Westerbeke 15.0 BTDCR Industrial Generator Manual

 OPERATORS MANUAL
MOBILE and INDUSTRIAL
GENERATORS
8.0KW BTDAR —10.0KW BTDAR
WESTERBEKE CORPORATION = 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK « TAUNTON MA 02780
WEB SITE- WWW. WESTERBEKE COM
dA WARNING
Exhaust gasses contam Carbon Monoxide, an odorless and
colorless gas. Carbon Monoride is poisonous and Can Cause
unconsciousness and death. Symptoms of Carbon Monoride
exposure can include:
» Dizriness * Throbbing in Temples
= Narcea » Muscular Twitching
» Headache » Vamiting
» Weakness and Sleepiness» Inability to Think Coherentiy
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET DUT INTD THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the anit and do aol restart
until i has been inspecied and repaired.
SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous condifions exist and
take the necessary precautions Io protect yourself, your
personnel, and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
ÁN WARNING: Do not touch AC electrical connections
while engine is running. Lethal voltage is present at
these connections!
Em Do not operate this machinery without electrical
enciosures and covers in place.
E Shut off electrical power before accessing electrical
equipment.
E Use insulated mats whenever working on electrical
equipment.
B Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
E Remove wristwatch and all jewelry when working on
lion
E Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS — HOT ENGINE
ÁAN WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
E Always check the engine coolant level at the coolant
recovery tank
ÁN WARNING: Steam can cause injury or death!
E In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS — FIRE
ÁA WARNING: Fire can cause injury or death!
M Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
Eu Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
B Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/senerator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
№ Be aware — diesel fuel will bum.
ÁN WARNING: Explosions from fuel vapors can cause
injury or death!
E Al fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel ina
well-ventilated ares away from spark-producing
equipment and out of the reach of children.
m Do not fill the fuel tank(s) while the engine 15 running.
№ Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
the fuel system.
® Do not alter or modify the fuel system.
E Be sure all fuel supplies have a positive shutoff valve.
© Be certain fuel line fittings are adequately tightened and
free of leaks.
№ Make sure a fire extinguisher is installed pearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
ACCIDENTAL STARTING
dA WARNING: Accidental starting can cause injury
or death!
№ To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
№ Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last
№ Make certain all personnel are clear of the engine before
startine.
E Make certain all covers, guards, and hatches are
re-installed before starting the engine.
WESTERBEKE
Engines á Generators
SAFETY INSTRUCTIONS
BATTERY EXPLOSION
AA WARNING: Battery explosion can cause injury
or death!
mu Do not smoke or allow an open flame near the battery
being serviced. Lead acid barteries emit hydrogen, à
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
Never connect the negative (—) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors,
Ventilate any compartment containing battenes to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, nings, and any other jewelry before handling
the battery.
Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A\ WARNING: Sulfuric acid in batteries can cause
| severe injury or death!
E When servicing the battery or checking the electrolyts
level, wear robber gloves, a rubber apron, and eye
jon. Batteries contain sulfunc acid which 15
destructive. If it comes in contact with your skin, wash if
off at once with water. Acid may splash on the skin or
caps.
dA WARNING: Carbon monoxide (CO) is 2 deadly gas!
mM Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warpmg exists. Pay close
attention to the manifold and exhaust.
Be sure the unit and its surroundings are well venblated
In addition to routine inspection of the exhausi system,
AA WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
m Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid detenoration of
copper twbing resulting in exhaust/water leakage.
Do not install exhaust outlet where exhaust can be drawn
through vents, or air conditioners.
Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs of carbon monoxide inhalation or
an
Vomiting Muscular twitching
Dizziness Intense headache
Throbbing in temples Weakness and sleepmess
AVOID MOVING PARTS
ÁN WARNING: Rotating parts can cause injury
or death!
E Do not service the engine while it is runming. If a
situation arises in which it is absolutely necessary 10
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all umes.
Do not check fluid levels or the drive belts tension while
the engine 15 operating.
HAZARDOUS NOISE
ÁN WARNING: High noise levels can cause hearing
loss!
№ Never operate an engine without its muffler installed.
® Do nol run an engine with the air intake (silencer)
removed.
® Do not run engines for long periods with their enclosures
Open.
dA WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue! |
e o
TABLE OF CONTENTS
Parts Identification... 2
introduction mm... aia nana
Warranty Procedures... me. .e....... 3
Serial Number Location ..........e-—. ===. ......s 4
Diesel Fuel, Engine Dil, and Coolant................
Generator Control Panels......................
Description of Switches.............—w=—...
Description of Gauges...
Remote Panel...
Preparations for Initial Start-Up..
Prestart Inspection .... MERE
Generator Voltage... EN
Starting/Stopping Precodare. STA
Safety Shutdown Switches ........————e——.-
Generator Break-in Procedure..........................
The Daily Operation...
Maintenance Schedule
Cooling System... wwe...
Changing Coolant ....c.ccccccisiimmisssussssrmsssansios
Thermostat:—. a
Fuel System ....
Fuel Filter/Water Separator Laa
Fuel Injection Pump ...
Fuel Exft POP. coc siniisiiasisissiiipmisrrei
Fuel Lift Pump Filter... ccissrérssssenssiese
Fuel File ever es |
Engine Fuel PUT ers
Engine Lubricating Oil... ВИ
Engine Oil 2 EERO
Remote Oil Filter...
Dil Pressure ... me...
Testing a Pressure...
Alternator Troubleshooting .... aora se
12 Volt DC Control Circuif ...............ese= .w.—.
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Glow Plugs... es pico Й
Generator Wiring Diagram #44735... u 25
Generator Wiring Diagram #044927... E 25A
Generator Wiring Schematic $44735............... 26
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Generator Wiring Schematic #044927..........26A
Remote Instrument Panel ...............................27
Engine Troubleshooting [Chart] .......................28
Engine Adjustments..................—————————)
Valve Clearance Adjustment ...........e——..... 30
Testing Engine Compression ..................w... 31
Fuel Imjectors:.—-=--— 222 as 31
Drive Belt Adjustment... a ve 31
Control Panel Troubleshooting ‘Chart... 29
Electronic Governor Adjustments... 33
Description... NE iat
Controller Adi ustment . canssnnacsemenennnenreneneananes 33
Inspect and Adjust... i 33
Linear Actuator Troubleshooting [Chart].. coa 34
GenRemote Calibration ......................———————.)
GenRemote Control Station ............................. 36
GenRemote Wiring Diagram ........................37
GenRemote Installation Diagram ....................38
Stop/Start Rocker Switch ...........ww... 20
GenRemote Specifications ...........................29
Generator Information ..................——— 0
Power Take Off Systems..................—.————————..+]
BT Generator verser 42
BT Generator Wiring SchematiC......................43
BT Generator Single Phase...............................4
Generator Voltage Adjustment ........................ 45
BT Generator Voltage Regulator.......................47
BT Generator Internal Wiring ... emana 48
Regulator Sensing Wye-Delta Confi igurations. 49
BT Generator Troubleshooting [Chart] ............50
Specifications 10.0KW/8.0KW BTDA................51
Specifications 15KW/12.5KWBTDB ................ 52
Generator Specifications 10.0KW/8.0KW........53
Generator Specifications 15KW BTDC..............54
Generator Specifications 12.5KW BTDB........... 54
Engine Torque O oa О
Sealants and Labricants:.. Komo 56
Metric Conversion Data .....................——————-7
Engines E Generators
PARTS IDENTIFICATION
INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance of our engines and generalors.
Thank vou for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
your nearest WESTERBEKE dealer for assistance.
This is vour operators manual. À parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days of submitting the Warranty Registry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's serial
Customer Identification Card
WESTERBEKE
Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model ISBTDAR — Ser 4U0000-E302
Expires 7/20/2004
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and cataloes). provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO. INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings of WESTERBEKE product
software and the unavoidable existence of earlier
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers. must not and cannot
be relied upon exclusively as the defimitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes vou through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
Âà CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
JWESTERBERS
INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter this information on the illustration of the name-
plate shown below, as this will provide a quick reference
when seeking technical information and/or ordering repair
parts.
SPECIFICATION] 50 HZ.
60 HZ
The engine serial number can also be found stamped nto the
engine block just above the mjection pump. The generator
serial number is stamped into the generator housing on the
flat surface on the left side of the generator.
WESTERBEKE
Нате
An identification plate on the engine mamfold also displays
the engine model and senal number.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase;the crankshaft is of
the same general type as that of a gasoline engine, and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of the fuel, lubncating and coohng systems.
Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for
contamination (that is water, sediment, etc.) in the foel sys-
tem is also essential. Another important factor is the use of
the same brand of ugh detergent diesei lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor and ignition systems are replaced by a single
component — the fuel injection pump — which performs the
function of both.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black name-
plate located on the generator end. You must provide us with
this information. so we may properly identify your generator
set In addition, include à complete part description and part
number for each pant needed (see the separately fumished
Parts List). Insist upon WESTERBEKE packaged parts
because will fir or generic parts are frequently not made to
the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTERBEKE dealer
will assist you in preparing an mventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessones, see WESTERBEKE'S ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators and is available at your WESTERBEKE
dealer.
Engines & Generators
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (ASTM), and has a cetane rating of 445 or better
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump 15 very critical: invisible dirt
particles which might pass through the filter can damage
these finely finished parts. It is important to buy clean fuel.
and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities. To assure that the fuel going into the tank for your
engine's daily use is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50
hours of break-in operation, and every 100 hours of operation
thereafter For recommended oil viscosity, see the following
chart:
Operating Temperature Dil Viscosity
Above 68°F (20°C) SAE 30, 10W-30 or 15W-40
41°-68°F (520°C) SAE 20, 10W-30 or 15W-40
Below 41°F (5°C) SAE 10W-30 or 15W-40
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
fo produce properties harmful to your engine.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
T5 psi (241.3 and 517.1 Epa).
NOTE: A newly started, cold engine can have an vil pressure
reading upwards of 60 psi (4.2 ke/cm”. A warmed engine can
have an oil pressure reading as low as 23 psi (1.8 kg/cm”.
These readings will vary depending upon the temperature of
the engine, the load placed on the engine, and the RPMs.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water 15 free from the
The antifreeze performs double duty. It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and comosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically bal-
anced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
antifreeze that is now available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial to the engine's cooling system. They
retard rust and add to the life of the circulating pump seal.
ANTIFREEZE PROTECTION
Freezing Temperatur: | 14% | SF | 4F | 40°F
(5%) | (13°C) (20°C) | (40°C)
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose of this recovery
tank is to allow for engine coolant expansion and contracton
during engine operation, without the loss of coolant and
without introducing air into the cooling system. This kat 1s
provided and must be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at or above the level of the engine's manifold, but it
can be located below the level of the engine * manifold if the
WESTERBEKE
Engines & Generators
GENERATOR CONTROL PANELS
DESCRIPTION OF SWITCHES
This manually controlled series of WESTERBEKE manne
diesel generators is equipped with toggle switches on the
engine control panel and, optionally, at remote panels.
All three switches are momentary contact type and serve the
following functions:
PREHEAT: The PREHEAT toggle serves two purposes:
preheating the engine for easy starting and bypassing the
engine oil pressure switch. The PREHEAT function closes
the K2 relay. as well as supplies current to the fuel solenoid
pull coil.
When the PREHEAT switch is depressed, the voltmeter,
panel lights, gauges and meters and the hold coil of the fuel
solenoid.
START: The START toggle switch closes the Kl relay that
energizes the starter solenoid and activates the starter.
While the PREHEAT switch is still depressed, depressing the
START switch engages the start solenoid. When the engine
begins to fire, the START switch should be released. The
PREHEAT switch should not be released until the oil
pressure reaches 5 - 10 psi.
STOP: The STOP toggle switch is a normally closed switch
providing power to the K2 relay. Opening of this switch
opens the power circuit to the fuel solenoid, stopping the
flow of fuel to the engine and shuts down the engine.
To stop the engine, depress the STOP switch. When the
STOP switch is depressed, the power feed to the fuel sole-
noid is opened, and the fuel flow to the engine is stopped.
The STOP switch should be depressed until the generator
stops rotating
NOTE: When the engine is shut down, the water temperature
gauge and the oil pressure gauge will continue to register the
last temperature and oil pressure readings displayed. They
will return to zero once electrical power is restored
EMERGENCY STOP: The EMERGENCY
stop switch on the side of the control box
is normally closed When depressed, it
will open the DC circuit to the control
panel and shut the engine down. As the
switch 15 not toggled it can be used when
performing mamtenance.
DESCRIPTION OF GAUGES
Coolant Temperature
Engine coolant (water) temperature should normally indicate
175° to 195° F (80° 10 90° C).
Engine Oil Pressure
Oil pressure (psi) may fluctuate depending on the generator
load but should range between between 30 to 60 psi.
DC Voltmeter
Indicates the amount the battery is being charged should show
13V to 14V.
Hourmeter
Registers elapsed time and is used as a guide for when to
perform scheduled maintenance.
REMOTE PANEL
For remote operation of the generator system, the same three
switches are used. The PREHEAT and START switches are
connected in parallel with the gauge panel's switches and
serve the same functions as in the gauge panel. The STOP
switch is in series with the gauge panel's STOP switch and
serves the same function. There is a REMOTE START/STOP
WIRING DIAGRAM in this manual.
GENERATOR
WESTERBEKE
NOTE: For additional information on Control Panels. Refer io:
STARTING/STOPPING PROCEDURE, DC WIRING
DIAGRAMS and TROUBLESHOOTING GAUGES.
WESTERBEKE
Engines E Generators
PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
This section of the manual provides the operator with prepa-
ration, initial starting, break-in, starting (warm or cold) and
stopping procedures. Follow the procedures as presented for
the conditions indicated and your WESTERBEKE generator
set will give reliable performance and long service life.
Before starting your generator set for the first time or after à
prolonged layoff, check the following items:
LJ] Check the engine oil level. Add oil to maintain the level
at the high mark on the dipsack.
[] Check the fuel supply and examine the fuel filten'separa-
tor bowis for contaminants.
[J Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the (+) bat-
tery cable is connected to the starter solenoid and the
negative (=) cable is connected to the engine ground stud
(this location is tagged),
[J Check the coolant level in both the plastic recovery tank
and at the manifold.
Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections.
Check load leads for correct connection as specified in
the winng diagrams.
Examine air inlet and outlet for air flow obstructions.
Be sure no other generator or utility power is connected
to load lines.
Be sure that in power systems with a neutral line that
the neutral is properly grounded (or ungrounded) as the
system requires, and that the generator neutral is properly
connected to the load neutral. In single phase and some
3-phase systems an incomplete or open neutral can sup-
ply the wrong line-to-neutral voltage on unbalanced
loads.
[1 Make sure the mounting installation is secure.
[1 Make sure that the generator is properly grounded.
Li
[ОВ Ed
ÁA CAUTION: wher starting the generator, it is |
recommended that all AC loads, especially large motors, |
be swilched DFF until the engine has come up fo speed
and, in cold climates, staris to warm up. This precaufion
will prevent damage caused by unanticipated operation
of the AC machinery and will prevent a cold engine from |
stalling. |
The speed of the generator engine 1s adjusted at the factory,
however, 1t is advisable to verify.
60 Hz The engine no-load speed is set a1 61.5 - 62 Hz
Al rated amperage hertz output may decrease to
48.6 - 59.0 Hz.
50 Hz The engine no-load speed 15 set at 61.5 Hz. At
rated amperage hertz output may decrease to
48.5 - 49.0 Hz
The speed of the generator engine 15 adjusted at the factory,
however it is advisable to verify. The voltages are easily
adjusted to optimum values no-load and full load (refer to
VOLTAGE ADJUSTMENT in thus manual). If possible, apply
actual service or test load of the same power factor as the
load to be used in service. If the voltage cannot be adjusted
to suitable values and fault seems evident, contact vour
authorized WESTERBEKE service dealer.
STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for both normal and cold weather starting. The
illustration below shows a cross-sectional view of one
cylinder. The glow plug is located in the combustion cham-
ber so that its tip is in the injector nozzie's spray path. When
the glow plug is energized by the PREHEAT burton, the plug
glows red at the tip and assists in igniting the fuel. The result
is a rapid start with less wear on the starter.
This system is common to WESTERBEKE diesels. The start
circuitry is designed so that the PREHEAT button must be
depressed for the time specified in the preheat chart. Then,
while keeping the PREHEAT button engaged, the START
button is depressed to crank the engine.
PREHEAT switch is depressed. Depressing the PREHEAT
switch activates the glow plugs in the cylinder head so use
the PREHEAT intermittenily to avoid overheating the glow
plugs.
PREHEAT: Depress the PREHEAT switch. The voltmeter and
panel lights, gauges and meters will be activated. The
PREHEAT switch should be depressed in accordance with
the following chart:
Temperature/Preheat
Atmospheric Temperature Preheating Time
+41°F{+5°C) or higher Approx. 10 seconds
+41 F(+5"C) to 23°F (-5°C) Approx. 15 seconds
+23"F{-5"C) or lower Approx. 20 seconds
Limit of contiduoes use 30 saconds before cranking
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches
15 psi. Then as long as the high water temperature and low
oil pressure protective circuits do not activate, the engine will
remain energized and continue to run.
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait 30 seconds; repeat the procedure above and preheat
longer. Never run the starter for more than 30 seconds.
Remote Starting Procedure
The remote start panel is the same as the engine-mounted
start panel except that it has a green LED hight and no
guages. When starting at a remote location, the green LED
lights when the generator is running at approximately 600
rpm. This indicates when the START switch can be released
since the starting of the generator may not be audible.
A. When the PREHEAT switch is depressed at the remote
start/stop panel the LED hight will illuminate. When the
START switch is depressed and the starter cranks the
engine this LED light will dim. When the engme starts
the LED light will brighten signaling to release the
START switch. Continue to hold the PREHEAT
depressed for a few seconds to allow oil pressure to build
up which closes the oil pressure safety switch that is in
the series path for 12V B+ to the fuel run solenoid. The
de
B. After the generator is started and the START switch is
released, the generator’s starter will not crank unless the
PREHEAT switch 15 operated first because this switch
supplies voltage to the START switch.
Once the engine starts, check the engine's instruments for
proper oil pressure and battery charging voltage. Apply a
light load to the generator and allow the engine's eperating
temperature to come up to 140-150"F (60-66*C) before
applying heavy loads.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEAT switch for 10-15 second intervals
will help stabilize the engine RPM until the operating
temperature reaches the 140-150°F and a load is applied to
the engine.
STARTING/STOPPING PROCEDURE
STARTING UNDER COLD CONDITIONS
Make sure the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table in the ENGINE
OIL section in this manual.
The battery should be fully charged to minimize voltage
STOPPING PROCEDURE
1. Remove the AC electrical load from the generator and
allow the generator to run for three to five minutes to
stabilize its operating temperatures.
2. Depress the STOP switch and hold it until the generator
is completely stopped.
3. Now release the STOP switch.
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should shutdown occur, do not attempt to restart
without finding and correcting the cause. Refer to the
heading “Engine Stops” in the TROUBLESHOOTING
section of this manual.
The following is a description of these automatic shutdown
switches:
Coolant Temperature Switch
A high water temperature switch is located on the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the DC voltage to the K2
relay, thereby shutting off the engine. This switch resets at
195°F (107°C). e.
COOLANT
COOLANT SENSOR
TEMPERATURE
SWITCH
Remote Stopping Procedure
To stop the generator, depress the STOP switch which opens
the normally closed B+ path for voltage to the engine's run
circuit. The STOP switch must be held open until the
generator comes to a complete stop and the green LED light
goes out.
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the
engine's oil gallery. Normally open in a static state, thus
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure fall to 5-10 psi, this switch will open,
interrupting the DC voltage to the K2 relay, thereby shutting
off the engine. ==
The generator's engine is protected by an engine mounted
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring will cause the breaker to trip. In this
event the generator will shut down and the voltage to the K2
relay is terminated. If this should occur, check and repair the
source of the problem. After repairing the fault, reset the
breaker and restart the generator
Engines á Generators
GENERATOR BREAK-IN PROCEDURE
Although your engine has experienced a minimum of one
hour of test operations af the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life of your engine is dependent upon how the engine 15
operated and serviced during its mitial hours of use.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
Erd vr à canso be: ovedosdiug te anni des
the break-in period.
Your new engine requires approximately 50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life of the engme.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
(water pump, oil pressure, battery charging) are functioning.
AFTER START-UP
Once the generator has been started, check for proper
operation and then encourage a fast warm-up. Run the
generator between 20% and 60% of full load for the first 10
hours.
A CAUTION: Do not attempt to break-in your
generator by running without a load.
After the first 10 hours of the generator's operation, the load
can be increased to the full-load rated output, then
periodically vary the load
[I Monitor the control panel gauges.
[) Check for leaks of fuel and engine oil.
[3 Check for abnormal noise such as knocking, fnction,
vibration and blow-back sounds.
[J Confirm exhaust smoke:
When the engine is cold — White Smoke.
When the engine is warm — almost Smokeless,
When the engine is overloaded — some Black Smoke.
To protect against unintentional overloading of the generator,
the generators output leads should be routed through a circuit
breaker that is rated at the rated output of the generator.
NOTE: Be aware of motor starting loads and the high current
draw can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
Once the generator has been placed in operation, there may
be adjustments required for engine speed (henz) during the
engine's break-in period (first 50 hours) or after this period.
A no-load voltage adjustment may also be required in
conjunction with the engine's speed adjustment. See
GENERATOR INFORMATION in this manual.
Ces] WESTERBEKE.
Engines 4 Generators
10
THE DAILY OPERATION
CHECK LIST
C] Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
[J Visually inspect the generator for fuel, oil, or water leaks.
(O Check the oil level (dipstick).
I] Check the coolant level in the coolant recovery
tankradiator.
[I Check your diesel fuel supply.
[] Look for clean fuel in the fuel/separator transparent bowl.
[I Check for loose wires at the altemator.
DO] Check the startine batteries (weekly).
[J Check drive belts for wear and proper tension (weekly).
START THE GENERATOR
(See STARTING PROCEDURES on previous pages).
Allow the engine to warm up for 5 to 10 minutes to reach an
operating temperaturesof 140° to 150°F (60°-66°C) before
bie AC lool Apply loads systematically allowing the
generator to adjust to each load before applying the next
Check the gauges for proper oil pressure, operating
temperature, and DC voltage.
NOTE: Some unstable running may occur in a cold engine.
This condition should lessen as normal operating
temperature is reached and loads are applied
dA CAUTION: Do not operate the generator for
long periods of time without a load being placed
on the generator.
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a
time. Allow the generator to run for a few minutes to
stabilize the operating temperature and depress the stop
switch. (See STOPPING PROCEDURES on previous manu-
als).
JWESTERBEKE
11
MAINTENANCE SCHEDULE
ÁA WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the enging’s DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic.
CHECK HOURS OF OPERATION
SCHEDULED EACH a : EXPLANATION OF SCHEDULED
MAINTENANCE DAY | 50 100 250 500 750 1000 1250 MAINTENANCE
| Fuel Supply U Diesel No. 2 rating of 45 cetane or higher.
Fuel/Water Separator E Check for water and dirt in fuel (drain/replace fifter
: Te =
Engine Oil Level Li Oil level should indicate between MAX. and LOW on
— = dipstick =
Coolant Level Г | Check at recovery tank; if empty, check at manifold
| and radiator. Add coolant if needed.
Drive Belts 0 | Inspect for proper tension (3/8 to 1/7” defiection)
_ = Weekly | | | and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine DO] | NOTE: Please keep engine surface clean. Dirt | Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engines ability fo and electrical connections. Keep bolis 4 nuts tight.
remain cool. Check for loose belt tension.
Fuel Filter o | ОТО ГО | О | O | initial change at 50 hrs, then change every 250 hrs.
Starting Batteries Ll] Every 50 operating hours check electrolyte levels
weekly and make sure connections are very fight Clean off
| Engine Oil (and filter) gra DO | OO | Initial engine oil & filter change at 50 hrs., then
_ | change both every 100 hours.
Generator Ojo) 8 0 Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
| for additional information.
Fuel/Water Separator О |2 |0 | 0 | 0 |0 | Change every 200 hours. —
Electronic Governor Control [] Г] | Check and or adjust the no-load speed in the panel,
(if applicable) | required (hertz) and the regulator board adjustment
as needed.
NOTE: These adjustment are not a warrantable
adjustment during or after the unit's break-in.
Exhaust System С О | O CJ] | Initial check at 50 hrs., then every 250 hrs. inspect
for leaks. Check the exhaust elbow for carbon
and/or corrosion buildup on inside passages; clean
and replace as necessary. Check that all
connections are fight
| Engine Hoses Ol Ol O| Ol O| O | Hoseshould be hard & tight Replace if soft or
| | sponoy. Check and fighten all hosé camps.
(IN ]WESTERBEKE
Engines & Generators
12
MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running rime.
CHECK
SCHEDULED | EACH HOURS OF OPERATION EXPLANATION OF SCHEDULED
MAINTENANCE DAY 50 100 250 500 750 1000 1250 MAINTENANCE
Coolant System O Г] | Drain, flush, and refill cooling system with
Air intake Filter alar a|O|o| O | Cieaneveny 100 hours. Replace as needed
Electric Fuel Lift O Ol Ol OO] O | Penodcally check the wiring connections.
Pump
DC Alternator О] L] [] | Check DC charge from alternator, Check mounting
bracket; Tighten electrical connections.
“Fuel Injectors 0 Check and adjust injection opening pressure and
"Starter Motor = CO | Check solenoid and motor for corrosion. Remove
| and lubricate. Clean and lubricate the starter motor
*Preheat Circuit = J | Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti-seize compound on threads.
"Engine Cylinder [1 | Check compression pressure and timing (see
Compression | ENGINE ADJUSTMENTS).
*Torque Cylinder Head O | 0 | At first 50 hours, then every 500 hours (see
Hold-down bolts = — ENGINE ADJUSTMENTS). _
*Adjust the Vaive Clesrances Cl LJ Adjust Valve Clearances (see ENGINE
*Radiator Г) | Remove, have professionally cleaned and pressure
tested.
*WESTERBEKE recommends this service be performed by an authonzed mechanic.
WESTERBEKE
Engines & Generalors
13
COOLING SYSTEM
DESCRIPTION
Westerbeke diesel engines are designed and equipped for
fresh water cooling. Heat produced in the engine by
combustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block and its internal moving
parts and the engine oil.
Fresh water coolant is pumped through the engine by a
circulating pump, absorbing heat from the engine. The
coolant then passes through the thermostat into the manifold,
to the radiator where it is cooled, and returned to the engine
block via the suction side of the circulating pump.
FRESH WATER COOLING CIRCUIT
NOTE: Refer ro ENGINE COOLANT section for the
recommended antifreeze and water mixture to be used as the
fresh water coolant.
When the engine is started cold, external coolant fiow 15
prevented by the closed thermostat (although some coolant
flow is bypassed sround the thermostat to prevent the engine
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow of the engine's
coolant to flow unrestricted to the external portion of the
cooling system.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss of coolant and without introducing air mto
the cooling system. This tank should be located at or above
the engine mamfold level and should be easily accessible.
CHANGING COOLANT
The engine's coolant must be changed according to thé
MAINTENANCE SCHEDULE. If the coolant 15 allowed to
become contaminated, it can lead to overheating problems.
AA CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by loosening the drain plug on the
engine block and opening the radiator pressure cap. Flush the
system with fresh water, then start the refill process.
NOTE: The percock on the radiator can also be used to drain
engine coolant.
AA WARNING: Beware of the hot engine coolant.
COOLING SYSTEM
Refilling the Coolant
Afier replacing the engine block drain plug. close the radiator
coolant petcock. then pour clean, premixed coolant into the
radiator and when the coolant is visible, start the engine.
Monitor the coolant in the radiator and add as needed. Fill
the radiator to the filler neck and install the pressure cap.
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap. Run the engine, observe the coolant expansion flow
into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the recovery tank if
needed. Clean up any spilled coolant.
NOTE: Periodically check the condition of the radiator
pressure cap. Ensure that the upper and lower rubber seals
are in good condition and check that the vacuum valve opens
and closes tightly. Carry a spare cap.
THERMOSTAT
A thermostat, located near the manifold at the front of the
engine, controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit. When
the engine is first started, the closed thermostat prevents
coolant from flowing (some coolant is by-passed through a
hole in the thermostat to prevent overheating). As the engine
warms up, the thermostat gradually opens. The thermostat is
accessible and can be checked, cleaned, or replaced easily.
Carry a spare thermostat and gasket
Replacing the Thermostat
Remove the cap screws and disassemble the thermostat
housing as shown. When installing the new thermostat and
gasket, apply a thin coat of sealant on both sides of the
gasket before pressing it into place. Do nor over-tighten the
Cap SCIEWS,
Run the engine and check for normal temperatures and that
there are no leaks at the thermostat housing.
The air filter cartridee prevents engine room dust and dut
from entering the engine, it also extends engine life, and
quiets the engine.
MAINTENANCE
The filter should be cleaned every 100 operating hours. Tap
the cartridge on a flat surface to dislodge loose dirt or clean
off with compressed air. If the cartridge is badly contaminated
FUEL SYSTEM
DIESEL FUEL
Use No. 2 diesel fuel with a cetane rating of 45 or higher. Do
not use kerosene or home heating fuel.
FUEL FILTER/WATER SEPARATOR
A primary fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The ownerfoperator is responsible for making certain the
fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator betwen the
fuel tank and the generator‘engine, Westerbeke recommends
а 10 micron filter be used.
The fuel injection pump is a very importan! component of
the diesel engine, requiring the utmost care in handling. The
fuel injection pump has been thoroughly bench-tested and the
owner-operator is cautioned not to attempt to service it. If it
requires servicing, remove it and take it to an authorized fuel
injection pump service facility. Do not attempt to disassem-
ble and repair it
The only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for engine idle
speed (see IDLE SPEED ADJUSTMENT under ENGINE
ADJUSTMENTS).
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the
pump and make sure that no leakage is present and that the
fittings are tight and secure. The DC ground connection at
one of the pumps mounting bolts should be clean and well
secured by the mounting bolt to ensure proper pump opera-
tions.
will purge air from the fuel system and provide a continuous
flow of fuel as the engine is running.
FUEL LIFT PUMP FILTER
To ensure clean fuel into the fuel tft pump, there 15 a small
inline fuel filter connected to the fuel lift pump elbow. This
filter should be replaced every 200 hours of operation.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel fuel, free
from water and dirt. To ensure this flow of clean fuel, the fuel
must pass through at least two fuel filters, à fuel filter/water
separator and the engine’s spin-on fuel filter. Visually inspect,
clean, and change these filters according to the mamienance
schedule in this manual
ÁA WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take care in caching
any fuel that may spill. DO NOT allow any smoking,
open flames or other sources of fire near the fuel
ENGINE FUEL FILTER
' |
Periodically check the fuel connections and the bowl for
leakage. Replace the filter clement after the first 50 hours
then follow the MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shut off the fuel supply.
2. Unscrew the retainer ring that holds the filter bowl to the
housing and allow the bowl to come away from the
housing,
3. Remove and replace the filter element and clean the bowl.
4. Replace the sealing “O0” ring and reassemble the bowl to
the housing. Thread the retainer ring on carefully so as not
to cross thread. When retainer contacts the “07 ring,
tighten 1/4 - 1/2 tums by hand. Open the fuel supply and
run the engine to inspect for leaks.
ENGINE LUBRICATING OIL
D | Г. | 2. Replacing the Oil Filter. When removing the used oil
| filter, you may find it helpful and cleaner to punch à hole
Oil PRESSURE — : in the upper and lower portion of the old filter to drain the
SENDOR | | oil from it into 2 container before removing it. This helps
10 lessen spillage. A small style automotive filter wrench
should be helpful in removing the old ail filter.
O 7 .
PRESSURE NOTE: Do not punch this hole without first loosening the
Sw filter to make certain it can be removed!
= Place some paper towels and a plastic bag around the
OIL filter when unscrewing it to catch amy oil left in the filter.
(Oil or any other fluid on the engine reduces the engine's
OIL PRESSURE cooling ability. Please keep your engine clean.) Inspect the
old oil filter as it is removed to make sure that the rubber
sealing gasket came off with the old oil filter. If thus
block, gently remove it.
on OIL SUMP OIL SCREEN
1. Draining the Oil Sump. Discharge the used oil through
the sump drain hose (attached to the front of the engine)
while the engine is still warm. Drain the used oil completely,
replace the hose in its bracket, and replace the end cap
securely.
gasker's sealing surface on the engine block free of oil and
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter. Screw the filter onto the threaded oil
о filter nipple, and then tighten the filter firmly by hand.
yellow/gray emulsion indicates the presence of water in NOTE: Generic filters are not recommended. as the
do e e E ir Sl kines of po Baws on
o TE generic parts mi entirely different genuine
qualified mechanic should water be present in the oil. parts. Immediately after an oil filter change and oil fill
exhaust, filling the engine. run the engine io make sure the cil pressure is normal and
that there are no oil leaks around the new oil filter:
3. Filling the Oil Sump. Add new oil through the oil filler
cap on the top of the engine or through the side oil fill.
After refilling, run the engine for a few moments while
checking the 1 nressure. Make sure there is no leakage
around the new oil filter or from the oil drain system, and
stop the engine. Then check the quantity of val with the
lube oil dipstick. Fill to, but not over the high mark on
the dipstick, should the engine require additional oil.
ps dt
17
REMOTE OIL FILTER (OPTIONAL)
INSTALLATION
This popular accessory is used to relocate the engine's oil fil-
ter from the engine to a mor convenient location such as an
engine room bulkhead.
NOTE: Refer to ENGINE OIL CHANGE in this manual for
instructions on removing the oil filter
APPLY A THIN COAT OF CLEAN OIL TO THE O-RING WHEN
INSTALLING THIS KIT. THREAD THE KIT ON, THEN HAND
TIGHTEN AN ADDITIONAL 3/4 TURN AFTER THE O-RING
CONTACTS THE BASE.
To install, simply remove the engine où filter and thread on
WESTERBEKF'S remote oil filter kit as shown. Always
install this kit with the oil filter facing down as illustrated.
Contact your WESTERBERE dealer for more information.
NOTE: Westerbeke is not responsible for engine failure due 10
incorrect installation of the Remote Oil Filter.
ÁA CAUTION: mis vital to install the oil lines
correctly. If the oil flows in the reverse direction, the
by-pass valve in the fitter assembly will prevent the oil
from reaching the engine causing an internal engine
[WESTERBERS
18
OIL PRESSURE
DESCRIPTION TESTING OIL PRESSURE
The lubricating system is a pressure feeding system using To test the oil pressure, remove the oil pressure sender, then
an oil pump. The engine oil is drawn from the oil sump by install a mechanical oil pressure gauge in it's place. After
the oil pump, which drives the oil, under pressure, trough warmine up the engine, set the engine speed at 1800 rpm
the oil filter, oil cooler and various lubricating points in the and read the oil pressure gauge.
engine. The oil then returns to the oil sump to repeat the
continuous cycle. When the oil pressure exceeds the speci- Dil Pressure — 35.0 Iv (3.8 kpca”) or more al 1800 mm.
fied pressure, the oil pushes open the relief valve in the oil Sender and Switch Toque — 9-13M40(17-1.8m-ikg)
pump and returns to the oil sump, keeping the oil pressure
within its specified range.
OIL PRESSURE
The engine's oil pressure, during operation, 15 indicated
by the oil pressure gauge on the instrument panel. During
normal operation, thé oil pressure will range between 40 and
60 psi (2.8 and 4.2 kg/cm).
NOTE: À newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kg/cm). A warmed engine can have
an oil pressure reading as low as 35 psi (2.5 kg/cm). These
LOW OIL PRESSURE
The specified safe minimum oil pressure is 4.3 + 14 psi (03
+ 0.1 kg/cm”). A gradual loss of oil pressure usually indicates
a wom bearings. For additional information on low oil pres-
sure readines, ses the ENGINE TROUBLESHOOTING chart
OIL PRESSURE RELIEF VALVE
An oil pressure relief valve is located on the engine block
just below the injection pump. This valve opens at
appoximately 50 psi [343 kpa] and maintains that pressure.
DC ELECTRICAL SYSTEM
ALTERNATOR
The charging system consists of 2 DC belt dnven alternator
with a voltage regulator, an engine DC winng hamess, a
mounted DC circuit breaker and a battery with connecting
cables. Because of the use of integrated circuits (IC's), the
electronic voltage regulator is very compact and 15 mounted
internally or on the back of the alternator.
ÁN WARNING: A failed altemator can become very
hot. Do not touch until the alternator has cooled down.
Use this troubleshooting section to determine if a problem
exists with the charging circuit or with the alternator. If it 1s
determined that the alternator or voltage regulator 1s faulty,
have a qualified technician check it
The alternator charging circuit charges the starting battery
and any accessory battery. An isolator with a diode, a
solenoid or a battery selector switch is usually mounted m
the circuit io isolate the batteries so the starting battery 15 not
discharged along with the accessory battery. If the alternator
is charging the starting battery but not the accessory battery,
the problem is in the service battery's charging circuit and
not with the alternator.
Testing the Alternator
AA CAUTION: Before starting the engine make certain
that everyone is clear of moving parts! Keep away from
sheaves and belts during test procedures.
Â\ WARNING: When testing with a multimeter:
DC and AC circuits are often mixed together.
Always isolate DC and AC converters, and shut down the
engine before performing DC testing. No AC tests should
be made without a proper knowledge of AC circuits.
1. Start the engine.
2. After the engine has run for a few minutes, measure the
starting battery voltage at the battery terminals using a
multimeter set on DC volts.
a. If the voltage is increasing toward 14 volts, the
alternator 1s working.
b.If the voltage remains around 12 volts, a problem
exists with either the altemator or the charging circuit;
continue with Steps 3 through 8.
MULTIMETER
Cou
©
$
|
Tum off the engine. Inspect all wiring and connections.
Ensure that the battery terminals and the engine ground
connections are tight and clean.
A CAUTION: 70 avoid damage to the BC charging
alternator, never shut off the engine battery switch
when the engine is running!
Tum on the ignition switch, but do not start the engine.
Check the battery voltage. If the bamery is in good
condition, the reading should be 12 to 13 volts.
TIMETER
&+
TESTING THE
ALTERNATOR VOLTAGE
(IGNITION ON - ENGINE OFF)
(IN ]WESTERBEKE
Engines & Generators
20
DC ELECTRICAL SYSTEM
6. Now check the voltage between the alternator output
terminal {B+} and ground. If the circuit 15 good, the volt-
age at the alternator will be the same as the battery, or if an
isolator is in the circuit the alternator voltage will be zero.
If neither of the above is true, a problem exists in the cir-
cuit between the alternator and the battery. Check all the
connections — look for an opening in the charging circuit
GROUND
7. Start the engine again. Check the voltage between the
altemator output and ground.
The voltage reading for a properly operating alternator
should be between 13.5 and 14.5 volts. If your alternator
is over- or under-chargine, have it repaired at a reliable
service facility.
NOTE: Before removing the alternator for repair, use a
voltmeter to ensure that 12 volts DC excitation is present
ar the EXC terminal if the previous test showed only bat-
tery voltage at the B output terminal.
If 12 vols is not present at the EXC terminal, trace the
wiring and look for breaks and poor connections.
do not use a high voltage tester (i.e. 2 megger) when
performing tests on the alternator charging circuit.
AA CAUTION: To avoid damaging the alternator diodes,
12 VOLT DC CONTROL CIRCUIT
The engine has a 12 volt DC electrical control circuit that 1s
shown on the wining diagrams that follow. Refer to these
diagrams when troubleshooting or when servicing the DC
electrical system.
ÁA CAUTION: 70 avoid damage to the battery charging
circuit, never shut off the engine battery switch while
the engine is renning. Shut off the engine battery switch,
however, to avoid electrical shorts when working on the
engine's electrical Circuit.
BATTERY
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 — 500 Cold
Cranking Amps (CCA).
Battery Care
Review the manufacturer's recommendations and then
establish a systematic maintenance schedule for your
engine's starting battenes.
[1 Monitor your voltmeter for proper charging during
engine operation.
[] Check the electrolyte level and specific gravity with a
hydrometer.
Use only distilled water to bring electrolytes to a proper
level.
Г] Маке certain that battery cable connections are clean and
tight to the battery posts (and to your engine).
[1] Keep vour batteries clean and free of corrosion.
| À WARNING: Sulfuric acid in lead batteries can
— cause severe burns on skin and damage clothing. Wear
protective gear.
[ex ]WESTERBEKE
Engines 4 Generators
21
DESCRIPTION
and starter button
When the starter button on the mstrument panel 15 depressad,
current flows and energizes the starters solenoid coil. The
energized coil becomes an electromagnet, which pulls the plunger
into the coil, and closes a set of contacts which allow high current
to reach the starter motor. At the same time, the plunger also
serves to push that starter pinion to mesh with the teeth on the
fiywheel
To prevent damage to the starter motor when the engine starts, the
pinion gear incorporates an over-running (one-way) clutch which
is splined to the starter armature shaft The rotation of the running
engine may speed the rotation of the pinion but not the starter
motor itself.
Once the started button 15 released, the current fiow cesses, stop-
ping the activation of the solenoid The plunger is pulled out of
contact with the battery-to-start cables by = coil spring, and the
flow of electricity is interrupted to the starter. This weakens the
magnetic fields and the starter ceases iis rotation. As the solenoid
plunger is relezsed, its movement also pulls the starter drive gear
from its engagement with the engine fiywheel
TROUBLESHOOTING
Prior to testing, male certain the ships battenes are aí full charge
and that the Starting system wiring connections (terminals) are
clean and tight Pay particular attention to the ground wire
connections on the engine block
To check the wiring, trv cranking the starter for a few seconds,
never mare than 10 seconds at a time, then run your hand along
resistance. Repair or replace any trouble spots.
Using a multimetes, test the voltage between the positive terminal
stud on the start solenoid and the engine block (ground).
If you read 12 volts, the starter is faulty.
( | ()
To test the ignition circuit, locate the ignition(s) terminal (it 15 one
of the small terminal studs and is wired to the ignition circuit).
Use a screwdriver, don't touch the blade, to jump from that
ignition terminal to the positive battery connection terminal on
the solenmd.
If the starter cranks, the fault lies with the ignition circuit
If the solenoid clicks but nothing else happens, the starter
и
If nothing at all happens the solenoid isn’t getting current.
connections. It is also possible that the solenoid is defective.
ÂÀ WARNING: There will be arching and sparks will
fiy when jumping terminals. Be certain-the engine
space is free of potentially explosive fumes, especially |
gasoline.
Engines & Generators
22
Test again by jumping the two large terminal studs. Hold the
screwdriver blade famiv berween the studs. Do not allow the
screwdriver blade to touch the solencid or starter casing, this
would cause a short
dA WARNING: There will be arching as the full
| starting current should be flowing thru the blade of the
screwdriver.
If the starter spins, the solenoid is faulty.
If the starter fails to spin, the motor is probably faulty.
If no arching occurred. There is no juice reaching the solenoid.
NOTE: Starter motors are either inertia type or pre-engaged. In
the pre-engaged model, the solenoid also moves an arm that
engages the starter motor io the flywheel of the engine. Using a
screwdriver to bypass the solenoid on such a starter will run the
motor without engaging the flywheel. Turn the starter switch on to
provide the power to the solenoid. Hopefully it will create enough
magnetic field for the arm to move even though the contacts inside
the solenoid are bad
23
STARTER MOTOR
SERVICE
Westerbele uses 2 standsrd marine starter motor wisch can be
serviced or rebuilt at any starter motor automotive service center.
If replacing the starter motor, make certam the new motor is
certified for marine use. Automotive starters do not meet USCG
standards. If in doubt, contact your WESTERBEKE dealer
TO REMOVE FOR SERVICE
1. Disconnect the negative battery cable.
2. If necessary, remove any components to gain full access to the
starter motor
3. Label and disconnect the wimg from the starter. (Do not allow
wires to touch, tape over the termomals ).
4. Remove the starter mounting bolts.
5. Remove the starter from the engine. In some cases the starter
will have to be turned to a different angle to clear obstructions.
Engines £ Generators
GLOW PLUGS
DESCRIPTION
The glow plugs are wired through the preheat solenoid.
When PREHEAT is pressed at the control panel this solenoid
should “click” on and the glow plug should begin to get hot.
To inspect the plug, remove the electrical terminal connec-
tions, then unscrew or unclamp each plug from the cylinder
head. Thoroughly clean each plug’s tip and threads with a
soft brush and cleaning solution to remove all the carbon and
oil deposits. While cleaning, examine the tip for wear and
burn erosion; if it has eroded too much, replace the plug.
TESTING
An accurate way to test glow plugs is with an chmmeter.
Touch one prod to the glow plug's wire connection, and the
other to the body of the glow plug, as shown. A good glow
plug will have a 0.4 - 0.6 ohm resistance. This method can be
used with the plug in or out of the engine. You can also use
an ammeter to test the power drain (5 - 6 amps per plug).
ÁN WARNING: These glow plugs will become very hot
to the touch. Be careful not to burn your fingers when
testing the plugs.
Re-install the plugs in the engine and test them agam. The
plugs should get very hot (at the terminal end) within 7 to 15
seconds. If the plugs don't heat up quickly, check for a short
circuit. When reinstalling the glow plugs, use anii-seize com-
pound on the threads.
ÁA WARNING: Do not keep a glow plug on for more
than 30 seconds.
Glow Plug Tightening Tome ~~ 7-11 Ab (1.89-1.5 mig)
ce CTS
Cpr
GENERATOR WIRING DIAGRAM
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26
GENERATOR WIRING SCHEMATIC
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Engines 4 Generators
27
ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems — Mote: The engine's electrical system is protected by a 20 amp
relating to engine service, the probable causes of these prob- manual resei circuil breaker located on a bracket ar the rear
lems. and the recommendations to overcome these problems. of the engine.
— Problem Probable Cause Verification Remedy
Key switch on, PREHEAT switch 1. Batiery Swikch not on. 1. Check switch and/or battery connections.
depressed: no panel dications:
tue! solenoid or electrica! fuel pump 2. Emergency stop Switch oll. 2. Check emergency stop Switch position.
3. 20-Amp circuit breskær tripped. 3. Reset breaker; if breaker trips again, check preheat solenosd
circoil and check circuit for shorts to ground
4. K2 relay 4. Check K2 relay
5. Loose battery connechons. 5. Check (+) connection to starter solenoid and (-) connection to
| engine ground stud. Check battery cable connechons.
| 6. Preheat solencid not operating. 6. Check solenoid 5” terminal for voltage
START SWITCH DEPRESSED, no starter 1. Connection to solenoid faulty. | 1. Check connection.
engagement
2. Fautty switch. 2. Check switch with chmmeter,
3. Faulty solenoid 3. Check that 12 volts are present at the solencid connection.
4. Loose battery connections. 4. Check battery connections.
5. Low battery. 5. Check battery charge state
6. Ki relay. 6. Check Ki relay.
START switch is depressed; pans 1. Poor connections to fuel solenoid. 1. Check connections.
indications OK; starter solenoid OK
fuel solenoid not functioning. 2. Defective fusi solenoid. 2. Check that 12 volts are present at the (+) connection on the
fuel run solencid.
3. Current miter. 3. Check limiter =
Generator engine cranks, but does not 1. Faulty fusling system. 1. Check that fuel valves are open.
start fuel solenoid energized. 1a. Switch to combine house and start batieries.
1b. Replace batteries.
1e. Check fuel IM pump.
2. Preheat solenoid faulty. 2. Check solenoid.
3. Low batiery 3. Replace batienes.
Engine can't be stopped. 1. Faulty DC alternator | 1. Remove Exc. connection at aîternator, repair altemator
Battery runs down. 1. Oil Pressure sich. 1. Observe i gauges and pansl lights are acthvalad when engine
is not running. Test the all pressure swilch,
2. High resistance leak fo ground. 2. Check wiring. Insert sensitive (0 - 25 amp) meter in battery
fines. (Do not start engine.) Remove connections and replace
after short is located.
3. Low resistance leak 3. Check ail wires for temperature nss to locats the fauit
4. Poor battery connections. 4. Check cable connections at battery for loose connections,
corrosion.
5. DC alternator not charging. 5. Check connections, check belt tension, test altemator See
DE ELECTRICAL SYSTEMIALTERNATOR
| Battery not charging 1. DC charge circuit faulty. 1. Pertorm D.C. voltage check of generator charging circuit. See
DC ELECTRICAL SYSTEM/ALTERNATOR in this manual.
2. Alternator drive. 2. Check drive belt tension. Alternator should tum freely. Check
for loose connections. Check output with voltmeter. Ensure 12
volts are present at the Be. termanal.
Generator engine sions. 1. Fuel feed pump stainer & dirty. 1. Clean stainer
2. Switches and'or wiring loose 2. Inspect wiring for short circuits and loose connechons.
or disconnected. inspect swiiches for proper operation.
3. Fuel starvation 3. Check fuel supply, fuel valves, fuel feed sirziner.
4. 20 Amp circuit bresker trpping. 4. Check for high DC amperage draw during operation.
Ensure breaker is not overly sensitive to heat which would
cause tripping.
5. Exhaust system & restricted. 5. Check for blockage, collapsed hose, carbon busidup at
exhaust elbow.
6. Water in fuel 6. Pump water from fuel tank(s); change fifters and
bleed fuel system.
7. Alt intake obstruction 7. Check air intake filter cartridge.
28
ENGINE TROUBLESHOOTING
Probable Cause
Verification Remedy
1. Coolant not circulating.
1. Thermostat — remove and test in hot water
Replace thermostat
2. Loss of coolant — check hoses, hose clamps, drain plug, sir
for lesks
2c. Broken or loose belts — fighten/replace.
2d. Air zak in system; run engine and open the pressure cap to
bleed air. Add coolant as nesded.
Generator engine shuts down,
Low oi pressure.
1. Lossofal
2. Oi pressure switch
1. Check dipstick, lock for of leaks at of filtar and at
ol drain hose connection.
2. Replace oil pressure swilch.
Exhaust smoking problems
1. Blues smoke.
2. Whitz smoke.
3. Black smoke.
1. Incomect grade of engine oil.
fa. Crankcase is overfilled with engine oil (oll is blowing ou
through the exhaust).
2. Engine is running cold.
da. Faulty injector or incomact mector timing
3. Improper grade of fuel
3a. Fuel bum incomplete due to high back pressure in exaust or
insufficient air tor proper combustion (Check tor restrictions in
eduust system; check arr intake.)
3b. improperiy timad injectors or valves or poor compression.
3c. Lack of air — check air intake and air filter. Check for proper
ventilation.
30. Overigad.
Engine alarm sounds, pulsates.
1. Loss of on.
2. Ol pressure Switch.
1. Check dipstick, look for ol leales at oil filer and al
gil drain hose connection.
2. Replace oil pressure switch,
1. Engine cooant
2. High temperature switch opens al
too low a temperature.
1. Check engine coolant level
2. Check for safistaciory operation with switch by-passed,
check with ohmmeter, replace if faulty.
Cpe
29
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjust-
ments be performed by a competent engine mechanic. The information
below is provided to assist the mecharic.
VALVE CLEARANCE ADJUSTMENT
Make the following adjustments when the engine is cold.
1. Remove the cylinder head cover
2 Slightly loosen the cylinder bead belts and retighten them
to the specified torgue in the number sequence shown
Tighiening Torque — 65=4/6-1(68=5 Nm)
Qw a 02 Q5
“ol AS
Mae x a 0
см On mM OB
os a o
ond
— THREE CYUNDER
3. Find top dead center compression position for No.1
piston by using the procedure that follows:
(a) Turn the crankshaft until TDC mark on the crankshaft
pulley is aligned with the mark on the timing gear case.
TOC (TOP DEAD CENTER)
MARK FOR HO.1
AND NO.4 PISTORS
TDC MARK FOF
NO.Z AND MND.3 PISTONS
(b) With No.1 piston at top dead center on the compression
stroke, the rocker arms will not be moved when the
crankshaft is turned approximately 20° in both directions.
(с) the rocker arms move, No.1 piston is at top dead
center on the intake or exhaust stroke. In such a case,
turn the crankshaft 360° in the direction of engine
rotation again. No.1 piston is now at top dead center on
the compression stroke.
4. Loosen the lock nut for the adjusting screw. With a feeler
causé inserted between the rocker arm and valve cap,
adjust the valve clearance by tuming the adjusting screw.
Make certain to adjust all the valves.
| 0.25mm
(0.0098 INCHES)
| INTAKE & EXHAUST
E. — Install the cylinder head cover.
Head Cover Boll Torque 2 - 3 f-ib (0.3 - 0.45 mig)
IWESTERBEKE
30
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine
adjustments be performed by a competent engine mechanic. The
information below is provided to assist the mechanic.
TESTING ENGINE COMPRESSION
Make certain the oil level (dipstick) is at the correct level
and the air intake filter is clean. The battery and starter motor
must also be in good condition.
1. Warm the engine to normal operating temperature.
2. Move the control lever to a position for shutting off the
fuel. (Disconnect the wires if a fuel shutdown solenoid
15 used).
Remove all the glow plugs from the engine and install
the compression gauge/adapter combination to the
cylinder on which the compression is to be measured.
Crank the engine and allow the gauge to reach a
Repeat this process for each cylinder.
COMPRESSION PRESSURE 427 psi (30 Kgl/cm”) al 290 rpm.
MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS
47.7 psi (3.0 Kglcm)
NOTE: If the readings are below the limit, the engine needs
repair.
6. Re-install the glow plugs and reset the fuel shut-off to the
pie
LOW COMPRESSION
When low compression is found, determine the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole. Allow the oil to settle.
Install the pressure gauge and repeal the above test. If the
compression reading rises dramatically, the fault is with the
rings.
If the compression valve does not nse, the problem is with
the valves.
A slight rise in compression would indicate a problem with
both the rings and the valves.
In case of severe vibrations and detonation noise, have the
injectors checked and overhauled by an authorized fuel
injection service center. Poor fuel quality, contaminant's and
loss of positive fuel pressure to the injection pump can result
in injector faults. Since fuel injectors must be serviced in a
clean room environment, 1t 15 best to carry at léast one extra
injector as a spare should a problem occur.
Before removing the old injector, clean the area around the
base of the injector to help prevent any rust or debsis from
falling down into the injector hole. If the injector will not Lift
out easily and 15 held in by carbon build-up or the like, work
the injector side-to-side with the ad of the socket wrench to
free it, and then ft it out.
The injector seats in the cylinder head on a copper sealing
washer. This washer should be removed with the injector and
replaced with a new washer when the new injector Is
installed.
INJECTOR TO CYLINDER HEAD TIGHTENING TORQUE
404 6-15 (5.5£ 0.5 kgi-m)
DRIVE BELT ADJUSTMENT (FAN BELT)
Proper inspection, service and maintenance of the drive belts
is important for the efficient operation of your engine (see
Drive Belts under MAINTENANCE SCHEDULE).
Drive belts must be properly tensioned. Loose drive belts will
not provide proper altemator chargme and will eventually
damage the altemator Drive belts that are too tight will pull
the alternator out of alignment and/or cance the alternator to
wear out prematurely. Excessive drive belt tension can also
cause rapid wear of the belt and reduce the service life of the
fresh water pumps bearing. A slack belt or the presence of oil
on the belt can cause belt slipping, resulting in high operating
temperatures.
The drive belt is properly adjusted 1f the belt can be defiected
no less than 3/8 inch (10mm) and no more than 1/2 inch
(12mm) as the belt is depressed with the thumb at the mid-
point between the two pulleys on the longest span of the belt.
A spare belt or belts should always be camed on board.
A WARNING: Never attempt to check or adjust the
drive belt's tension while the engine is in operation. |
Adjusting Belt Tension
1. Loosen the alternator adjusting strap bolt and the base
mounting boit.
With the belt loose, inspect for wear, cracks and fraved
edges.
Pivo: the altemator on the base mounting belt to the left
or right as required, to loosen or tighten.
Tighten the base mounting bolt and the adjusting strap
bolt
. Run the engine for about 5 minutes, then shut down and
recheck the belt tensions.
i
3.
4.
5
(IN ]WESTERBEKE
Engines & Generators
31
CONTROL PANEL TROUBLESHOOTING
MANUAL STARTER DISCONNECT (TOGGLE SWITCHES)
NOTE: The engine control system is protected by a 20 amp manual reset circuit breaker
located on the engine as close as possible to the power source.
| Problem Probable Cause Verification/Remedy
PREHEAT depressed. no panél indications | 1. Qi Pressure switch. 1. Check semiches and/or bettery connections.
preheat solenoid not energized. 2. 20 amp circuit bresker tripped. | 2. Reset breaker If it opens again, check preheat solenoid
circuit and run circuit for shorts to ground.
| 3. K2 relay faulty. 3. Check relay.
| START SWITCH DEPRESSED, no starter | 1. Connection to solenoid faulty, 1. Check connection.
engagement
2. Faulty switch. 2. Check switch with ohmmeter.
3.. Fauity solencid. 3. Check that 12 volts are present ai the solenoid connection.
4. Loose battery connections. 4. Check battery connections.
5 Low battery. 5. Check battery charge state.
| 6. Ki relzy 16. Check relay.
NO IGNITION, cranks. does not start 1. Faulty fusing system. 1. Check for fuel
2. Check for air in the fuel system. 2. Allow system to bleed
3. Faulty fuel ER pump. | 3. Replace fuel if pump. |
NOT CHARGING BATTERY 1. Fauity alternator drive. 1. Check the drive belt and its tension. Be sure the aliemator
turns freely. Check for loose connections. Chack the
output with 2 voltmeter. Ensure 12V are present at the
BATTERY RUNS DOWN 1. Ci pressure switch. 1. Observe if the gauges and panel Sights are activated when the
2. High resistance leak to ground.
| 3. Low resistance leak to ground.
4. Faulty aiemator
engine 15 not running. Test he ol pressure switch
Check the wiring, insert sensitive (0-25 amp) meter in battery
ines (Do NOT start engine). Remove connections and replace
after short is located.
Check ail wires for temperature rise fo locale the tauit
After 2 good battery charging, disconnect altemator at output. |
If lealage stops. Remove añemator and bench test Repair or
replace.
TROUBLESHOOTING WATER TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated
by the gauge when the instrument panel is energized, the first
step is to check for 12 volts DC between the ignition (B+)
and the Negative (B-) terminals of the gauge.
Assuming that there is 12 volts as required, leave the
instrument panel energized and perform the following steps:
1. Disconnect the sender wire at the gauge and see if the
gauge reads zero, which is the normal reading for this
simanon.
2. Remove the wire attached to the sender terminal at the
sauce and connect it to ground. See if the gauge reads full
If both of the above gauge tests are positive, the gauge 15
undoubtedly OK and the problem hes esther with the
conductor from the sender to the gauge or with the sender.
If eather of the above gauge tests are negative, the gauge is
probably defective and should be replaced.
Assuming the gauge is OK, check the conductor from the
sender to the sender terminal at the gauge for continuity.
Check that the engine block 15 connected to the ground.
Some starters have isolated sround terminals and ıf the
battery is connected to the starter (both plus and minus
terminals), the ground side will not necessarily be connected
to the block.
32
ELECTRIC GOVERNOR ADJUSTMENTS
DESCRIPTION
The system is composed of three basic components:
1. Controller. Mounted in the instrument panel.
2 Sensor. Installed on the bellhousing over the flywheel
ming geal
3. Actuator. Mounted at the front of the engine and
attached with linkage to the throtile arm of the injection
= =
LINEAR
ACTUATOR
CONTROLLER ADJUSTMENT
1. Speed. This adjustment is used to raise or lower the
engine's speed to the desired hertz.
2. Gain. This adjustment affects the reaction time of the
actuator to fhe generator/engine load changes.
NOTE: A high gain adjustment can induce an oscillating
of the actuator producing a hunting mode. In such
cases lessen the gain adjustment.
Calibration
1. With no power to the govemor, adjust the GAIN to 9:00
o'clock.
2. Start the engine and adjust the speed by turning the speed
pot clockwise to desired speed.
ROTE: Controllers are factory adjusted to minimum rpm.
However. for safety, one should be capable of disabling
the engine if an overspeed should exist.
3. At no-load, turn the GAIN potentiometer clockwise until
the engine begins to hunt. if the engine does not hunt,
physically upset the govemor linkage.
4. Turn the GAIN potentiometer counterclockwise
until stable.
NOTE: The controller operates on 12VDC. The voltage
range is + 20% (9.6VDC 12VDC 14.4VDC). If voltage
varies above or below these ranges, the controller will
not operate and the engine will run in an idle mode until
proper voltage is supplied to the controller
PRISION TN
FNEZST4É 24V
TE ELECTRON
CONTROLES
L
TERMINAL BOARD #2
REFER TU WIRINS DIAERAIET
INSPECTION AND ADJUSTMENT
The controller has two adjustment pods. You need à mini
screw driver to adjust these. One is speed and the gain
These are noted on the drawing of the controller.
When you press the preheat switch the actuator linkage
attached to the throttle arm of the injection pump should
move outward towards the injection pump and retum back
into the actuator in a quick motion.
Start the engine. The speed should be in the low idle range
600-700 rpm. If the engine speed is higher than tus idle
range, shut the engine down. Check the linkage between the
actuator and throttle arm. The throtie arm stop should be
shout touching the open idle stop screw boss. Adjust the link-
age to position the throttle lever. The controller has an adjust-
ment screw for speed adjustment. Turn this screw outward
(counter clockwise) a few tums. Restart the engine.
NOTE: If there is any oscillating of the actuator linkage
producing hunting, adjust the gain towards zero “O” until
this hunting is removed.
Increase the engine speed slowly with the speed adjusting
screw turning it inwand (clockwise). In some instances this
screw may need to be turned 6-10 tums before an increase In
engine speed is noted. Bring the engine speed to 1800 rpm
(60 Hz), 1500 rpm (50 Hz). Momentarily push the actuator
lirikape towards the actuator and release. The actuator should
quickly regain proper speed. If there is any hunting adjust the
gain towards zero 0” until this hunting is removed.
When the gain is adjusted you may need to readjust the
speed at no load, shut the generator down.
Push the DC exciter circuit breaker in. Start the generator.
Check speed (Hertz) set at 60 Hz.
Load the generator.
If the govemor is slow to react and maintain 60 Hertz adjust
the gain clockwise. Again you may need to adjust the speed
at no load.
You will find the governor will maintain 60 + 0.5 Hertz right
up to the full rated amperage output for the generator.
(ES WESTERBEKE
Engines & Generators
33
LINEAR ACTUATOR TROUBLESHOOTING
1. Check the battery volzge al the controller termine! block
with the Prebezl/On sