

up.

This

prevent

a

STARTING

A

for a

·

ventilating

fumes

1. Depress this

2. Depress starts, the

NOTE:

the

oil pressure shutdown circuit allowing pressure to rise enough maintain the ignition circuit

3.

Release

Once ator ature

If

an

gauges for

NOTE:

This condition should smooth out and when the generator loads are applied

THE

GENERATOR

WARNING:

minimum

from

the

primes

the

release

ON

switch

Keeping

the

The

engine

and

allow

(130°-150°

optional instrument panel is installed, monitor the

normal

Some unstable running may occur

Ventilate

of

five

blowers

the

generator

ON

switch and hold it down (5-15 seconds),

carburetor. Continue to depress ON.

START (white), when the generator

the

START

a few seconds longer.

the

ON

switch.

is running apply a light load to the gener-

the engine

F/

55°-56°C) before applying heavy loads.

readings.

the

generator

minutes

remove

prior

any

explosive

compartment

switch. Continue to engage

switch,

depressed by-passes

to

close the switch and

to

warm up to operating temper-

as

to

starting.

the engine warms

compartment

The

gasoline

and

bilges.

the

oil

in

a cold

engine.

up

A

CAUTION:

the

engine exhaust pump cooling enter

with

is

pumping

system

the manifold from

happening

through~hull

co«ecting Engine

damage wa«antable in

mind.

STOPPING

1. Remove the generator to run for an added 3 to 5 minutes (this stabilizes

its

qperating temperature).

2.

Depress the When the generator stops, release the

3.

NOTE:

In

an the stop panel.

switch,

Prolonged

starting

raw

can

water.

raw

during

enginets

once

the

cylinders

the

exhaust

by

closing

shutoff~

cause

draining of

resulting

Issue:

the

THE

GENERATOR

AC

loads from the generator and allow the

STOP

(red) switch.

emergency,

remove

cranking

result

This

water

through

cranking.

by system the

the

excessive

from

in

may

way

raw

the

raw

intervals

filling

happen

the

This

of

fills.

water

exhaust

water

owner/operator

if

the

generator will not

the 8 amp

fuse

the

because

raw

water

the

exhaust

Prevent

supply

muffler,

engine

entry

should

STOP

in

the

without

engine

water

can

this

cranking.

Is

not

keep

switch.

stop

control

the

and·

a

this

using

Engines & Generators

7

DESCRIPTION

Although your engine

test

hour of assembly procedures operated properly, a break-in

life of operated and serviced

Breaking-in a piston and scored, break

Your conditioning operation to

maximize the perlormance Perlorm following:

Start the engine according section. Run the engine water

reach

AFTER

Once the generator tion

between

operations

your

engine

new

rings

to

smoky

operation

which

is

-in

period.

new

engine requires approximately 50 hours of initial

this

conditioning

pump,

oil pressure, battery

its

full

rated speed

START-UP

and

then encourage a

20% and

has

at

were

is

dependent

during

engine basically

the cylinder

indicate

caused

by

to

while

has

been

60%

of

experienced a minimum of one

the

followed

break

carefully,

are

fast

GENERATOR

factory

to

make

sure accurate

and

that the engine

time

is

required. The service

upon

how

the engine

its

initial hours of

involves

walls.

Excessive oil consumption

that

the cylinder walls are

overloading

in

each

and

service life

keeping

to

the

STARTING

checking that all systems

charging)·

signs

of

an

started,

check for proper opera-

warm-up.

full

load for

the

use.

seating the

the

engine during

moving part

of

the engine.

in

mind the

PROCEDURE

are

functioning.

overload.

Run

the generator

first

10

in

hours.

BREAK·IN

is

the

order

PROCEDURE

the

After load

can

periodically

Avoid

overload

smoky

exhaust Monitor it within the generators'

1800

rpm

control of the generators

drawn

current

NOTE:

Be current amperage

amperage.

GENERATOR

Once

the generator

(raw

governor adjustments the engine's break-in

(see

period

ENGINE

also

be required in conjunction

ment

(see

first

10

hours of

be increased

vary

the

current being

to

produce

aware

drawn

draw

See

to

the

load.

at all

times.

with

reduced output

rating.

60

from

the

generator.

of

motor

required for

can be 3

GENERATOR

ADJUSTMENTS

has

been

required

period

ENGINE

ADJUSTMENTS. A

GENERATOR

SPEED

the

generators

the

full-load

An

overload

drawn

Since

hertz,

or

engine

break

starting

to 5 times

INFORMATION

placed

for

(first

(HERIZ)ADJUSTMENTunder

no-load

with

INFORMATION).

operation,

rated

output,

is

signaled

voltage

from

at

loads

motors. normal

engine speed (hertz) during

50

and

frequency.

the

generator

the

generator operates

1500

to

produce

-in

is

governed

and

the

high

This

starting

running

in

operation,

hours)

voltage

the

engine's speed adjust-

there

or

after

adjustment

the

then

this

by

a

and

50

hertz,

by

the

manual.

may

this

keep

at

be

may

THE

CHECK

Follow

• Check that all generator circuit breakers (power panel)

•

• Check the oil

• Check the coolant

• Check your

• Check the starting

• Check the drive belt

CHECK WITH

• Check for abnormal noise

•

LIST

this

checklist each

the off position before

Record

the hourmeter

to the maintenance Visually

blow-back sounds.

Confirm When When the engine When

inspect the engine

exhaust

the

engine

the engine

level

fuel

THE

schedule).

(dipstick).

level

supply.

batteries

ENGINE

smoke:

is

cold is is

day

before starting your

starting.

reading

for

warm -almost overloaded -some

in

your log (engine hours

for

fuel,

oil,

in

the

coolant recovery tank.

(weekly).

wear

and

proper tension

RUNNING.

such

as

knocking, vibration

-White

Smoke.

Smokeless.

or water leaks.

Black

DAILY

generator.

(weekly).

Smoke.

are

relate

an:tf

ROUTINE

NOTE:

Some unstable

This

condition should

is

reached and loads

in

A

CAUTION:

periods generator.

of

time

running

abate

are

Do

not

without

may

as

normal

applied.

operate

.a

load

occur in a cold

operating

the

generator

being

placed

engine.

temperature

for

long

on

the

8

ALARMS

AND

CIRCUIT

BREAKER

SAFETY

The engine switches.

without

~ng

TROUBLESHOOTING

The

switches:

High

An exhaust temperatllre switch is located on the exhaust

elbow. the sensor indicate an excessive exhaust temperature quate.supply This resets

HIGH

SHUTDOWN

is

protected

Should a shutdown

SWITCHES

by

three

occur,

finding and correcting the cause.

Engine

starts,

runs

and

then

section

of this

following

Exhaust

DC

switch opens at

at

1s

a description of these

Temperature

Normally closed, this switch will

voltage (shutting off

of

raw water

approximately

··~

'

SWitch

the

causes

260-270"F

225'"F

(107°C).

EXHAUST

automatic

shutdown

do not attempt to restart

Refer

to

the

shuts

down

in

the

ENGINE

manual.

autoJIUltic

open

engine) should

high exhaust temperatures).

(127-132°C).

shutdown

and interrupt

the

switch's

(an inade-

This switch

TEMPERATURE.

SWITCH

MOUNTED

EXHAUS(ELBOW

AT

THE

·head-

LOW

OIL

PRESSURE

Allow

oil

pressure

gallery.

sure.

(0.4-

.

Engine

Tlie

manual draw wiring event breaker and fault,

This

switch's sensor

Should

generator's engine is protected

or electrical overload

repair

the

kg/cD).

engine

the

sourc;e

2

Breaker

0.7

Circuit

reset circuit breaker (20

or

the generator will-shut

interrupts

reset the breaker and restart the generator.

ALARM

!llarm

switch

engine's oil pressure

),

this

switch

wiring-

will cause

the

DC

circuiUf

of

the

SWITCH

is

located off

monitors

will

activate a pulsating alann.

amps

anywtrere

the

down

because

problem.

the

the engine's

fall

to

5-10

by

an

engine

DC).

Excessive current

in

the

inst:rum.ent

breaker

this

After repairing

the

shoUld

to

opened

occur,

engine's oil

oil

pres-

psi

'DIL

AlARM

DIL

PRESSURE

mol!Jlted

panel

trip.

•

In

this

check

the

PRESSURE

SWITCH

COOLAIT.TEMPERATURE

A coolant temperature housing. coolant's 6peta.ting

210"F

This switch will activate a continuous

(9~C).

switch·

temperature

SWITCH

is

located

reaches

. .

THERMOSTAT

ALARM

SWITCH

on

tbe>thermostat

alarm

aPproximately

ASSEMBLY

if

the

OVEilSPUD

BOARD

High

RPM

Shutdown

An overspeed

generators engine's speed correcting the tarily

DIAGRAMS

NOTE: When troubleshooting a possible faulty

switch. For test purposes to by-pass the switch.

Move DO NOT purposely by-pass a faulty switch so to

be

create a potential

engine

depressing the

in this

connection

able

to

operate the generator. This could

SWitch

switch

in

by

grounding

reaches

problem,

stop

manual.

T4

safetY

the

DC

circuit

out

2175

rpm(approximately).

this switch

switch.

onto

hazard.

Refer

TS.

shuts off

the

ignition

can

be reset by

to

the

WIRJNG

TERMINAL

th~

system

if

After

momeq'-

as

the

l"'fAriWESTERBEKE

Engines:& Generators

9

A

WARNING:

running. use

the

correct

servicing

NOTE:

Many

more

difficult and

MAINTENANCE

Never

Wear

any

of

the

attempt

the

proper

tools

for

the

engine's

following maintenance jobs

may

require

to

safety

equipment

each

job.

BC

electrical

the

expert knowledge

perform

Disconnect

SCHEDULE

any

service

such

the

equipment.

are

as

goggles

battery

simple

of

a service

while

the

and

terminals

but others

mechanic.

engine

gloves,

are

is

and

when

SCHEDULED MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Spark Generator

Fuel Starting

(and

Engine

Re-torque

*Adjust

Clearances

Air

Exhaust

Engine

Inlet

Separator

Oil

Level

Belts

Inspection

Plugs

(if

Filter

(Lift

Batteries

House

Batteries)

Oil

Cylinder

the

Valve

Screen

(Flame

System

Hoses

Fuel

Filter

applicable)

Pump)

of

Engine

Head

Arrester)

CHECK

EACH

DAY

D

weekly

D

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000 1250

NOTE:

Please

keep

engine

surface

clean.

and

oil

will

inhibit

the

engine's

ability

to

remain

cool.

D

D D

D 0 0 D D D D

D

D D D D D

D

D D D D D D D

D D D D D D

D D D D

0 D

D D

D

D D 0 D

D

0 0

Dirt

0

EXPLANATION

Unleaded higher.

Check if

Oil dipstick.

Check Add

Inspect

and

Check and Check

Check Check

with

(if Inspect Every

and excessive

Initial change

retorque Initial

Clean

Initial

for

exhaust on Check

spongy.

gasoline

for

water

and

necessary).

level

should

indicate

at

recovery

coolant

if

needed.

for

proper

adjust

if

needed.

for

fuel,

oil

electrical

applicable)

make

leaks. inside

Hose

Replace every 250 operating hours.

connections.

for

loose

gap;

inspect

that

AC

connections

no

chafing -see

for

fuel

50

operating

sure

corrosion.

engine

oil & filter

both

every

at

50

adjustment

at

50

hours,

check

at

Check

elbow

passages;

that

all

should

be

Check

leaks.

connections

hrs.,

50 for

connections

and

OF

SCHEDULED

MAINTENANCE

with

octane

rating

dirt

in

fuel

(drain/replace

between

tank;

if

empty,

tension

(3/8"

to

Check

belt

edges

and

water

leaks.

Keep

bolts & nuts

belt

tension.

for

burning

and

are

clean

GENERATOR

addition

information.

Check

wire

hours

check

electrolyte

are

very

change

at

100

hours.

them

every

500

at

50

hrs.,

then

every

then

every

100

hrs.,

then

every

siphon

brake

operation.

carbon

and/or

clean

andreplace

are

tight.

hard & tight.

tighten

Replace

all

hose

of

FULL

check

1/2"

Inspect

corrosion.

and

INFORMATION

connections.

tight.

50

hours.

250

corrosion

clamps.

89

or

filter

and

LOW

at

manifold.

deflection)

for

wear.

wiring

tight.

secure

levels

Clean

hrs.,

then

500

hrs.

Inspect

Check

buildup

as

necessary.

if

soft

or

on

off

the

continued

Engines & Generatnrs

10

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

by

running

hourmeter

time.

gauge

to

SCHEDULE

log

your

engine

hours

or

record

your

SCHEDULED MAINTENANCE

Heat

Exchanger

Raw

Water

Pump

Coolant

System

*Starter

Distributor

*Engine

*Exhaust

Motor

Cylinder

Compression

Valve

Clearance

Elbow

and

CHECK

EACH

DAY

50

0

HOURS

OF

OPERATION

100

250

500

0 0 0 0 0

0

0 0

0

0 0

0

750

1000

1250

0

EXPLANATION

MAINTENANCE

Clean

or

replace

anode.

cap

and

clean

out

debris.

for

professional

Remove

for

wear,

Lubricate Drain,

flush,

appropriate Check

solenoid

and

lubricate.

pinion

drive.

Check

ignition

distributor Incorrect

performance. timing

Test

exhaust casting WARNING: A defective

carbon

cleaning

the

pump

replace

both

when

and

antifreeze

and

Clean

timing.

cap

and

valve

clearance

Check

and

adjust

elbow

is

corroded

monoxide

cover

if

needed.

re-assembling.

refill

cooling

motor and

rotor.

compression

valve

for

or

leakage.

OF

SCHEDULED

Open

heat

exchanger

remove

every 1 000

and

pressure

and

inspect

Also

replace

system

mix.

for

corrosion.

lubricate

Check

will

clearances.

casting

deteriorated.

exhaust

the

condition

result

in

pressure

integrity.

elbow

testing.

the

impeller

the

with

starter

of

poor

Replace

can

end hours

gasket

Remove

motor

engine

and

if

cause

Carburetor Screen

*WESTERBEKE

Filter

recommends

this

service

0

be

performed

by

an

0 0 0

0

authorized

mechanic.

Clean

at

first

50

hours

and

every

250

hours.

Engines & Generators

11

GASOUNE

Use

-,.leaded

follow

companionways ventilate

NOTE:

The

detector/alarm

GASOLINfJWATER

A primary

installed between the

water and other contamirulnts from the be

carried

Most

instaliers

the installation

that contaminants in the fuel can

These

through'') to meet bowls have drain valves to use impurities,

89

.octane

U.S.

Coast

Guard regulations,

to

prevent fumes

after

fueling,

engine

torrtpartment should

properly

SEPARATOR

:fuel

filter of the water separating type must be

fuel·

to

the

fuel

syStem

~lude

~kage

gas

~e filiers must have

0

U;S.

or higher

installed

tank

,on

a type of

as

they

Coa8t

Guard

gasoline.

from

and:

and

the engine to

the

engine.

filter/water~

are

well

cause.

metal

when

FUEL

When

fueling,

clare.

off all

hatcQes

enteij11g

have

working,

AfiJ

bowls

requirements.

checking for water and

a

gasqline

FILTER

fuel

before they

aware

(not

·the

· · ·

of

and

boat,

and·

.

fuine

remove

can

with

the

problems

..

see-

Tbe'metai·

SYSTEM

The

pump

filter

also

clean

off the magnet [the magnet

from

the

fuel].

base hex nut with a

~ggasket

AwARN•G:

CDIIIIBI:fioJJS

Malee

Sllre

fuel

system

.FUR

UFT

should

be cleaned

The

pump base

wrench.

Fuel

is a fire

proper

t:DIRptments.

bazanl

relltilation

PUMP

can

When

leakage

and

every

250

removes

be

removed

reaSsembling,

at the fuel

should

exiSts

WJ.flnerel

operating

metal

by

twisting

rephice

PIIIIIP

be

t:DITBI:ted.

simnt:ing

hoi!rS;

particles

the

or its

#14PURPLE

PRESTART

·

BIJ7TON

GASOUNE/WATER

SEPERATOR & RlTER

·C~

The carburetor is a single barrel

by

metalic choke. Refer to

for more information. ·

RJa

UFI'

PUMP

Periodically check the fuel connections

and make sure that no leakage is present and that are tight and pump's mounting bolts should be clean and well the

mo~ting

The start sequence energizes

the

pump operates, it creates

ticking is heard, check for Also checkthat the ground wire is properly connected

ground.

NOTE: At initial start-up or when re-commissioning the engine,

it maybe necessary to prime the engine's fuel system. depress and hold the electric fuel pump which will pump fuel through the engine's fuel system and 4-6 seconds then proceed to start the engine.

secure.

The DC ground connection at

bolt to ensure proper

ON switch. This will activate the engine's

fill

the carburetor's fuel bowl. Do this for

downdraft

CARBURETOR

to

pump

the

fuel

lift pump

an

audible ticking

12

volts

at

the

type

with

an

electric

ADJUSI'MENTS .

and out of

operation.

pump

the

fittings

one

of the

secured

as

the

piston

sound.

If

connections.

to

To

pump

by

in

no

do this

Periodically check pump

and

make sure that no leakage

fittings

are tight one of the pump's mounting bolts secured.l:zy operations.

the

fuel connections

and

secure. The DC

the mounting bolt to ensure proper

is

ground

should

to

and

present

connection

be clean

out of

and

that

and

pump

the

at

well

IW'IWESIERBEKE

f

Engirtf!S

&_Generators

12

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine engines are designed and equipped for fresh water cooling. Heat produced in the engine by tion and friction circulates throughout the engine. coolant cools the engine block, the engine fresh water coolant to raw water exchanger, similar in function water

flows fresh water coolant ferred to the fresh water coolant is conducted through the tube walls exhaust system where finally it other words, the engine is cooled by fresh water coolant, this coolant is cooled transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent of each

other.

allows the cooling water passages

. harmful deposits.

FRESH

NOTE:

WATER

Refer to

recommended

fresh

water

Fresh water coolant is pumped through the engine lating pump, absorbing heat from the engine. The coolant

then passes through the thermostat into the manifold, to the heat exchanger where it block via the suction side engine

is

the

closed thermostat (although some coolant

bypassed around the thermostat to prevent the exhaust fold from overheating). As the engine warms up, the thermostat gradually opens, allowing coolant cooling system.

to

Coolant

A coolant recovery tank allows for engine coolant expansion and contraction during engine operation, without cant loss of coolant ing system. This tank should engine manifold level and should be easily accessible.

NOTE:

Periodically

sure

cap.

good

condition

closes

tightly.

is

transferred

oil.

The heat is transferred externally from the

through the tubes of the heat exchanger while

flows

to

the

raw

water which is then pumped into the

by

raw water, and the raw water carries

Using

only

COOUNG

the

ENGINE

antifreeze

to

fresh water coolant which 11ris

circulating fresh water

its internal moving parts, and

by

means

of

to

an

automotive·radiator.

around

tl_le

tubes; engine

is

discharged overboard. In

fresh water coolant within the engine

to

stay clean and free

CIRCUIT

COOLANT

and water

section for

mixture

to

coolant.

is cooled, and returned to the engine

of

the circulating pump. When the

started cold, external coolant

full

flow

unrestricted

Recovery

and

check

Ensure

that

and

check that the

Carry a spare

to

the

Tank

without introducing air into the cool-

be

the

condition

the

upper

cap.

flow

is prevented

flow

of

the engine's

e~temal

located at or above the

and

vacuum

portion of the

of

the

lower rubber

valve

combus-

a.

heat

the

be

used

by

flow

is

any

manifold

seals

opens

trans-

from

as

a circu-

mani-

signifi-

pres-

are

and

Raw

the

by

in

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE

become contaminated,

A

oritit:al; a substantiallllllllber

trat:ed

Drain the engine coolant by loosening the drain plug

engine block and opening the

the system with fresh

NOTE:

be

used

A

Wear

Refilling

After replacing the engine block drain plug, close the heat exchanger's coolant petcock. Then run the engine at idle and slowly pour clean, premixed coolant into the manifold.

NOTE:

When a steady the

petcock

Monitor the manifold sure

cap.

Remove the cap coolant mix the cap. flow

into the recovery tank.

After checking for leaks, stop the engine and allow it Coolant should engine cools

needed.

TO

COOLANT

RECOVERY

COOLANT

SCHEDULE.

it

CAUTION:

bat:k

The

drain

to

help

WARNING:

pmtet:tive

Open

the

Run

Clean

TANK

Proper

to

DDD/ing

water,

petcock

drain

engine

Beware

gloves.

the

Coolant

the air-bleed petcock

flow

of

coolant

and fill

the

sy$tem

coolant in the manifold and add

to the filler neck and install the manifold pres-

on

the coolant recovery tank and

to

halfway between

the engine and observe the coolant expansion

draw

back into the cooling system

down.

Add coolant

up

any spilled coolant.

If

the coolant is allowed

can lead to overheating problems.

cooling

sysflllll

on

syst11111

of

maintenanoe

engine

failures

DDIIDSion.

ma,tifold pressure cap. Flush

then start the refill process.

the

heat

exchanger

coolant.

of

the

bot

engine

on

the

heat

appears

until

at

the

manifold

LOW

and MAX and replace

to

the recovery tank

COOLANT

EXPANSION

t:an

should

coolant.

exchanger.

petcock,

remains

as

needed. Fill

fill

as

be

on

also

close

with

to the

if

to

is

the

full.

cool.

l"ffiN'lWESTERBEICE

l Engines & Generators

PRESSURE

/

CAP

COOLING

HEAT

EXCHANGER

Cool

raw

water

flows

through the inner exchanger. the which The engine coolant engine The engine coolant qther; harmful deposits

Heat

After approximately and motive exchanger).

NOTE:

As the engine coolant passes

heat of

the

internal engine is conducted

is

then

pumped

and

the circuit repeats itself.

this

keeps

Exchanger

pressure test the engine's heat

radiator shop should be able

Operating

into

the

exhaust

(now

cooled)

and

raw

water are independent of each

the

engine's water

found

in

raw

water.

Service

1000

hours of operation, remove,

in

silty and/or tropical

that a heat exchanger cleaning be peifonned

every

1000 hours.

THERMOSTAT

A thermostat controls continuously flows the

engine is first started the closed thermostat prevents

from

coolant thermostat to prevent ing).

As the engine

The thermostat is accessible and can be checked, cleaned, replaced easily. Carry a spare thermostat

Replacing

To

avoid spilling

manifold level [REFER TO CHANGING COOLANTj.

Remove the cap

housing

gasket, apply a thin gasket before pressing it into cap screws. Replace engine and check for no

leaks at

flowing (some coolant

the

as

-shown.

the

coolant temperature

through

warms

the closed cooling circuit.

the

exhaust

up,

the thermostat gradually

Thermostat

coolant,

screws

thermostat housing.

drain the coolant

and disassemble the thermostat

When

installing

coat

of sealant on

pi~.

the

coolant in the manifold.

normal

temperatures and that there are

tubes

around

system

flows

back

passages

exchanger.

to

clean

waters

is

by-passed

manifold

and

the

new

both

Do

not over-tighten

of the heat

these tubes

to

the

raw

water

and

discharged.

though the

clean

from

the

clean

(A local

and test the

more

as

from over-heat-

gasket.

down

thermostat

sides of the

auto-

may

require

often

the coolant

When

around the

opens.

below

and

Run

the

heat

then

or

the

SYSTEM

ZINC

ANODE

A zinc anode (or pencil) circuit within anode in

the of electrolysis condition the

anode cleaned or replaced,

should

NOTE:

and

vessel

HEAT

If

the

wj:rich loosening the anode hex

boss

zinc

is in poor condition, flakes exchanger and clean the

have

a spare heat exchanger

one

becomes damaged Replace the gasket (refer exchanger end gasket part install

the

heat

is

to

sacrifice itself

raw

water cooling

on

other

of

the zinc

be

carried onboard.

Electrolyiis is

location,

EXCHANGER

D-RING

zinc

anodes need

the zinc anode

from

possibly

within the

a new zinc

exchanger.

anode.

is

located

exchanger.

to

electrolysis

circuit,

components

anode

should be checked

the

result

not

that

of

END

GASKET

replacement,

is

threaded with a

with

another

tearing

there

Remove

inside

end

when

removing the end

to

your

number),

in

the

raw

water cooling

The purpose of

action

thereby reducing

of the

system.

as

required. Spare

of

each particular

the

engine.

hold

the

wrench

wrench. This

off the exchanger

are

probably a lot of

the

end

of

of all zinc

gasket in case

engine model's

debris.

0-ring and

the

zinc

taking place

the

effects

The

monthly

and

anodes

installf:ztion

hex

boss

into

while

prevents

shell.

If the

zinc

the

heat

Always

the

present

cover.

l1eat

cover,

and

,·

the

THERMOSTAT ASSEMBLY

COOLANT

TEMPERATURE

ALARM

SWITCH

14

NOTE:

The

not

require insulate housing

threads

the zinc from the

preventing

sealant

of

the

Sealant

electrolysis

zinc

should

metal

anodes

are pipe

not

be use4

of

the heat exchanger

action on

NEW

the

ZINC

ANODES

threads

as

it

zinc.

REPLACE

and

may

CLEAN &

do

OFF

REUSE

RAW

WATER

NOTE:

Always install the strainer at or below

the

strainer

A

clean engine's cooling strainer in

the

glass

Perform operation:

1.

Close the

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open

7.

Run

NOTE:

Also follow

aground.

If

the

engine normal may raw

reading,

have

water through the cooling system

INTAKE

will

always

raw

water intake strainer

system.

when

making your periodic engine

should be

the

following maintenance after

raw

and

clean the strainer

the

glass.

the

sealing washer if

and

the

seacock.

the

engine and check for

temperatUre

the

been caught

STRAINER

be

self-priming.

Include a visual inspection of

clear.

water seacock.

install the

the

above procedure after having

gapge ever

cause

may

up

in

the strainer, slowing

COOLING

the

waterline

is a vital

filter.

necessary.

strainer.

leaks~

be that silt, leaves or grass

component of the

check.

every

100

shows

a

highe~

this

The water

hours

run

than

the

flo~

so

of

hard

of

SYSTEM

RAW

WATER

The

raw non-ferrous housing has

flexible blades

within

the impeller housing, producing

On

no account should this

always

be

(an

impeller

when

lubricant operation. are

cautioned

up.

The

broken

or tom impeller blades.

SCHEDULE.

NOTE:

Should a failure occur with

(seals

and

chase

a new pump and rebuild

Changing

Close the raw water intake valve.

and,

with impeller out of the Move

the

push

the

bling,

apply a

gasket.

Open the raw water intake valve.

Run

the

check for water discharge at flow

indicates

PUMP

water

pump

is

a self-priming, rotary

and

a Neoprene

which

wipe against a curved

a spare impeller and impeller cover gasket

kit).

Raw

water pump impeller

(raw

water)

Such failures are

to

make

sure raw water

raw

water pump should

bearings), it

the

aid of

blades

impeller into

thin

engine

the

may

Raw

Water

two

small screwdrivers, carefully

pump.

Install the

to

conform

the

pump's housing.

coating of lubricant

and

check for leaks

pump

has

impeller.

the

JlUr!JP_

be run

is

not present during

not

warrantable,

flow

be

inspected periodically

See

MAINTENANCE

the

pump

be

more

cost efficient

the

original pump

Pump

to

the not primed itself

Remove

the

curved

stem

Impeller

new

to

around

tube.

pump

The

impeller

cam

pumping

d:rJ.

There

failures

engine

and

operators

is

present at

:SO

internal

to

as a spare.

the

pump

impeller

cam

the impeller

plate

When

assem-

the

pump.

Absence

properly.

and

with

plate action. should

aboard

occur

start-

parts

pur-

cover

pry

gasket.

and

Also

of

water

a

for

the

·

RAW

WATER

TYPICAL

INTAKE

[OWNER

INSTALLED)

STRAINER

15·

A

CAUTION:

impellei; the

they

cooling

exchanger

It

any

must

circuit.

of

be

located

They

the

vanes

often

have

to

prevent

can

be

broken

blockage

found

in

off

the

in

heat

ENGINE

LUBRICATING

OIL

DESCRIPTION

The lubricating system is a pressure feeding system using an

oil

pump. The engine oil is drawn from the oil sump by the

oil

pump, which drives the oil, under pressure, through the

oil

filter, oil cooler and various lubricating points in the engine. The oil then returns continuous cycle. When the oil pressure exceeds the specified pressure, the oil pushes open the relief valve in the oil pump and returns to the oil sump, keeping the oil pressure within its specified range.

to the oil sump

to

OIL

repeat the

FLOW

CHANGING

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil hose and pump the old oil out. Make sure the is properly secured in its holder after all of the old been drained.

Always observe the old oil emulsion indicates the presence this condition is rare, it does require prompt attention prevent serious damage. Call a competent mechanic if water is present in the oil. Raw water present in the oil can be the result engine and/or a siphoning through the raw water cooling circuit into the exhaust, filling into the engine.

THE

ENGINE

to

drain, or attach a pump to the end of the drain

of

a fault

OIL

oil

as

it is removed. A yellow/gray

of

water

in

the oil. Although

in

the exhaust system attached

drain hose

oil

has

to

the

OIL

PUMP

·OIL

GRADE

Use a heavy

Specificatio~

eiJgine break-in

change

SCHEDULE in this

Westerbeke disapprove oils

are using be

as

listed in the MAINTENANCE SCHEDULE

section

oils

are

NOTE:

engine

oil as called for in the

Section

oll

and

filter after the initial 50

operation.

intervals as specified in

of

this manual Change the

'f4en follow the

MAINTENANCE

manual.

Corporation does not approve or

the use

used,

conveiltional

of

this

used.

The

statements regarding synthetic

of

synthetic oils.

engine

oil.

manual

break-in

and

~ust

Oil

change intervals.must

not·extended ifsjtnthetic

information above supersedes all

oil

If

be perforin!ld

honrs

of

and filter

synthetic

oil.

TIGHTEN MOISTEN

FILTER

GASKET

CLEAN

OIL

INSTALLING

A

WARNING:

contaminants. and

nails

thoroughly discard used

clothing or

oil

properly.

BY

HAND

THE

NEW

WHEN

Used

Avoid

WITH

engine prolonged using

rags

containing

oil

soap

contains

skin

contact.

and

water.

used

harmful

Clean

Launder

oil.

Discard

skin

or

16

INSTALLATION

This

popular accessory

ter

from

the

engine

room

bulkhead.

NOTE:

Refer to ENGINE OIL

instructions

To

install, simply remove the engine

on

removing

WESTERBEKE's remote oil filter kit install

this kit

with

Contact your WESTERBEKE dealer

is

used to

to

a more convenient location

relocate

CHANGE

the oil

filter.

the oil filter facing

REMOTE

the

in

this

oil

filter and thread

as

shown.

down

as

for

more

OIL

engine's

manual for

information.

oil

such

as

Always

illustrated.

FILTER

PN#032149

NOTE:

filan

on

incorrect

A

rectly. pass

from failure. immediately

(OPTIONAL)

Westerbeke

installation

CAUTION:

If

valve

reaching

If

the

in

there

is

oil

the

and

not

of

·It

is

flows

filter

engine

is

no

check

responsible

the

Remote

vital

to

In

the

reverse

assembly

causing

oil

pressure

the

hose

for

engine

Oil

Filter.

Install

the

oil

direction~

will

prevent

an

intemal

reading,

coniJletJ!tlolirs.

failure

due

lines

cor-

the

by-

the

oil

engine

shutdown.

to

THE

OUT

CONNECTION

MUST

ATTACH

OIL

TO

AT

ALTER.

CONNECTION REMOTE

THE

IN

APPLY A THIN

INSTALLING

TIGHTEN

CONTACTS

THIS

AN

ADDmONAL3/4

THE

COAT

KIT.

BASE.

OF

CLEAN

THREAD

OIL

TO

THE

TURN

THE

KIT

ON,

AFTER

D-RING

THEN

HAND

THE

D-RING

WHEN

APPLY A THIN GASKET

WHEN

CQNTACTS

THE

COAT

OF

CLEAN

INSTALLING.

BASE,

AFTER

TIGHTEN

I

OIL

TO

THE

IT

AN

AODmONAL

ALTER

FILTER

·

Engines & Generators

17

CARBUREtOR

ADJUSTMENTS

CARBURETOR

The

carburetor

cleanable The

electric

opens

the choke automatically

remains

generator load

on

Air

ScreeD/Flame

The

air

releasing of

operation,

screen

in

is a single

metal

screen

choke

uses

running.

the

is

started, is

generator.

Some

on

(The

Arrester

screen/flame

the hold-down

every 100

a water soluble cleaner such

arrester

barrel,

down-draft

air

intake

filter/spark

a 12-volt heating

once

the engine

hunting

hours

choke,

choke

can

clamp.

will occur

and is

is

factory

easily

Clean after

from

then

element

when

rumring

be

removed

the

on.

as

GUNK.

type

with

arrester.

which

starts

the

without

set).

first

Clean

a

and

by 50

hours

the air

Carburetor

Clean then.clean the

screen

there

Idle Mixture

a

Ajustment Screw the jet

out

Note:

induce a sooty

Yz

this

are

to 1

An

Filter

Screen

filte~

element after the

~d

mspect

every 250

1f

necessary.

no

leaks.

Jet

is

performed with the generator not operating.

in

turn.

idle

mixture

exhaust

Tighten

slowly until you

jet adjusted

discharge

first

50

hours

operating

the

plug

feel

too

at

hours.

and

it seat. Then back it

far off

engine

start-up

of

make

its

seat

operation,

Replace

certain

can

and

shut-

down.

FROM

FUEL

FILTER

SEE

ELECTRIC

IN

THIS

MANUAL

ENGINE

ADJUSTMENTS

UNDER

IDLE

MIXTURE

JET

Engines & Generators

·fa

·

NOTE:

WESTERBEKE

ments

be

below

is

ENGI.NE

recommends

performed

provided

by a competent

to

assist the

ADJUSTMENTS

that

the

engine

mechanic.

following

mechanic.

·

engine

The

information

adjust-

ELECTRIC

The electric choke

CHOKE

uses a 12

volt heating element

opens the choke automatically when The choke is

the

choke rotating the cover clockwise counterclockwise set at the factory

. temperature. The

commissioning engine is operating on

the underside of

HIGH

Cheek the ignition compartment

adjusted

by

loosening

to

for

choke

for

the

in.

TENSION

CORDS

wires

heat

can

with

the

engine off

the three cover-securing

to

LEAN the

RICH

the

choke. The

an

average of

may

need readjustment at engine

ambient temperature of

The

choke reference

the

choke

cover.

(IGNmON

every 500 operating

deteriorate

Check the resistance of each wire. because the wire connection inside separated or the insulator the wires from the spark plugs, cap, then pull

THE

RESISTANCE

the

cap

VALUE

may

off the spark

IS

410

OHM

be

grasp

PER

TESTING RESISTANCE

the

engine

and

70"F

(21

WIRES)

the

wires.

Do

not pull

the

cap

damaged.

and

plug.

INCH.

starts.

cooled.

screws

choke

and

choke

°C)

room

the

mark

hours

on

may

become

When

twist the

which

Adjust

and

is initially

area the

is

·located

as

engine

the

wire

removing

molded

IGNITION

1.

Attach a timing light front crankshaft the

Each timing mark represents

2.

· Start the engine

operating

3. Using the timing

ccim:kshaft

ignition timing scale embossed cover. distributor

TIMING

8.5.~¥!

12.5Kw

15.0Kw

ENGINE

Iiit

compression, warm Remove the spark

(screws into a

Crank the ignition maximum reading

Measure

nMING

timing

scale embossed

and

temperature:

light,

pulley with'theproper

Do this

SPECIACATIONS

13° 13" 18"

by

body.

BTDC

BTOC BTOC

loosening

Refer

± ±

±

COMPRESSION

becomes

necessary

pl!J.g

engine

(close

coil. Allow

the

compression·

the

plugs

hole)

the

and

to

the

#1

spark plug

on

groove

the

and

engine's

2°.

warm

the

engine

align

the

timing

on

the

and

slowly

to

the timing specifications:

t•

al1800

rpm

1"

al1800

rpm

1"

al1800

rpm

TEST

to

check the

engine and shut it

and install a

with a gauge.

off the

compression

~ord.

pressure for

raw

engines

water)

gauge

the front

to

engine's

compression

each

that the pressure differential for each cylinder

· specifications.

and

timing

cover.

its

normal

groove

mark

rotating

cylinder

down.

and

to

reach a

cylinder.

is

mark

in

the

on

the

front

the

adapter

unplug

within

the on

front

the

Ensure

the

COMPRESSION

LIMIT

OF

If

a cylinder's

the limit, add a small

PRESSURE

DIFFERENCE

plug hole and repeat pressure, the damaged.

piston

If

the added

pressure suspect poor

wear.

Reinstall

raw

water

thru

/'"WV"IWESTERBEKE

) Engines

!It

·Generators

19

AT

300

UMIT

AT

300

BETWEEN

compression

CYliNDERS

or pressure

amount

the

test.

ring and/or cylinder

oil

does

valve

the

plugs,

ignition

seacock.

RPM

of engine

If

the

I}Ot

contact,

170 128

2.8

differential

oil

causes

increase

valve

wireS,

LBJIN'

[12.0

LB/IN'

[9.0

LBJIN'

[2.0

through

an

wall

may

compression

seizure,

and

coil.

Kg-cnr]

Kg·cm2]

is

below

the spark

increase

be

worn

or

valve

Open the

of

or

NOTE:

ments

be

below

is

ENGINE

WESTERBEKE

performed

provided

to

by

assist

ADJUSTMENTS

recommends a

competent

the

that

engine

mechanic.

the

following

mechanic.

engine

The

information

adjust-

VALVE

After valve

NOTE:

engines

CLEARANCE

the

initial break-in period (approximately 50

clearances should

Retorque

valves

the

cylinder head

(see

TORQUING

BOLTS).

1.

Remove

2.

Position the No.I piston at

compression valves. crankshaft

valves.

CLEARANCES:

the rocker cover and gasket

stroke

While

facing

360"

clockwise and adjust the remaining

VALVE

CAM

SIDE

ADJUSTMENT

be

adjusted.

bolts

before

THE

CYUNDER

Top

Dead

Center ('IDC) of its

and adjust the

the

front of

SIDE

INTAKE

EXHAUST

INTAKE

EXHAUST

#1

and

the

engine, rotate

0.010

in

.0012

in

0.007

in

0.009

in

hours),

adjusting

HEAD

#3

exhaust

(0.25mm) (0.30mm) (0.18mm) (0.23mm)

the

CYLINDER

BOLTPAnERN

TORQUING

After the initial break-in period (approximately 50 hours),

cylinder head Loosen the cylinder head bolts one half turn in

shown. the sequence shown rocker cover stud

HEAD

THE

CRINDER

bolts

should be re-torques. ·

(The engine should

beiow.

securely.

1

HEAD

BOLTS

be

cold). Then tighten the

One

bolt at a time. Tighten

the

order

bolts

the

8

the

in

3.

Replace the

ROCKER

rocker

COVER

VALVE

CLEARANCE

cover and rocker cover

TIGHTENING

TORQUE:

2.6-4.0

VALVE

CLEARANCE

CYLINDER

5&-59

OIL

The

by

the

normal

· 60 psi (2.8 and 4.2

NOTE:

reading an

oil

Ft-lb

gasket.

(4.11-6.0

Kg-m)

readings

engine

TESTING

To

test the install a mechanical oil pressure warming and read

Oil

Pressure

Sender

1-..IWESTERBEKE

· l Engines & Generators

HEAD

BOLTS

Ft-lb

(7.8-8.2

TIGHTENING

Kg-m)

TORQUE:

PRESSURE

6

engine's

oil

pressure,

oil pressure gauge on the instrument panel. During

operation,

A newly

up

pressure

will

and

up

the

and

Switch

the

started.

to

60

psi

reading

vary

the

TP.l'M.·

OIL

PRESSURE

oil

pressure, remove the oil pressure sender,

the

engine, set

oil pressure

35.0

lblin'

Torgue

during

operation,

oil pressure will range between 40

kglcm2).

cold

engine

can

(4.2

kglcrrf). A warmed

as

low

as

35

depending

(3.8

upon

the

gauge.

kg/em')

9

-13

gauge

engine

or

more

ft-lb

the

· ·

(1.2

is

have

an oil

engine

psi (25

kg/em:).

temperature

in

it's

speed

at

1800

rpm.

·1.8 m ·kg).

indicated

place.

1800

and

pressure

can

have

These

of

the

then

After

rpm

20

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the first

thereafter

SPARK SPARK

NOTE:

the spark of

PLUGS

50

hour break-in period, then inspected every 250 hours

and

replaced as needed.

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite Anti-Seize applied to the threaded

plugs

the spark

Do

not

is

hot.

Allow

remove

the

engine

spark

to

cool

plugs

before

them.

0.031- ±

will retard corrosion, making future removal

plugs

10

-151b·ft

easier.

0.0002 (1.5

in.

(0.8-0.05

-2.31

mm).

kg-m).

while

ponion

INSPECTING THE

SPARK

PLUGS

of

DRIVE

The drive belts must be properly tensioned. Excessive drive belt tension service life

and engine coolant pump. A on the temperatures and the failure

1.

BELT

ADJUSTMENT

can

cause rapid

of

the bearing and the alternator, raw water pump,

belt

can cause belt slipping, resulting

To adjust the alternator and the engine coolant belts,

loosen the alternator mounting bolts and pivot alternator as needed. Retighten the bolts.

2.

To

adjust the raw water pump belt, loosen the mounting

bolts and slide the pump up and

the

Retighten

NOTE:

When the belts are loose, inspect

frayed edges,

3. The drive belts are properly adjusted no less than 3/8 inch (lOmm) and (12mm) as the belt midpoint between the two pulleys the belt.

4. Operate the engine for about 5 minutes, then shut down

the engine and recheck the belts tension.

NOTE:

Maintain a 22 lb pressure to the belt's outer face

proper

ried on board.

bolts.

and

belt

operation. Spare belts should always be car-

wear

ofthe

belts and reduce the

slack

belt

or

the presence

in

high operating

of

the

same

components.

down

as needed.

for

wear, cracks and

replace if necessary.

if

it can be deflected

no

more than 1/2 inch

is

depressed with the thumb at the

on

the longest span

the

of

oil

for

of

CHECK

FOR CARBON BURNING

AND

A

WARNING:

drive

belt's

tension

Never

while

attempt

the

engine

to

check

or

is

in

operation.

adjust

a

21

ENGINE

NOTE:

WESTERBEKE recommends that the following

engine adjustments be

mechanic. The information below is provided to assist the

ADJUSTMENTS

peiformed

by a competent engine

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The belt-driven, mechanically operated governor maintains

the engine's rpm under various load conditions. Engine speed determines

Governor

Operate the generator to bring the unit up to operating tem-

perature before adjusting the governor.

NOTE:

adjust the linkage before proceeding with the adjustment.

There are three adjusting points on the governor (see illustration).

1.

Increase/Decrease Speed Adjustment. This adjusting bolt

sets the no-load speed the governor and the throttle lever should be hold the throttle ball joint position (when the engine .is not running). Make sure this

linkage moves freely and that the ball joint connectors are

properly lubricated. Use graphite Disconnect the ball joint and apply graphite lube to the inside

2. Hunting/Regulation Adjustment. engine speed between no-load and full-load adjust this eye bolt to draw the spring closer to the lever hub. The increase/decrease speed bolt adjusted as well.

If move the spring away from the lever hub (check speed adjustment).

Bumper

3. a no-load surge into the governor so far that it

the hertz and voltage output

of

the generator.

Adjustments

If

the governor is severely

at

no-load to obtain a safe output voltage

just

slightly closed; about the width

at

the linkage arms

of

the joint.

the governor surges under load, adjust this eye bolt to

Screw Adjustment. This screw is used to remove

ONLY. NEVER

out

of

adjustment, manually

of

the engine. The linkage between

adjusted to

end

towards the closed

lube for this purpose.

If

the variation in

is

too

great,

may

need to be

tum

the bumper screw

incre~es

the no-load speed.

of

the

Governor

1. Periodically lubricate the linkage arm attaching points at

2. Governor oil capacity - 3 ounces

3. Change the governor oil every

4. Periodically adjust the governor belt tension (see DRIVE

SPEED

Maintenance

the governor arm and throttle lever. Use a graphite lubricant or equivalent.

NOTE:

Free movement

proper governor/throttle operation.

NOTE:

Do not overfill the governor.

To change the oil, remove the governor from the engine, remove the oil fill and the fill level plug, and drain all the

oil. Reinstall on the engine and engine oil. Replace the plugs.

BELTS ADJUSTMENT). Since belts stretch slightly, this stretching will, to some degree, affect the govenor's action.

LINKAGE

HUNTING REGULATION ADJUSTMENT

ADJUSTMENT

of

this linkage arm is important

10/30 engine oil.

250 hours

till with 3 ounces

of

operation.

of

10/30

for

22

NOTE:

Synthetic oil is recommended

for use

in the governor.

DESCRIPTION

The

charging system consists regulator, cuit the

regulator back of

an

engine DC wiring harness, a mounted DC cir-

breaker

use

and a battery with connecting cables. Because of

of integrated circuits (IC's), the electronic voltage

is

very

compact and

the

alternator.

ALTERNATOR

of

an

alternator

is

mounted internally or

with

a voltage

on

the

TESTING

1.

Start

the Engine.

2.

After a

few

minutes

tery

voltage at the battery terminals using a multi-meter

set

on

DC volts.

The

voltage should be increasing toward

the

alternator

of

running measure

is working. Tum

to

Step 4 .

rnm

the

14

starting

volts.

If

bat-

it

is,

TROUBLESHOOnNG

A

WARNING:

hot.

Do

not

This

troubleshooting section is exists with the charging circuit or with the determined that the alternator or voltage best to

have

The

alternator charging circuit charges the

the

service

battery. battery selector switch late the batteries so the service battery

with

the service battery.

ing

battery

service

battery

Testing

A

that

sheaves

A

DC applfcatiiJIIS. Isolate before made

the

WARNING:

everyone

and

WARNING:

and

AC DC

performing

without

A failed

touch

a qualified technician check it out

An

but

not the service battery,

charging circuit and not with

altemator

until

the

alternator

isolator with a

is

usually mounted

If

the alternator

to

determine

can

has

n:gulator

diode,

is

not discharged along

is

the

Alternator

Before

is

clear

belts

during

MOLT/METERS

circuits

and

are

Always

AC

converters DC

pmper

starting

of

moving

often

disconnect

testing.

knowledge

the

parts!

test

pmcedures.

AND

mixed

and

No

of

engine

DC

together

shore

shut

AC

tests

AC

bectJIIIe

alternator.

starting

in

charging

problem

Keep

CIRCUITS:

power

down circuits.

very

csoled

dswn.

if

a problem

is

bad,

battery and

a solenoid, or a

the

circuit

the start-

is

in the

the

alternator.

make

away

in

marine

cords,

generators

should

be

If

it is

it

to

iso-

certain

ffDIII

is

0

MULTIMETER

COM

'

TESTING BATIERY • ALTERNATOR (ENGINE

3.

If

the starting battery voltage remains around after the engine problem exists with the alternator

a.

Thm

off the engine. Inspect all wiring and

Ensure that the battery terminals and the engine connections are tight and clean.

A

CAUTION:

charging switch

when

b.

If

a battery selector switch is

ensure that it is

c.

Tum

on

d. Check

condition the reading should

THE

STARTING

RUNNING)

is

started and run for a

To

avoid

damage

circuit,

the ignition switch, but

the

never

shut

the

engine

on

battery voltage.

is

the correct setting.

running!

If

or

to

off

the

in

the charging

do

your battery be

12

few

minutes, a

the charging

connections.

the

battery

engine

battery

not start the

is

in

to

13

volts.

volts

circuit.

ground

.

circuit,

engine.

good

TESTING BATTERY EN_GINE

THE

VOLTAGE

NOT

I...,.,.IWESTERBEICE

l Engines & Generators

23

RUNNING

-::-

GROUND

~--tMULTIMETER

7.

Now

check

the

voltage between the alternator output

minal

(B+)

and

ground.

at

the

alternator

isolator is

1.0

exists Check all the connections - look for charging circuit.

in

the circuit the alternator voltage will be

volts

lower.

If

in

the circuit between the alternator

If

the circuit is

will

be

the

same

neither of the above

DC

good,

as

the

battery,

is

true,

and

an

opening in

MULTIMETER

ELECTRICAL

ter-

the

voltage

or if

an

.5

-

a problem

the

battery.

the

· ( 14.0]

SYSTEM

Checking

Check the voltage of have a voltage between running. charging circuit. Troubleshoot the service battery charging circuit

by

isolator, battery switch, and

the

If

not,

checking

Service

the

there

is

the

Battery

service battery. 1bis battery should

13 and 14 volts when the engine

a problem in the service battery wiring and connections,

the

battery itself.

the

solenoid,

is

G

COM

.,

TESTING BATTERY/ALTERNATOR

(ENGINE

8. Start the engine again. Check the voltage between alternator output and ground.

The voltage reading for a properly operating alternator. should be between is

over- or under-charging, have it repaired at a reliable

service facility.

NOTE:

voltmeter

at the

tery present

fo.r

breaks and poor connections.

THE

STARTING

RUNNING)

Before removing

to

ensure that

EXC terminal if

voltage at

the

at

the

EXC terminal, trace the

13.5 and 14.5 volts.

the

alternator for

12

volts DC excitation is present

the

previous test showed only

B output terminal.

ae::::=---'

If

your alternator

repair;

If

12

volts

wiring

and look

is

ENGINE

GROUND

the

use

a bat-

not

MULTIMETER

GROUND

A

CAUTION:

diodes, when

do

performing

To

not

use a high

avoid

tests

damaging

voltage

on

the

alternator

SERVICE

TESTING BATTERY

THE

{ENGINE

the

alternator

tester

(i.e. a megger} charging

BATTERY

SERVICE

RUNNING)

circuit.

.

12

VOLT

Dt;

The engine shown diagrams elec1Jical

A

circuit, the

however,

engine's

bas

on

the-

wiring diagrams that

when·

system. ·

CAUTION:

never

engine

is

to

avoid

electrical circuit.

BATTERY

The

nritlimlllll

the engine's

Cranking

12

Amps

CONTROL

a 12 volt DC ·electrical control circuit that is troubleshooting or

To

shut

mnning.

:rel:P]Jlll).ended

volt DC control circuit is

(CCA).

CIRCUIT

avoid

damage

off

the

engine

Shut

electrical

follow.

Refer to these

when

servicing the DC

to

the

battery

off

the

engine

shorts

when

capacity of the battery used in

600-

charging

switch

battery

working

900

while

switch,

on

the

Cold.

Battery

Re\dew the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine's

0 Monitor your voltmeter 0 Check the electrolyte level and specific gravity

0 Use only distilled water

0 Make 0

A

cause protective

Care

starting batteries and house batteries.

for

proper chargipg

engine operation.

hydrometer.

to

bring electrolytes to a proper

level.

certain

that battery cable connections

tight to the batteiy posts (and

Keep

your batteries clean and

WARNING:

severe

burns

gear.

SUlfuric

on

skin

acid

and

to

in

your engine).

free

of

corrosion.

lead

batteries

damage

clothing.

during

with

are

clean

can

a ·

and

Wear

24

ENGINE

The

following troubleshooting tables are based upon certain engine problem indicators and the most likely causes problems.

When

troubleshooting indicates an electrical problem, see the

ELECTRICAL SYSTEM WIRING DIAGRAM, as these may

reveal other possible causes listed below.

of

the problem which are not

TROUBLESHOOTING

of

the

NOTE:

The engines control system (electrical system) is protected by a 8 Ampere manual fuse located on the control panel.

The generator has an

panel which should be in the

troubleshooting.

AC

circuit breaker

off

position when peiforming

at

the control

PROBLEM

Engine crank.

Engine but

then

down.

Engine but

does

up

to

speed.

does

starts,

shuts

starts,

not

runs

come

PROBABLE

1.

Voltage

drop

at

starter

terminal.

2.

Engine

circuit

breaker

3.

8

amp

fuse/holder

4.

Battery

is

low

or

5.

Loose

battery

connections.

Faulty

wire

6.

7.

Faulty

8.

Faulty

9.

Faulty

10.

Raw

1.

Faulty

(oil

temperature).

2.

Faulty Dirty

3.

4.

Low oil level in sump.

5.

Faulty fuel pump.

1.

Governor out

2.

Governor linkage binding.

connection.

start

switch. starter starter

water

filled

shutdown

pressure,

overspeed

fuel/water

relay. solenoid.

coolant

3. Faulty fuel pump.

4.

Restricted fuel supply.

5.

Throttle plate binding.

6.

AC

generator issues.

7.

Air intake restricted.

8. Exhaust restricted.

9.

Air in fuel system.

CAUSE

solenoid

has

is

faulty.

dead.

cylinders.

switch.

or

exhaust

switch.

separator

of

adjustment.

tripped.

filter.

PROBLEM

Engine

cranks

fails

to

start.

Engine

hunts.

Engine

misfires.

Engine

backfires.

.l

Engine Overheats

but

PROBABLE

1.

Out

of

fuel.

2.

Engine

is

Bad

ignition

3.

Faulty

4.

5.

6.

spark Unplugged Faulty

etectricalconnection.

1. Governor

CAUSE

flooded.

coil.

plug.

distributor

needs

2. Faulty governor.

3. Faulty fuel pump.

Generator overloaded.

4.

5.

Valves

need

adjustment.

1.

Poor

quality

fuel.

2.

Incorrect

3.

Dirty

4.

Cracked Faulty

5.

Spark

6.

High

7.

Valve

8.

1.

Spark Incorrect

2.

3.

Engine

4.

Dirty

5.

Cracked

6.

High

1.

Coolant cooling

2.

Faulty Belts

3.

Raw

4.

5.

Faulty

timing.

flame

arrester.

distributor

ignition

wires.

plugs

are

exhaust

back-pressure.

clearances

plug

wires

timing.

is

flooded.

flame

arrester.

distributor

exhaust

back-pressure.

loss.

Pressure

system.

raw

water

are

loose

or

water

pump

thermostat.

cap.

worn.

are

cap.

Refill.

pump

broken.

worn.

wire.

adjustment.

incorrect.

connected

test

impeller.

wrong.

25

ENGINE

TROUBLESHOOTING

PROBLEM

Low

oil

pressure.

High

oil

pressure.

No

DC

charge

starting

battery.

Blue

exhaust

discharged

engine.

to

smoke

from

the

PROBABLE

1.

Low

oil

level.

Wrong

2.

3.

4.

5.

6.

7.

1.

2.

1.

2.

1.

2.

3.

4.

5.

SAE

Faulty

or

wrong

Relief

valve

Faulty

oil

Faulty

engine

Faulty

oil

Dirty

oil

or

engine.

Relief

valve

DC alternator connections. Faulty

Lube

oil

is

·High

lube Crankcase Valves

are

incorrectly.

Piston

rings

or

unseated.Black

type

is

stuck.

pump.

bearings.

filter.

wrong

is

stuck.

DC

alternator.

diluted.

oil

level.

breather

worn

are

CAUSE

oil

type

SAE

or

adjusted

worn

exhaust

in

the

oil

filter.

type

hose

engine.

oil

in

is

clogged.

smoke

the

PROBLEM

Black

exhaust discharged engine.

Poor

performance

at

generator

smoke

from

speed.

the

1.

Dirty

flame

Idle

mixture

2.

Valves

3.

adjusted.

4.

Piston Contaminates

1.

Faulty

2.

PROBABLE

are

rings

fuel

CAUSE

arrester.

jet

too

rich.

worn

or

incorrectry

are

worn

or

in

fuel

system.

pump/contaminated.

unseated.

26

LAY-UP

&

RECOMMISSIONING

General

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

season or for long periods accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own lay-up and recommissioning,

if

others do the procedures.

These procedures should provide protection for your engine/generator during a lay-up and also help familiarize you with its maintenance needs.

If you have any questions regarding lay-up procedures, call your local servicing dealer. He will be more than willing provide assistance.

Propeller

The transmission and propeller half couplings should always be opened up and the bolts removed when the boat is hauled out

of storage in the cradle. The flexibility of the boat oftens puts a severe strain the boat is taken out or put in the water. In some cases, the shaft has actually been bent by these strains. This does not apply to small boats that are hauled out not in use, unless they have been period

Fresh

A 50-50 solution mended for This solution may require a higher concentration depending on the area's winter climate. Check the solution to make sure the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture. Operate the engine to ensure a complete circulation and mixture system. Then recheck the antifreeze solution's strength.

Lubrication

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

with new oil.

Shaft

the water or moved from land to water, and during

on

the propeller shaft or coupling

of

time.

Water

of

the antifreeze concentration throughout the cooling

Cooling

of

use

in the fresh water cooling system at all times.

System

Use

ENGINE LUBRICATING

"engine oil change". Run the engine and check for proper oil pressure and make

sure there are

no

leaks.

of

inactivity. Others prefer to

or

will serve as a checklist

Coupling

[Propulsion

dry for a considerable

Engine]

or

of

the water when

both, while

Circuit

antifreeze and distilled water is recom-

of

antifreeze,

the correct grade

OIL

of

oil. Refer to the

pages in this manual for

to

Fuel

System

Top off your fuel tanks with unleaded gasoline

or higher. A fuel conditioner such as stabilizer should be added. Change the element in your gasoline/water separator and clean the metal bowl. Re-install and make certain there are no leaks. Clean up any spilled fuel.

Fuel

System

Top off your fuel tanks with No.2 diesel fuel. Fuel additives

such

as control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water seperator used in the system. Change the element in your primary fuel filter/water seperator, has one, and clean the seperator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and allow it to run

5 -

10

for system. Check for any leaks that may have been created in the fuel system during this servicing, correcting them needed. Operating the engine for 5 - 10 minutes will help allow movement equipment

Raw

Water

Close the through-hull fitting. Remove the raw water intake hose from the fitting. gallon bucket check the zinc anode found in the primary heat exchanger the engine and clean

any zinc debis from inside the heat exchanger where the zinc anode is located. Clean the raw water strainer.

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

Start the engine and allow all through the raw water system. the engine. This antifreeze mixture should protect the raw water circuit from freezing during the winter lay-up,

as providing corrosion protection. Remove the impeller from your raw water pump (some

antifreeze mixture will accompany it, so catch Examine the impeller. Get a replacement, cover gasket. until recommissioning, but replace the cover and gasket.

[Gasoline]

of

STABIL

[

Diese~

BIOBOR and

minutes to make sure no air is left in the fuel

on

STABIL

of

the treated fuel through the injection

the engine.

Cooling

Place the end

of

clean fresh water. Before starting the engine,

or

Do

not replace the impeller (into the pump)

should be added at this time to

Circuit

of

replace it as required and also clean

of

this mixture to be drawn

Once the bucket is empty, stop

gasoline

if

the fuel system

this hose into a five

it

if

needed, and a

89

octane

as

well

in a bucket).

on

A

CAUTION:

oil

in

the combustion chemicals internal

parts.

sump

deposits

which

Do

over

can

not

leave

the

lay-up

combine

reduce

the

engine's

period.

to

produce

the

life

Engine

harmful

of

your

old

engine

oil

and

engine's

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the opening shove the cloth out recommissioning, and you may need assistance

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

Manifold

of

the intake manifold to block the opening. Do

and

Thru-Hull

of

sight.

(If

an

attempt is made to start the engine,

of

the servicing dealer). Make a

Exhaust

it is not visable at

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of

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NOTES:

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GE,...ERATORS, AND OPTIONAU.Y

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31

BLANK PAGE

32

BLANK PAGE

Engines & Generators

33

B.&

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35

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USE

OF

ELECTRIC

The

power

required

than

is

required

require

much

(AC)

motors circumstances, easy-starting applied Because

run,

their

motor

is repulsion-induction current varies

with

to

an

air

motor

to

In

general,

to

medium

MOTOR

(HP)

*NOTE:

more

for

this

is

that

larger

sizes.

Because

required can

bring experienced and,

if

possible,

REQUIRED

Run

the

ator's

capacity,

on

the checked plant

and

meter

is

portable

NOTE:

tains

AC

generators

volt

AC hot leg for

good

motor

to

keep

more

require

than

loads,

after

the

motor

they

require 5 to 7 times

use

should

to

be

driven

to

start

as

to·run.

the

load

compressor,

which

no

the

current

starting

SIZE

1/6 1/4 113 112 314

1

In

the

above

some

small

the

hardest

the

heavy

for

only

an

the

motor

in

starting

reduce

OPERATING

generator

and

generator's

periodically

the

appliances

not

installed

meter

and

When

the

equipment

AC

terminal

starting

MOTORS

to

start

an

it

running

current

to

more

current

other

types.

such

as

washing

is

started,

be

avoided,

by

a

small

motors

require

The

connected

for

example,

load

is

connected

required

loads

will

AMPS

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

table

the

motors

starting

surge

of

current

instant,

up

to

speed

motors,

the

load

first

with

finally

loaded

data

plate.

to

ensure

it

supplies.

to

monitor

amprobe.

vessel

in

which

of

120

volts

block

the

vessels

response

electric

motor

after

it

start

them

to

start,

They

are

machines,

such

as

much

whenever

generator.

from 2 to 4 times

current

required

to

it

An

will

require

to

start

115-

be

approximately

FOR

maximum

than

for

larger

types

(split-phase)

needed

the

generator

in a few

turn

off

on

the

SPEED

no

load

applied,

to

its

The

output

proper

operation

If

voltage

the

generator

only,

it

be

configured

distribution

from

the

GENERATOR

is

considerably

is

started

than

under commonly

small

current possible,

Capacitor

electric

Amps

will

seconds.

all

other

electric

full

voltage

an

AC

and

is

recommended

generator.

others.

similar

or

where

power

to

start

motor

more

Volt

motors

as

AMPS

(AMPERES)

6.4

9.2to

10.4

14.4

20.4

for

ones.

for

starting

not

electrical

motor.

then

capacity

should

of

voltmeter

load,

is

to

provide

panel.

Some

motors

Split-phase

used

on

loads

tools.

to

start

as

if

the

electric

and

as

much

any

motor

connected

current

connected

follows:

FOR

STARTING

to

22.4*

32.2*

to

72.8*

to

29.2*

to

40.8*

26to

52

Starting

The

reason

are

not

made

motors

be

damaged

If

difficulty

loads

at

half

the

as

indicated

be

the

generating

or

check

it

installed

that

one

This

will

INFORMATION

more

are

-

to

than

a

is

for

in

is

if

it

is

gener-

amp-

with

a

con-

the

120

ensure

GENERATOR

Frequency

by

the

following:

•

When output

•

When output

Therefore,

drive

engine's

of

the

AC

GENERATOR

•

Maintaining Connections

corroded, salts,

up.

heating

•

For petroleum all

• In

inspected overlleated

•

The checked

for not cracking. generator identified the

•

The

maintenance noisy

•

Examine of motion Repair and

Carbon

WESTERBEKE detector

even

The

from exhaust entering

If

carbon

air

FREQUENCY

is a direct

the

frequency

the

frequency

to

output

generator

change

speed

connections

result of

the

must

MAINTENANCE

reasonable

of

terminal

and

insulation

dust,

engine

Clogged

unusually

surfaces addition

drive

any

be

head

the

ventilation

and

reduce

severe

based

to

reduce

to

periodic

for

tightness

terminals

discs

on

periodically

evidence

allowed

rear

or

shaft

cause

to

The

bolts

shaft

must

by

6

radial

armature

is

required

rough-sounding,

the

bearing

should

is

detectable,

must

be

major

made

Monoxide

in

the

vessel's

in

small

amounts,

presence

the

and

of

engine

hose,

or

your

boat.

monoxide

correct

carbon or

that

the

ADJUSTMENT

engine/generator

is

run

at

3600

rpm,

is

60

Hertz.

is

run

at

3000

rpm,

is

50

Hertz.

generator's

be

exhaust,

life

conditions,

coatings

rusting

and

single

if

of

incipient

become

which

be

marks,

bearing

at

be

detected

inspect

quickly

damage

frequency,

changed

at

the

generator.

cleanliness

boards

and

surfaces

carbon,

openings

of

windings.

should

and

cleaning,

of

all

connections,

loose

or

bearing

possible

for

cracking

rusty

fasten

hardened

one

is

lubricated

However,

have

it

periodic

when

the

or

to

the

generator.

along

is

important

rectifiers

may

start

etc.

may

thin

rust-inhibiting

be

sprayed

corrosion.

the

generator

damaged

generator's

tightness

because

the

drive

steel

at

each

if

the

replaced

intervals.

force

bearing

major

Detector--------,

recommends

generator

fumes

is

problem

mounting a carbon

living

quarters.

is

deadly.

monoxide

or

from

from a nearby

present,

ventilate

immediately!

indicates

the

speed,

as

indicated

the

AC

voltage

the

AC

voltage

the

generator's

with a reconfiguring

may

become

conducting

are

allowed

cause

excessive

or

evidence

wires.

should

of

failure.

rust

may

disc

SAE

grade

of

the 6 comers

and

sealed;

bearing

No is

applied

and

shaft

components

Carbon

an

exhaust

vessel

the

area

if

to

build

brushed

should

Discs

side

be

of

be

screws

should

accelerate

to

the

8,

no

becomes

movement

If side

for

wear.

will

monoxide

over

and

monoxide,

exhaust

leak elbow/ are

with

clean

of

rub

Engines & Generators

36

BT

GENERATOR

This

generator is a

which

requires only

duce

AC

output The copper

stator

are responsible

erator.

The magnetic

be

induced into the related

tion.

Diodes located in the exciter rotor rectify this

DC

and supply it to

creates

an electromagnetic

windings

supplied parallel produced main

tifier.

the

a

rated

available produce

of

to

the

in the auxiliary stator The rectifier produces a

exciter stator windings,

AC

to work in tandem

a more stable

four-pole,

the

for

field

the

main

stator,

a load. A step

AC

output

and

is, in

turn,

output

An

optional solid-state AC

brushless,

driving

and

the

self-exciting

produced

exciter

windings

field

inducing

down

of

the

windings

supplied

DC

enabling

with

output

force

of

laminated

causes

rotor

of

the

which

an

transformer

main

stator.

of

the

to a full-wave

voltage

the

transformer

self-excited

the

engine

iron

feature

an

AC

windings

rotating

rotates

through

AC

voltage

is

connected

An

AC

transformer

to

further

generator

voltage

generator

to

pro-

in

the exciter

of

this

voltage

during

voltage

field.

This

the

which

voltage

and

bridge

excite

to

produce

regulator

SINGLE/THREE

·

..

gen-

to

rota-

in

rec-

to

is is

the

is

to

Acircui~·bt:eaker

.tors.

lbis

circuit breaker will automatically disconnect

ator

power bieaker can tor

to

ensure no power

NOTE:

This

add-on

kit

WESTERBEK.E

is installed on all WESTERBEKE

iri

~ase

be

manually shut off

circuit breaker is available

for

earlier model

dealer.

CIRCUIT

PHASE

of

an electrical overload. The

when

servicing.

is

coming into the boat.

as a WESTERBEKE

generations;

BREAKER

PART

NUMBERS

15KW·42710 12KW·42709

contact

genera-

circuit

the

genera-

your

gener-

AC

TERMINAL

BOARD

BT

GENERATOR

SINGLE

PHASE

[&STUD]

ELEClRONIC

VOLTAGE

BA

,..,.,fWESI"ERBEKE

Engines & Generators

37

BTGENaiATOR THREE

[12

PHASE

STUD]

BT

GENERATOR

NOTE:

Refer

to

the

text

ORANGE

and

12

STUD

diagrams

INTERNAL

for

the

proper method

WIRING

of

testing

for

resistance

SCHEMATIC

and

continuity.

6 5

9

10

3

2 7

8

A

EXCITER

B

AUXILIARY DIODES ROTATING POSt

RESISTOR)

C

MAIN

STATOR

MAIN

STATOR

0

COMPOUND COMPOUND AUXILIARY

G

BRIDGE

ACTERMINAL BOARD

GREEN

COMPONENT

STATOR

(6)

RECTIFIER

WINDINGS

ROTOR

FIELD

WINDINGS

WINDINGS AUXIL1ARY

TRANSFORMER

YELLOW

RESISTANCE

10.0Q

(A,B,C)_1.0-1.2Q

:11Q/infinite

7.0-S.OQ infinite

20-22Q

WINDINGS_1.5-1.8Q

WINDINGS_.019-.021Q

____

_

.

VALUES

[OHMS]

BT

GENERATOR

SINGLE

PHASE

12

COMPOUND TRANSFORMER

STUD

BRIDGE RECTIFIER

TRANSFORMER CONNECTION

1-2+3

[VOLTAGE CONNECTION)

HERTZ

38

:JUNC:TION

TERMINAL

1 & 4

BT

GENERATOR/SINGLE

RED

.__

___

L-...,.VEL="'""Low...------~-

=.._---IA.VP..

PLUG

.,_-------==---

PHASE

SO

eye.

60

Hz

TERMINAL

A.

EXCITER

A·1

(Selector

B.

EXCITER

1.

Auxiliary

2.

Diodes

3.

Rotating

4.

Posi

C.

MAIN

1.

Main

2.

Main

3.

Main

STATOR

and

A-2

in

ROTOR

(6}

Resistor

STATOR

Stator Stator Stator

WINDINGS

Exciter

Stator

COMP

position)

and

FIELD

Windings Field

Windings

Windings Windings Auxiliary

1&

Windings

(a-b-c)

Windings

2 ·

AVR

PWG

BLUE

/WHITE

(fO HEIII7NOUS 8AII)

BT

GENERATOR/SINGLE

10KW·15KW

I...J""'--1--'"'-'

BLACXIWHITE

(fO

GENERATORS

D.

Q-4-

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RECTIFIER)

COMPOUND

1.

Compound

2.

Compound

3.

Compound

Resistance easily

for

D-3

by

locating

shown

on

winding

resistance

component's

G.

BRmGE

A.

V;R.

Optional

l&U.OIIV

(TO

SELECTOR

PHASE

TRANSFORMER

Transformer Transformer Transformer

readings

the

RECnFIER

and

components

the

color

above

schematic.

values

electrical

Automatic

/WHRE

SWITCH)

Windings Windings Auxiliary

voltage

in

the

coded

checks exciter

wires

When

be

sure

to

connections.

Voltage

CIRCUIT

Windings

can

be

circuit

at

the

connection

checking

lift

both

of

Regulator

BREAKER

accessed

A,

G,

C·3

and

points

the

Plug

(6

Prong).

39

VOLTAGE

REGULATOR

ADJUSTMENTS

Description

The voltage regulator optimum AC alternator performance. It complete protection circuitry to guard against operating conditions that could

is

an

advanced design which ensures

is equipped

be

detrimental

to

the

AC

with

alternator.

Volts

This potentiometer is used to adjust output voltage. At proper

· engine operating ±1%

from a no-load condition

·and from power factor

ations up to -6%. Prior

to

starting the engini, turn the mers (using a mini phillips screwdriver) clockwise (Minimum) direction until stops.

Thrn

the AMP and HERTZ trimmers completely clockwise

(Maximum) in the same With the alternator running at no-load, at normal speed,

with

VOLT

age

will oscillate. Slowly rotate the

The

vpltage output

lize.

Increase the voltage

tion, only the green LED will stay

speed

the output voltage should be

to

a full rated generator output

1.0 -0.8

adjust at minimum, it is possible that output

of

the alternator will increase

with engine drive speed

VOLT

you

manner.

VOLT

to

the desired

value.

lit

and

fully

feel

adju8t

held

STAB

trim-

in a

coun,ter

them hit'their

clockwise.

and

stabi-

In

this situa-

vari-

and

Stability

This potentiometer permits variation·

response to generator load changes so pensation and obtain a minimum recovery time

voltage output ·

In order

·running

Thrn the starts terclockwise until the voltage is stable within 1 or 2 tenths of a

to

adjust the regulator stability

at no-load and the output must

STAB

adjuSt

slowly clockwise until-the voltage

to

fluctuate. At this point rotate the

volt.

VOLTAGE

of

the

regulator's

as

to

limit overcom-

the

alternator must

be

monitored.

STAB

REGULATOR

DIAGRAM

to

the

adjust

normal

coun-

at

volt-

be

Amp·Hertz

These

two

adjustments are protection circuits in the voltage regulator by the illumination

1.

Delay~

2.

Low

Both systems have

adjusted using the respective potentiometer. Each

circuits are able to cause an adequate reduction in excitor voltage overheating.

The overload protection system temporary overloading motor start-up or other similar load surge demands. The lator also has a third LED (green), that tor operation

with the generator.

Setting

In

order to set the AMP overload protection, the

must

1. Load

the hertz

Rotate the

2. its put should come on.

3. Slowly output age yellow LED

.4. Return

and

Sqol.ild

NOTE:

remove

Setting

NOTE:

jumper

two setting,

1.

To

·

lower (54

2. Rotate the Hertz adjustment counterclockwise slowly until

the the

3. Increase the engine speed to its normal speed (frequency).

The put will return to normal.

With

tion

overload protection (yellow

speed protection

an

to

safeguard the excitor windings and prevent their

to

indicate correct operation

the

Overload

be

loaded to its full output rating. ·

the

alternator to its rating, then decrease the speed of

engine by 10.10% (54 Hertz

on

50 hertz units).

AMP

stop. Wait about 15-20 seconds after which the

of

the alternator should drop and the yellow LED light

·rntate

the

~ltage

output at the start of the adjustment. At this point the

to

the alternator voltage will rise to its normal value.

When

the

If

the unit

strap

60

Hertz

the

adjust the underspeed

the engine speed

hertz

alternator's same time the red "LED" light comes

red ''LED" light will

the above adjustments made, the regulator should func-

normally.

increases

light should come

nominal speed,

this not happen, repeat the adjustment.

changing

60

hertz jumper bar

Underspeed

is

operating

is

in

place

tenninals.

alternator should

on

60

hertz

AC

used

in conjunction with the

that

are indicated

of

a colored LED lights.

LED).

(red

LED).

intervention threshold which can

has a delay which permits

of

the generator

during

glows

during genera-

of

the

times such

regulator

of

the two

two

be

as

regu-

Protection

alternatOr

on

60 hertz units,

adjustment counterclockwise until it hits

·

AMP adjustment clockwise until the

to

approximately 97%

on..

th~

yellow

LED

will turn off ·

from

60

hertz

to

50

hertz

from

the

regulator

45

AC

of

the

operation,

board.

out-

volt-

Protection

at

60

Hertz

ensure

tluJt the

on

the

regulator

In

order

to

be

running

(low

frequency)

at

90%

units,

45

hertz

output voltage starts

go

out and the

adjust

of

board

the

at

no-load.

protection circuit,

its

normal

on

50

hertz

to

AC

between

the

underspeed

running speed-

units.

decrease and at

on.

voltage

out~

.

I.,.,.,IWESI'ERBEICE

-.

(Engines &

c;lenerators

40

BT

GENERATOR

The

following troubleshooting chart is designed

insight

into problems brushless ulation. trols, between lems

ity

Owing to

troubleshooting

cause and effect

are

covered

Keep

in

mind that a

is

required for

that

lethal

extreme Only a few

NOTE:

caution is

When

generators operating on compound transformer

voltages

basic

fault

which

may be encountered with

the

simplicity is

relatively

in

the

text of this manual

basic

this

troubleshooting,

are

present in the circuitry; therefore,

essential

tools

are

finding, troubleshoot components in the order indicated below.

of

the equipment and

easy,

is

understood. Most potential

fundamental

when troubleshooting a

necessary for diagnosis and

once

the

knowledge

and

always

TROUBLESHOOTING

to

give

the

BT

reg-

con-

relationship

prob-

of

electric-

remember

generator.

repair.

These

are

hand tools:

meter

capable

sion

required

Before the

problem as possible, nessing problem than

equipment fault.

initial

trip bridge of

these

died

early and

of

in

attempting

the

problem.

which is related

to

the problem equipment,

rectifier, so that if

easily replaceable

reading

any

efficiently.

CHART

an

ampprobe

less

than

one

component

repairs,

In

Bring

get a clear

preferably

some

cases,

to

the

method of

basic

the

problem

parts,

repair

the

and a quality

ohm

due

winding

from

this

problem

an

may

tools

such

should

operation

as:

resistances.

explanation of

individual

bring

with

diodes

be

.can

volt-ohm-

to

the

preci-

wit-

to

light a

rather

you

and

found

in

be

reme-

on

the

one

1.

LOW

VOLTAGE

F.

Selector

B.

Rotor

Components

8·2

Exciter

8·3

Rotor

8·1

.

Exciteor

A.

(1-1

+2)

2.

RESIDUAL

A.

(1-1+2)

G.

Bridge D·3.Transformer C·3.Main

F..

Stator

Selector

A

+ - I I

COMPONENT

REFER

TO

THE

60·100

VOLTS

AC

Switch

Rotor

Diodes

Field

Windings

Rotor

Windings

Exciter

Stator

Windings

VOLTAGE · EXCITER

Exciter

Stator

Rectifier

Auxiliary

Switch

CIRCUIT

Windings

a,b,

c

FAULTY

· 3.

r-------------------,

I 8 :

I I I I

+I

I I

I :

I I

1 I

2 : 1 2 3 l

~-----------------J

I

CHECKS

INTERNAL

NO

AC

C.

B·4.Posi B·2.Diodes

D.

8·3.Rotor

r----------1

I c . . D I

I I I I ,

I I

: 1 t 1

~~

!Q;;

I.

I j I

I I : I

: 3 I

'----------

WIRING

VOLTAGE

(1

+2)

Exciter

Resistor

(4-6

(1

+2)

Compound

Field

DIAGRAMS

OUTPUT · MAIN

Stator

Windings

open/shortened)

Transformer

Windings

;----------;

1 1

! )

I I

1•1

!

.J

~-;--1

l

...

1--"'-:

--7',.1'--

1

1 2 I

l!. -

_3 --- .J

STATOR/ROTOR

Windings

50

Hz

TERMINAL

-8

1

r--<1~---:

I

COMPONENTS/TRANSFORMER

60

Hz

TERMINAL

3

GREEN

F/

YELLOW

BlACK

I

i

'

.__

___

L-~YE=l~LO~W~------------~

G

BLACK

--=.:=----!

RED

GREEN

+

.-L-.a-,

A.V.R.I----------:B::::LU:::.E--1

PLUG

BLACK

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

41

BLUE

SO eye.

BT

GENERATOR

TROUBLESHOOTING/SINGLE

PHASE

4

TESTING

BRIDGE

4. Leaving

touch point #5 with the needle should

5. Place

and the negative (-)

should not register

deflection indicates connections and the deflection. If defective and should

NOTE:

results

Component

A. Exciter Stator

A-1

A-2 12.9 ohm

C.

Main Stator

C-1

C-2 0.089 Auxiliary Wmdings

C-3 0.85ohm

A

- + I I

11·~·

+ - I b 1

1

2~

~~

~i

SHEEN

YELLow

9LACK

the

negative

the

positive ( +) lead of

the rectifier fails

Different

from

the

Resistance

&A-2

49.4

ohm

0.089

ohm ohm

~-----------------,

I B .

I : I I

I I

! : * 4 l

1 2 3 l

~-----------------~

RED

==---

·--.

F~

'

I '

; I

I

~

"

1-

YELLOW

occur.

any

style/model above

11.5

ohm

G

+

~

-

~

vruow

1

I

-

THE

RECnFIER

(-)

ohmmeter lead

the

positive (

the

lead

on

point #3. The ohmmeter

deflection

infinite

resistance). Reverse these

ohmmeter

be

should

of

the previous tests

replaced.

meters

tests.

Values

B. Excitor Rotor/Field

B-1

B-2

D.

Compound

D-1 D-2 0.007 ohm

Auxiliary Wmdings

D-3 5.02ohm

r---------~

; C i : D !

I I I I

I

II

I

I I

.

I

I 3 I

.

~

i

-

AC

1§

::::

~

BLACK

BlACK

on

point #4,

+)

lead.

No

ohmmeter

of

on

the needle (no

again

may

produce

1.05

ohm,

8.9

ohm

'l:'ramformer

0.007

ohm

I

2 I

!

I 1

I

·-------.J

11~1~1011

VB.UJN

-

+

1A.V.R.1

-

H

PLUG

deflection

point

#1

register

(1 -4)

it

no

is

opposite

~--------~

•

I

l

I

3=#==

I

LF-

&

REP

BLACK

2

~-

~~

I I

1.1

IIEP

GREEN

of

~-

~

E. A.C. Terminal Board

G. Bridge Rectifier (early models)

The

model code number

housing

on

a flat surface above the rear generator carrier

F.

Selector Switch

H. Optional AVR

is

found

stamped in the generator

bearing.

NOTE:

These

two

model

BT

rated

lower

than

the

generator

drive

engine

COMPONENT

Exciter

1.

WindingsA-1

is

rated

since

horsepower

RESISTANCE

Stator

Windings

andA-2

generators

capabilities

according

produces

are

of

the

generator.

to

the

capabilities

kilowatts.

CHECKS

Resistance readings for exciter windings A-1 and

with the selector switch in the

between the positive (

the bridge

rectifier (G). Neither of these two leads should

+) and

have the continuity to the generator

2.

WmdingA-1

COMP

negative

case/ground.

Resistance readings for exciter windings A-1 with the selector switch

wire and the black at

yellow

in

the ELEC position is taken between the

the

A.V.R plug (G).

3. Wmding A-2

Resistance readings for exciter winding A-2 with the

selector switch green wire lifted off the rectifier terminal

NOTE:

The

white

has

been

changed

colors,

however,

in

the ELEC position

negative

(G) and

of

the

red wires lifted off the positive (

the bridge rectifier (G).

striped

wiring

to

solid

colors

remain

the

same.

on

(-)

terminal

earlier

current

is

E

6

•2

•5

W2

•6

•7

Vl

•3

•B

.

BLUE

(TO

HERI'ZNOil'S

~

i

RED

I

WHilE

(TO

IIERIZNOI3'S

BI.UElYIIIITE

(TO

III'IEIIM.

JWIIITE

BAll)

BI.ACKJWHITE

(TO

llliiDGE

BT

GENERATOR

INTEliNAL

WIRING

SCHEMAnC

(WJOPTIONAL

NOTE:Striped

model

·

matchup

AVR)

wires

generators.

to

the

current solid color

were

The

i

I

.

I

.

I

_,

l!!

~

..

BLUE

5

8

7

&Oj

J

50c)IC.

used

on

models

However;

of

the

A-

2

position are taken

(-) leads lifted off

taken between the

of

the

bridge

+)

model

generators

generators,

BAR)

RECfiFIER)

used

colors will

the

BLAcK/WIIIrE

(TO

SELECTOR

YEU.OW

IWMITE

(TO

SELECTOR

on

early

,however,

wires.

SWITCH)

SWITCII)

42

BT

GENERATOR

Testing

1.

Residual

The amount generator

the problem/fault may lie.

Voltage

This voltage is the

from

magnetism in the exciter stator measured between the AC Neutral and Hot leg(s) with no-load on the generator running at The presence following generator components

INFERNAL

a. Exciter Rotor

b.

Rotating Field (B-3);

c.

Main

Stator

d. Compound Transformer

The fault lies in one or more in the exciter circuit:

Voltage

of

no-load voltage produced by the

can

be an indicator

10-14

volts

AC

of

residual voltage is an indication that the

WIRING

SCHEMATICS.

(B-1

(C-1

& C-2); and

of

where

voltage produced

field.

60

are

OK.

a,

b,

& c) & (B-2);

(D-1

& D-2).

of

the following components

in

by

hertz.

the generator

This voltage

Refer to

a. Exciter Stator (A-1 & A-2)

b.

Bridge Rectifier (G)

c. Selector Switch (F)

d. Main Stator Auxiliary Wmdings (C-3)

e.

Compound 'Ii'ansformer Auxiliary Winding (D-3)

2.

Twelve ings

(12) volt

should cause the generator to produce between 140 -

150 volts AC between each hot lead and the neutral (12 volts

DC is applied between the lifted(+) and(-)

the bridge rectifier, + to + and - to Correct voltage produCed with twelve volts DC excitation indicates the fault is in one or more

components b, d or e. · . .

If

the generator does not produce 140 -

then include a and

DC

excitation

c.

of

the exciter stator wind-

). of

the

.. · ··

above

· · · · ·

150

volts

··

I

BATIERY

CONNECTION.~-;-~-

/'·../

:~.:

:f_

I

TESTING

BRIDGE

THE

RECTIFIER

leads

listed

··

AC,

TROUBLESHOOTING

3.

The

absence

fault

with the main stator windings

the

compound transformer windings Apply as

explained m paragraph

and/or compound transformer will

is

cause the generator engine to shorted windings to eventually excitation is continued.

4.

Voltage output rotorf!ield !3-1, B-2 or B-3. Excitation explained m paragraph 2 should produce a voltage to

the original low output.

BRIDGE

The

bridge rectifier is supplied windings transformer terminals lows:

11

Diodes

in

supply

it to the windings of the exciter stator to induce a

through

of

· ·

measured fier

during engine operation is

8 -

Failure

of

produced

sent..

due to the magnetism

cause

the generator to produce residual

Testing

for

Faults

(Meter

.

1.

Set the ohmmeter needle to zero.

2. Connect the positive ( +) lead

#4. Taking the ohmmeter's negative(-) lead, momentarily

con~t

register no deflection for

3.

Remove the positive ( the lead, momentarily

mete~'s

showmg a passage of meter the

of

at)y

voltage from

1~

vol~

DC

excitation to the exciter stator

2.

output greater

(25-

100 volts) indicates a

output and,

than

when

removed, the

RECTIFIER

in the generator stator (C-3)

{D-3).

The

AC

voltage

of

the rectifier during engine operation

120Volts

N/LFIL

-

20

volts

AC

11

the rectifier convert

which the exciter rotor

across the(+)

120 Volts

NIL FIL NIL

15

:volts

the bridge rectifier

by the exciter stator

the

Bridge

with

used: Simpson

points #1, #2, #3, and #5.

negative

needle should deflect

rectifier.

and(-)

AC

Rectifier

an

Ohmmeter

260

scale

+)

(-)

lead

to

touch

8 -

in

at 70°F

on RXl ( +

lead

point #4

the

C-1

A fault

windings

load

produce

residual

fault

AC

voltage

and

measured

120/240

NILFIL

- 20

volts

this

AC

revolves.

terminals

as

follows:

1201240

F/L

15

volts

will

result

windings.

the exciter

(21

from

any

of

the

from

and,

points

#1,

when

voltage

generator indicates a

and

C-2

and/or

D-1

and

D-2.

windings

in

the

main

stator

such

as

a short

down

and

the

smoke

as

the

and

less

than

rated

in

the

exciter

of

the generator

partial

rise

voltage

will

return

from

the

auxiliary

the compound

across

the

AC

is

as

fol-

AC

voltage

to

DC

and

The

DC

voltage

of

the bridge

AC

in

a weak

A weak

stator,

voltage.

field

which

recti-

being

is

will

oq

DC)

and

set

the

ohmmeter to point

The

ohmmeter

points

point

with.

#2,

and

each

through

#4

touched.

and

the

positive

#3.

point

the

should

connect

The

is

touched,

diodes

as

in

field

pre-

(

+)

ohm-

in

NOTE:

Current

configured

BT

Generators

use

d«ferently, connections

a bridge

are

the

rectifier

that is

same.

1..,.,-IWESTERBEKE

l Engine$ & Generators ·

43

BT

GENERATOR

TROUBLESHOOTING/SINGLE

PHASE

Main

Stator

1.

Group

lifted lead #4 from the insulated terminal below the transformer and lead Lead #5 should be lifted from the terminal block in order to totally isolate the stator windings

2.

Group

lifted lead former and lead #3 lifted from the order to totally isolate the stator windings lead

NOTE:

lifted stator

connections

Main

Stator

3.

Main for these windings are measured between the black

double lead connection lifted bridge rectifier (G) and the red Voltage/Hertz connection bar.

NOTE:

these

Main

Stator

Windings

#1. The resistance value is measured between the

#6

lifted from the AC terminal block.

of

group #1, .

#2. The resistance value is measured between the

#1

from

the

insulated terminal below the trans-

AC

terminal block. In

of

group #2,

#2

should be lifted from the terminal block.

No

continuity should

leads

and

of

the

two

Windings

Stator

No

winding

Auxiliary

20 -22

Auxiliary Windings. The resistan<;e values

continuity should be found between either

groups

Windings

the

groups.

Ohms

or

to

1.5 -1.8

be

found between any

case

ground or between

off

the AC terminal

#3

lead lifted off the

the

generator

Ohms

case.

of

the

of

3. Transformer Auxiliary Windings. Resistance is

measured between the yellow wire lifted minal block

switch in the ELEC position and the the Voltage/Hertz connection bar.

#2 and #3 red leads that

the windings to totally isolate these windings. There should be no continuity found from either to

the case/ground or to either

Selector

This switch

optional position.

NOTE:

With windings

stator

bridge

rectifier

Bridge

The illustration below shows the color coded wires at the two AC terminals and the color coded wires at temunals.

NOTE:

When

correct polarity connection on

of

the bridge rectifier (G) with the selector

come

of

Switch

is

is normally set in the COMP position.

AVR

is installed, the switch is toggled to the ELEC

the

selector switch

are

and

Rectifier

removing

divided, the

Wiring

or_

in

ELEC position

one

group

other

group

through

reinstalling connections, maintain

the

( +)

off

the AC ter-

#1

red

lead lifted off

Off this

from the auxiliary

the transformer groups.

same

bar, lift

of

these connections

the

is

excited

and

through

the

A.

V.R.

the

( +) and (-) DC

(-) DC

terminals.

If

an

exciter

the

Compound

1.

Group

lead transformer and lead

2.

Group

lead transformer and lead

NOTE:

these lifted

Transformer

1. Resistance value is measured between lifted

#4

from the red insulated terminal stud below the

2. Resistance value is measured between lifted

#1 from the red insulated terminal stud below the

No

continuity should be found between either

leads

BLUE

or to

BlUE

#8

lifted

off

the AC terminal block.

#7

lifted

off

the AC terminal block.

the

generator case/ground.

of

GREEN

BlUE

RED

(TO

HER1Z

YEllOW

{TO

SELECT.OR

I

BLACK

(TO

SElECTOR

SWfTCH)

SWITCH)

NOTE:Striped

model generators. matchup to

BAR)

wires

the

were

The

current

44

used

on

colors

will

solid color

early

,however;

wires.

YEllOW

BLACK

SELECTOR

SMTCH

BT

GENERATOR

TROUBLESHOOTING

Exciter

1.

Auxiliary

2.

Rotor/Field

Auxiliary windings group

tenninal points winding illustration and count off the porcelain knobs from the 12 o'clock point either left or right to locate terminal points

a,

b and

of tenninal points A & need

to appears. fault.

There should

of

the three tenninal points and the rotor shaft/case

ground.

Windings

Rotating Field Windings. Refer to the illustration above

of

the exciter

noted as

striped wires. ohmmeter between connections ing appears. verify the resistance reading. With

lifted, there should

This would indicate a short to ground with.these field windings.

on

the

groups. Position the exciter rotor as shown in the

c.

Measure the resistance value between the pairs

unsolder

If

this

the

these

occurs,

be

1.0

·1.2

REDJWHITE

rotor.

( +)

and ( -)

Measure

need

not

If

this

a,

b and

c.

Locate the

exciter rotor for these auxiliary

B,

B & C, and C & A. There is no

connections unless a faulty reading

unsolder and verify the winding

no

continuity found between any

Ohms

(Rm)

The

field

winding connections are

connections

the resistance value with your

these

two connection points. These

be

unsoldered unless a faulty read-

occurs unsolder the connection

be

no

continUity

of

the red & white

these

connections

to the rotor shaft.

three

and

11

OHMS

THROUGH

INFINITE

BLOCKING'-'

NOTE:

meter

the

4.

When age glow

S.

----11

Attempting will

auxilit:iry

leads are put across the diode, as illustrated,

passes through the diode allowing the headlight

bri~tly.

Reverse

block voltage passing through it, and the headlight should not

glow,

a. Should the

directions, the diode is open internally.

b.

Should the directions, the diode is shorted internally.

In both a and b

Check the resistance values

and

the integrity ofthe resistors connected between the

field

windings.

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

give

erroneous

winding's

the

leads across the diode.

or it

may

bulb

above,

THE

DIODE

-110HMS.

1-+<J--·

INANITE--+-

to

check

·

diodes

.readings

connections.

glow

faintly.

not

glow

with leads connected in

glow

with leads connected

the diode should

of

RESISTANCE

1------

in

place

on

the

The

be

the rotating

High

beam

is

veJY

with

an

diodes

diode should

in

replaced.

field

12V

faint.

12VBAmRY

VALUE

ohm-

due

to

volt-

to

both

windings

bulb

3.

Diodes.

rectify the auxiliary windings voltage to The

a common some jumper battery. A short the above without diode

Six

diOdes

or

to

check it

diodes

AC

voltage

the

rotating

can

be

automotive

leads

an

open

with

are

mounted on the exciter rotor; they

produced by the

to

DC

voltages and supply this DC

field

windings.

easily

checked in place with the use

12-volt high

and

the generator's 12 volt starting

in

a diode can easily be found with

having

to unsolder and isolate each

an

ohmmeter.

beam

three

groups

of

headlight bulb,

j.....,.IWESJERBEKE

l Engines & Generators

45

6. Rotating Field

between the two red & white wires connected and

(-) tenninals

7. Posi-resistor. Infinite readings between both yellow leads

lifte4

from the ( +) and (-) terminals A short in the posi-resistor will cause a loss of the rotating

field.

W"mdings

of

AC

output voltage will drop

7.0-8.0 ohm. Readings

the exciter rotor as shown.

on

the exciter

to

zer~.

to

the ( +)

taken

rotor,

BT

GENERATOR

TROUBLESHOOTING/SINGLE

PHASE

No-Load

Voltage adjustment being governed by

1. The selector switch

2.

3. To raise

VOLTAGE/HERTZ

If

do Bar. AC

The Hertz terminal that the generator will

The Voltage/Hertz Connection Bars diagrams below). To ensure a proper connection follow the blue/white connect to for

NOTE:

and

to

lator produce

(REPOSffiON FOR

TO

TERMINAL

Voltage

Adjustment

is

made with the generator regulation

the

compound transfonner.

must be in the COMP position.

To

confirm no-load voltage, start the generator

a momentary (moderate) load to excite the transfonner.

The voltage produced by the generator after the momen-

tary load is removed is no-load voltage. Note the voltage

output from the generators hertz).

The

no-load voltage should

volts at 61.5-62 hertz (232- 236 volts at 51.5-52 hertz).

or

lower the voltage, shims (non-conductive material) are placed or removed from under the steel laminated bar on top

The

transfonner.

soften

at

temperatures in the 176° F (80° C) range. A

small reduction times be accomplished

laminated steel

ing shims

material used for shimming should not

in

no-load voltage

bar

to

and

the

transfonner core.

CONNECTION

there is

no

automatic voltage regulator (AVR) installed,

not change the wiring on the Voltage/Hertz Connection

SimQJy

terminal for

60Hz.

if

correspond

CURRENT

50Hz)

60Hz

reconfigQre the AC voltage connections at the

the

hertz

blue

or

blue/white lead should be connected

order

of

the numbered connections on some

or

blue lead to the

the

correct terminal: stud 6(V1) for

See the BT

When

the

optional

the

Blue/White

will

sense incorrect voltage and

abnormally

to

the

(Blue)

Hertz

high

MODELS

THIS

WiRE

•

120 volt leg(s) (230 volt

be

between 121-124

of

varying thickness

of

the compound

(1

to 3 volts) can some

by

gently tapping

reduce the gap between the exist

BAR

chang~

be

set to produce.

may

be

reversed (as in the

AC

terminal block,

WIRING

VOLTAGE/HERTZ

SCHEMATIC.

voltage

lead

the

unit

output

regulator is

not

correctly

is

operating

cause

voltage.

CONNECTION

BLUfJWHITE

and

the

top

to

it

50

Hz, 5(W2)

is

installed

positioned

at,

the

generator

EARLY

MODELS

apply

50

of

the

should

the

regu-

BAR

to

115V

1

'

50Hz

® ®

23DV50Hz

® ®

120V60Hz

• • • •

BT

Generator

NOTE:

The

from

I I 0

hertz.

For terminal copper

wire

connection.

neutral stud

Generator

1. Frequency is a direct result 1800 1500

2. To change generator frequency follow the steps below.

a. Connect the

following the correct diagram above

b.

If

lead to correspond to the hertz selected Voltage/Hertz Connection Bar.

c.

Start the engine, monitor voltage and adjust engine noload speed. Adjust diesel units by the linkage between the throttle arm on the injection pump. 60 50

d.

After the no-load hertz adjustment is made, the no-load voltage may need

generator was producing the correct no-load voltage the previous hertz setting, changed hertz setting.

In the event

ness under the laminated steel bar 60 50

e.

Load the generator to the rated amperage output corresponding to the hertz speed Rated Loaded

60 hertz: loaded speed, 58.5-59.0 hertz 50 The (amps) 60 hertz: 108-110 volts 50

Six

Stud

AC

frame

volts

output

ends

sized for

The

and

for I/4

ground

and

leads

I I

01220

wire

from inch the

amperage

frame ground

the

generator

Voltage

must

volts 50

the

AC

studs that will accept multi-strand

wire frame.

Connections

be

moved

hertz

to

terminal

rating

from

connects

Frequency

of

engine/generator speed:

rpm=

60

hertz;

rpm=

50

hertz.

AC

output leads to the AC terminal block,

..

an AVR is installed, reposition the blue or blue/whlte

and

fuel solenoid or the throttle

hertz: no-load speed, 61.5-62.0 hertz. hertz: no-load speed, 51.5-52.0 hertz.

to

be readjusted.

it

needs adjustment, adjust the shim thick-

hertz: no-load voltage, 121-124 volts hertz: no-load voltage, 232-236 volts,

Speed

hertz: loaded speed, 48.5-49.0 hertz

lowest acceptable voltage at full rated output

hertz: 205-210 volts

would

In

be

of

the

of

the generator.

120/240V

• •

when

changing

230

volts

50

block,

use

the

hot lead

between

on

most cases,

correct at the

the

lever

if

transfonner.

60Hz

the

at

46

f.

Should excitation repositioning Connection

and increase the order.

NOTE:

justment

these tions being motor

result

~LIJE

(TO

HERtz

BAR)

the

voltage

can

be

connections

Bar.

yellow/white)

loaded

No-load

adjustments

type

of

voltage

with

the

placed

loads).

overload,

BT

GENERATOR

drop

below

the

proper rate, loaded

increased

Repositioning

from

compound

to

on Loss

will

to

raise this voltage

on

the

V?ltage!Hertz

the

two

leads (red/white

{1)

to

(2)

or (3) terminals will

voltage out progressively in that

may

be

effected needing

transformer.

compensate for overload condi-

the

generator/engine (inductive-

of

generator hertz/speed, the

cause a drop

Do not

"in

voltage output.

by

read-

use

TROUBLESHOOTING

•~~=j...___.....

6 5 4 4 8

~.

L1230V50Hz

L1120V60Hz

YELLOW

(TO

SELECTOR

SWITCH)

A.V.R.

NOTE:

The

frame

ground

must be moved when

from

115V/50Hz

The

frame groundwire

between

generator frame.

the

to

neutral

Plug

wire

changing

230V/50Hz.

connects

stud

and

the

(TO

BRIDGE

RECnFIER)

and

Connections

AC

TERMINAL

L1115V

50Hz

6 8

L'~~s=~

N

Terminal

Wiring connections quency are illustrated

NOTE:

below

BOARD·

0

9

0

CONNECTIONS

L1230V50Hz

0

7

9

0

Block

Connections 1 the

compound

Wiring

L1120V60Hz

Connections

needed

to

obtain proper voltage

in

the

diagrams above.

and 4 are

transformer.

[12

STUD]

located on

two

4

red

terminals

L2

and

240V

fre-

60Hz

N

• •

·

NOTE:

For

ouput leads from

.

accept

multi-strand copper

the

wire

AC

terminal block

sized for

47

use

the

average rating

terminal

from

A

JUMPER

the

hot

IS

LOAD

1/4"studs that

lead

connection

REQUIRED

BETWEEN CONNECTIONS.

~ndsfor

• •

BT

GENERATOR

NOTE:

AC

generator troubleshooting must be performed with the engine operatin

TROUBLESHOOTING/3

PHASE

at

60Hz.

NO

AC

VOLTAGE

RESIDUAL NO

LOAD

LOW

AC

VOLTAGE

NO

LOAD

HIGH

AC

150

VAC

UNSTABLE

FAULT

OUTPUT

VOLTAGE

15 -20

VOLTS

60 • 100

OUTPUT OR

HIGHER.

VOLTAGE

AT

NO

PRODUCED

AC.

OUTPUT

VAC.

VOLTAGE

AT

OUTPUT.

LOAD.

AT

1.

Short main

2.

Shorted on

exciter

3.

Four open

1.

Blown 6 AMP auxiliary

2.

Faulty

1.

Open exciter

·

2.

Shorted

1.

F,aulty

1.

STB needs

PROBABLE

or

open

in

the

stator

winding.

pozi·resistor

rotor.

or

more

shorted

diodes

on

exciter

fuse

circuit

AVR.

voltage

regulator

or

shorted

diodes

rotor 1 to 3 diodes.

exciter

rotor

winding.

voltage

regulator.

pod

on

regulator

adjustment.

or

rotor.

in.

CAUSE

4.

Open

stator

5.

Open field

3.

Shorted stator

3.

Faulty

2.

Faulty

in

exciter

winding.

in

rotating

winding.

or

open

auxiliary

voltage

main

winding.

regulator.

AC

VOLTAGE

60

- 100

DROP

UNDER

LOAD

VOLTS

AC.

r-------------.

I I

A

EXCITER

STATOR

~

0

::l

..,

>-

_________

L-

.J

E

VOLTAGE

1.

Diode(s) breaking applied

REGULATOR

on

exciter

down

when

(inductive)

BLVE

rotor

load

1-3

is

diodes.

Q

.....

a:

RED

GREEN

·48

VEL

LOW

BT

GENERATOR

3

PHASE

TWELVE

INTERNAL

WIRE

RECONNECTABLE

WIRING

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

I I

I A

I I

1 1 I DsrATOR l

I

I I I

I 1 I C I

1

L-1-

~

....

w

>-

EXCITER

STATOR

r----

:

exPITER

I

+ I 5

I I

I I I I

I

L-----r----------~

-I--

..

bl

c•

I

:

~

I

- -

--

ROTOR

(6)

*

DIODES

-----,

FIELD

I.

J

~

~------,

12:...----+-11--1-{----------.11

110

:

s--...:.,_~----1-:-~---

I 6

I

:------~~~

2

I

4

I

I I

....

~

I , I

I I

L

_____

I

~-------1

l

_j

---------.1

E

VOlTAGE

REGULATOR

Q

w

a:

II

6.3AMP

F

FUSE

GREEN

9

7

3

/

A.

EXCITER

B.

EXCITER

C.

ROTATING

STATOR

ROTOR

FIELD

(17.9

obm)

WINDINGS

(2.49

OHM)

Resistance

abc

(0.6 ohm)

YELLOW

Values

D.

MAIN

AUXILIARY

E.

f.

AUXILIARY

STATOR-WINDINGS

WINDING

VOLTAGE REGULATOR

CIRCUIT

(1.2

FUSE

(0.05

OHM)

49

BT

GENERATOR

TROUBLESHOOTING

CHART

Low

voltage

adjustment

Low

voltage

further

as a load

Vettage

OK

Voltage

unstable.

Low

voltage

and

loss

of

No

loss

of

High

voltage

correct

voltage

(115

·120

High

voltage

Low

voltage

growling

nofse

engine

speed

Generator is 0 volts

at

Low

voltage

load

is

applied,

Problem

at

NIL

and

from

regulator

at

NIL

is

at

NIL

and

(70

volts)

voliage

engine

speed

(125-

when

volts).

at

NIL

{0

- 5

from

when

does

not

NIL

(1

0 -

voltage

F/L.

potentiometer.

and

voltage

applied.

low

at

NIL

as

load

and

135

volts)

loaded

and

F/L.

volts)

at

generator

load

is

excite;

20

volts)

drops.

No

drops

F/L.

with

is

appfied.

hertz.

at

NIL

with

and

applied.

voltage

at

NIL,

with

loss

is

when

.

of

1.

Regulator

2.

Exciter

1.

Diode(s)

2.

Auxiliary

rotor

1.

Auxiliary

2.

Exciter A-2

is

3.

Auxiliary

1.

Detective

2.

Engine

3.

Electrical

1.

Selector

1.

Generator's

1.

Generator's

2.

Short

windings

1.

Main

2.

Compound D-1,

1.

Generator's

2.

Short

transformer.

1.

Oiodes(s)

Probable

board

stator

winding

in

exciter

windings

shorted

(B-2).

windings

stator

compound

open

windings

regulator

is

hunting.

connections.

switch

engine

in

compound

D-3.

stator

windings

transformer

0-2.

engine

in

the

main

in

rotating

cause

defective.

A-1

rotor

shorted

in

exciter

in

the

exciter

D-3

·or

board.

Engine's

in

wrong

speed

transformer

shorted

windings

speed

stator

windings

exciter

open.

(B-2).

rotor.

winding

G-3

open.

rpm

fluctuating.

position.

(rpm)

high

(rpm)

high.

auxiliary

C-1,

is

slow.

(B-2)

at

NIL

C-2.

shorted

or

shorted.

1.

Replace

transformer;

A.

V.R.

2.

Check their

connections.

1.

Check

2.

Check

1.

Check

2.

Check

3.

Check

1.

Check exciter

regulator

2.

Check

3.

Check

..

1.

Place

selector

1.

Check

_1.

Check

2.

Check

1.

Check and

connections.

2.

Check

1.

Adjust

2.

Check

1.

Check this

section.

Verification/Remedy

the

regulator

board.

then

switch

values

in

the

values

and

of

DC

operation

and

secure

in

and

adjust

and

adjust

and

connections

-

and

resistance

and

resistance

speed

as

shown

B-2

in

the

to

of

exciter

voltage

Operate

COMP

potentiometer. resistance

the

diodes

the

resistance

the

resistance

the

continuity

the

continuity

the

stability

stator

windings.

board.

the

engine

fur

clean

switch

NIL

speed

NIL

rpm

continuity

continuity continuity

the

engine's

the

diodes

B-1

and

Adjust

NIL

ELEC

and

C-3

and

0·3

rotor.

and

continuity

and

continuity

the

connection

the

connection

from

the

and

the

connections.

See

ENGINE

-

position.

NIL

voltage.

N/L·voltage.

of

values values

and

adjust

in

this

manual.

rotating

exciter

voltage

adjust

with

windings

to

ground.

to

ground.

of

the

winding.

of

the

winding.

the

regulator

unit

on

COMP.

fuel

system.

ADJUSTMENTS

D·3

windings.

of

C-1,

C:.2

of

0-1,

D-2

NIL

voltage.

as

explained

With

and

to

Replace

windings

windings.

·

the

.

in

2.

3.

4.

Low

voltage

at

NIL

and

FIL

(50-

70

Voltage

correct

at

NIL.

but

not

at

loss

of

engine

rpm

(hertz).

Voltage

correct

at

NIL

loss

of

voltage

High

voltage

from

at

regulator

and

at

F{L.

NIL

with

potentiometer.

FIL

no

adjustment

volts).

with

1.

2.

1.

2.

3.

4.

1.

Bridge

rectifier

Auxiliary

windings

Auxiliary

windings

Exciter

stator

Generator's

Generator

Rotating Generator's Low

Diode

Regulator

overload.

diode

power

in

exciter

engine

load

board

defective.

B-1 0-3

windings

speed

failing.

engine

speed

factor.

rotor

detective.

shorted. and/or

(A)

are

(rpm)

is

low.

B-2

shorted.

G-3

open.

is

too

50

low.

.

2.

Follow

3.

Check

the

4.

Check

the

connections.

1.

Check

the

2.

Check

the

engine's

1.

Monitor

2.

Check

3.

Check

4.

Check regulator

1.

Check

1.

Replace transformer;

A.

V.R.

test

procedure continuity continuity

continuity NIL

the the the

the

board.

the

potentiometer.

rpm

and

rpm.

load. diode. electronic type

of

load

diodes

in

regulator

then

switch

and and

and

governor

the

for

the resistance resistance

resistance

adjust

applied.

exciter

board.

to

ELEC

bridge

reetifiet values. values

values

the

NIL

operation.

Consider

rotor.

Adjust

NIL

and

of

windings

of

the

voltage.

use

of

voltage

adjust

with

windings.

Check

optional

with

and

adjust

BTGJBTGA

8.5KW

SPECIFICATIONS

Engine

Type

Engine

Speed

Governor Combustion

Bore & Stroke

Piston Firing

Direction Maximum Compression Compression

(Umlt between

Chamber

Displacement

Order

·

of

Rotation

Torque

of

difference cylinders)

Dimensions

Weight

Fuel

Consumption

lncHnation

Valve

liming

Valve

Seat

Angle

Valve

Clearance

General

Distributor

Spark

Plug

Thread

Spark

Plug

Type

Carburetor

(STD

Ratio Pressure

Size

type)

SPECIFICATIONS

Gasoline,

four-cycle,

cooled,

vertical

mechanism.

1800

rpm

1500 Hoof, Multi-sphere

@

rpm

@

flyball

2.76 x 2.74

3.03 x 2.74

965.4

cubic 1-3-4-2 Clockwise,

51.31b-ft

(7.1

9.2:1

170

psi

(12

(2.8

psi

[2.0

Height:

23.63

Width:

18.75

Length:

31.50

5131bs

(232.7

1.4

U.S.gph

(approximate)

Continuous Temporary

Intake

Opens

Intake

Closes

Exhaust

Opens

Exhaust

Closes

Intake~

Exhaust45°

Intake

0.0098

Exhaust

0.0098

in-tine

(18.5

60

Hertz

50

Hertz

type,

type

inches inches

inches

when

kg-m)

kg!cmt)

kg/cmt])

inches

kgs)

(6.0

15•

20°

(not

15°

44°

SSO

inches

two-cylinder,

overhead

hp

at

1800

5%

speed

(70

x

69.6

(77

x

69.6

(1.0711ters)

viewed

from

at

1800

at

300

(600.20

(476.25

(800.10

LPH)

at

full

to

exceed

BTDC

ABDC

BBDC

6°

ATDC

(0.25mm)

inches

(0.25mm)

IGNITION

Battery

ignition,

12

distributor

COil

and

spark

Solid

stata

igniter

14mm x 1.25

Westerbeke

Down

draft

approved

with

plugs

type

pitch

part

type,

flame

volts,

Igniter,

with

signal

number single

arrester

mobile

barrel

fresh

valve

rpm

regulation

mm)

the

front

rpm

mm)

rated

20

min.)

negative

pick-up,

generator

033805

with

water-

max.)

BTG

BTGA

.

output

ground,

ignition

and

USCG

LUBRICATION

Pressure

type

by

Trochoid

pump,

spin-on

or better.

IOW-40

chain-driven

type

General

Oil

Alter

Sump

Capacity

(not

including

Operating (engine

hot)

Oil

Grade

filter)

Oil

Pressure

by

crankShaft

Full

flow,

paper

3.9

u.s.

qts

25-35

psi

API Category

.

SAE

30W,

element,

(3.7

liters)

(1.7 -2.50

SJ,

SL,

IOW-30

kg!cm•)

SM

or

FUEL

General

Fuel

Lift

Pump

Fuel

Screen

(engine)

Conventional

pump

UnleadCd

·Ethanol blend

12

volt

Reusable

carburetor

fuel

Air

Cleaner

Air

Row

(engine

combustion

'

General

Operating

Sea

Fresh

Water

Sea

Water

System

(fresh

Temperature

Pump

Row

Capacity

water)

Metal

35

COOLING

Fresh controHed

130-.1SOO F (55-SSO

Centrifugal

Positive

belt-driven.

6.7

(measured

5

qts

carburetor

89

DC,

lift

screen

and

pump)

screen

type

cfm

(1.0

cmm)

water-cooled

with

type,

displacement,

gpm

(25.31pm)

before

elbow)

(4.7

Hters)

type

with

Octane or better.

El

0

maximum.

capacity

6 fl

(1.8m)

type

(one

at

one

--cleanable

heat

inlet

in

base

of

early

block.

therrnostatically-

exchanger.

C)

metal

impeller, rubber

at

1800

rpm

discharging

fuel

lift

to

style

belt-driven.

impeller,

into

the

exhaust

ELECTRICAL

Starting

Battery

DC

Battery

Starter

DC

No-load

.

DC

Cranking

Battery

Gapaci1y

Charger

Current

12-volt negative 400-600

C.C.A.

90-125

(ampere-lltiUI'S}.

l2VDC 50

12-Volt, mounted

90

175

Amp

-

200

amp

1.2

Kw,

(max)

amps

at

ground

rated

minimum

rated alternator

reduction

lype,

11.5

volts

(cold

engine)

solenoid

I~IWESIE1iBEKE

l

EngineS.&

Generators

51

BTGJBTGA

8.5KW

AC

General

Voltage

Regulation Frequency Rating

60Hz(1800rpm)

50 AC

(Volts

Hz

(1500

Circuit

Regulation

AC)

rpm)

Breaker

Brushless, Pre-lubricated, Reconnectable, regulation regulator)

120

.

220

SPECIFICATIONS

GENERATOR

.four

pole,

revoMng

bearing

phase

state

hertz

load.

to

full

amps

of

the

generators

voltage

field.

design.

transformer

voltage

load.

rated

(optional

or

1201240

Volts -50

:t:

5%

no

load

:t:

3 Hertz

120voHs 120/240

volts

220voHs To

be

rated

amperage

single

voHs -60

Hertz

to

full

(5%)

no

70amps 70135

31

at

120%

OutPut

solid

load

amps

and

Generator

NOTE:

Air

Cooling

Increase

Engine

Combustion

Requirements,

(60

Hertz)

at

Spark

Plug

Gap

liming

air

supply

1800

rpm

TUNE-UP

200 -225

cfm

50

Hertz

(1.0

(5.7 -6.4

(60

operation

cmm)

Hz)

Air

requirements

15%

for

35

cfm

SPECIFICATIONS

0.031

:t:

0.002

inches

18"

:t:

1 •

BTDC

at

1800

cmm)

at

(1500

(0.80

rpm

1800

rpm)

:t:

rpm

0.05mm)

Engines & Generators

52

.

BTG

12.5

KW

SPECIFICATIONS

Engine

Type

Engine

Speed

Governor Combustion Bore & Stroke Piston Rring Direction Maximum Compression Compression

(Umit between

Dimensions

Weight Fuel

Inclination

Valve

General

Distributor

Spark Spark Carburetor

Chamber

Displacement

Order

of

Rotation

Torque

of

difference cylinders)

Consumption

liming

Seat

Angle

Clearance

Plug

Thread

Plug

Type

(STD

Ratio Pressure

Size

type)

SPECIFICATIONS

Gasoline,

four-cycle,

cooled,

vertical

mechanism. 1800

rpm@

1500

rpm @ 50

Hoof,

flyball

Multi-sphere

3.03 x 2.74

79.1

cubic

1-3-4-2 Clockwise,

63.6

lb-ft

(8.8

9.2:1 170

psi

(12

(2.8

psi

[2.0

Height:

23.63

Width:

18.75

Length:

33.63

5331b's

{241.7

1.6

U.S.gph

(approximate) Continuous

TemporarY

Intake

Opens

Intake

Closes

Exhaust

Opens

Exhaust

Closes

Intake

45o

Exhaust45° Intake

0.0098

Exhaust

0.0098

in-line

{22.5

60

Hertz

type,

type

inches

when

viewed

kg-m)

kg/cm

inches

kgs)

(6.0

LPH)

15°

25°

(not

15° 44°

53° 46°

inches

four-cylinder,

overhead

hp

at

1800

5%

speed

(77 x 69.6

(1.2961iters)

from

at

1800

2

at

300

)

2

])

(600.10

(476.25

{854.20

at

full

to

exceed

BTDC ABDC

BBDC

ATDC

(0.25mm)

IGNITION

BatterY

ignition,

12

volts, distributor coil

and

spark

Solid

state

igniter 14mm x 1.25

·

Westerbeke Down

draft

approved

with

plugs

type

pitch

part

type,

flame

igniter,

with

signal

number

single

arrester

negative

mobile

033805

barrel

fresh

valve

rpm

max.)

regulation

mm)

the

front

rpm

mm)

rated

output

20

min.)

ground,

pick-up,

generator

with

USCG

water-

ignition

and

General

Oil

Riter

Sump

(not

including

Operating

(engine

Oil

Grade

General

Fuel

UftPump Fuel

Screen

Air

Cleaner

Air

Row

(engine

General

Operating

Fresh

Water

Sea

Water

Sea

Water

System

(fresh

water)

· .

Starting

BatterY DC

BatterY

Starter

DC

No-Load

DC

Cranking

Capacity

filter)

Oil

Pressure

hot)

(engine)

combustion

Temperature

Pump

Row

Capacity

BatterY

Capacity

Charger

Current

LUBRICATION

Pressure

type

by

Trochoid

liters)

kg/cm

spin-on

SM

or

lOW-40

pump,

2

)

by

crankshaft

Full

flow,

paper

element,

3.9

U.S.

qts

(3.7

25-35

psi

(1.7 -2.50

API Category SJ, SL,

~AE

30W, IOW-30

FUEL

Conventional pump

Unleaded 89 Octane Ethanol blend EIO maximum.

12

volt

Reusable carburetor

fuel

Metal

41.1

DC,

screen

pump)

screen

elm

(1.16

and

carburetor

lift

type -cleanable

or

capacity

type

(one

one

in

base

cmm)

type

better:

6ft

(1.8m)

at

of

COOLING

Fresh

water-cooled

controlled 130-150° F Centrifugal Positive

displacement,

belt-driven.

6.7

gpm

(25.31pm) (measured elbow)

5

qts

(4.71iters)

ELECTRICAL

12-volt negative ground

400-600 C.C.A. rated minimum

90

-125

(ampere-hours)

12VDC

SO

12-Volt,

1.3

mounted 90

Amp

(max)

175-

200

block,

with

(55

type,

before

heat

thermostatically-

exchanger.

-66°

C)

metal

impeller, rubber

at

1800

discharging

. .

amp rated alternator

Kw,

reduction

type,

at

11.5

volts

amps

(cold

engine).

chain-driven

type

or

better.

with

fuel

inlet

to

early

style

belt-driven.

impeller,

rpm

into

the

solenoid

lift

exhaust

Engines & Generators

53

BTG

12.5KW

General

Voltage

Frequency Rating

60Hz

50

Hz

AC

Circuit

Regulation

(VoHs

AC)

(1800

rpm)

(1500

rpm)

Breaker

SYSTEM

AC

GENERATOR

Brushless, Pre-lubricated, Reconnectable, regulation

regulator) 120

or

220

Volts -50

± 5%

± 3 Hertz (5%)

120

volts

120/240 220

volts

To

be

amperage

SPECIFICATIONS

four

pole,

single

(optional

120/240

volts -60

Hertz

no

load

to

full

no

1

04

volts

104/52 47amps

rated

at

120%

output

and

revolving

bearing

phase

solid

state

hertz

load.

load

to

full

amps

of

the

voltage

field.

design.

transformer

voltage

load.

generator's

rated

Generator

NOTE:

Engine Air (60

Cooling

Increase

Combustion

Requirements,

Hertz)

at

Spark

Plug

Timing

air

supply

1800

rpm

TUNE-UP

Gap

220

cfm

(6.23

50

cfm

Hertz

(1.16

cmm)

(60

Hz)

operation

cmm)

Air

requirements

15%

for

41.1

SPECIFICATIONS

0.031 ± 0.002 13"

BTDC ± 1"

inches

(0.80 ± 0.05mm)

at

1800

at

1800

(1500

rpm

rpm)

Engines & Generators

54

BTG

15.0KW

SPECIFICATIONS

Engine

Type

Engine

Speed

Governor

Combustion Bore & Stroke Piston Rring Direction Maximum Compression

Compression

(Limit

between Dimensions

Weight Fuel

Inclination

Valve

General

Distributor

Spark Spark carburetor

Chamber

Displacement

Order

of

Rotation

Torque

of

difference

cylinders)

Consumption

Timing

Seat

Angle

Clearance

Plug

Thread

Plug

Type (STD

Ratio Pressure

Size

type)

SPECIFICATIONS

Gasoline,

four-cycle,

cooled,

vertical

mechanism. 1800

rpm @ 60

1500

rpm @ 50

Hoof,

flyball

Multi-sphere

3.03 x 3.15

90.0

cubic 1-3-4-2 Clockwise,

76.61b-ft

(10.6

9.0:1 170

psi

(12

(2.8

psi

[2.0

Height

23.63

Width:

18.75

Length:

33.63

560

lbs

(254

1.9

U.S.gph

(approximate) Continuous

Temporary Intake

Opens

Intake

Closes

Exhaust

Opens

Exhaust

Closes

Intake

45°

Exhaust

45°

Intake

0.0098

Exhaust

0.0098

in-line

(27

hp

Hertz Hertz

type,

type

inches

when

kg-m}

kg/cm

kglcm•n

inches

kgs}

(7.2

15°

25°

(notto

15°

58°

58° 15°

inches

two-cylinder,

overhead

at

1800

5%

speed

(77

x

80

(1.481iters)

viewed

from

at

1800

2

)

at

300

(600.10

(476.25

(854.20

LPH)

at

full

exceed

BTDC

ABDC

BBDC ATDC

(0.25mm)

IGNITION

Battery

ignition,

12

voHs,

distributor

coil Solid

igniter 14mm x 1.25 Westerbeke Down

approved

and

state

draft

with

spark

type

type,

flame

plugs

pitch

part

igniter,

with

signal

number

single

arrester

negative

mobile

033805

barrel

fresh

valve

rpm

max.)

regulation

mm)

the

front

rpm

mm)

mm}

rated

output

20

min.)

ground,

pick-up,

generator

with

USCG

water-

ignition

and

General

Oil

Riter

Sump

capacity

(not

including

Operating (engine

hot)

Oil

Grade

General

Fuel

Lift

Pump

Fuel

Screen

Air

Cleaner

Air

Row

(engine

combustion

General

Operating Fresh

Water

Sea

Water

Sea

Water

System

Capacity

(fresh

water)

Starting

Battery

Capacity

DC

Battery

Starter

DC

No-Load

DC

Cranking

filter)

Oil

Pressure

(engine)

Temperature

Pump

Row

Battery

Charger

Current

LUBRICATION

Pressure

type

by

paper

qts

(3.71iters)

(1.

7 -

SJ,

lOW-30

Trochoid

element,

2.50

kg/cm

SL,

SM

or

by

crankshaft

Full

flow,

3.9

U.S.

25-35

API

Westerbeke BTG 8.5, BTGA 8.5, BTG 12.5, BTG 15.0, BTG 10.0 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual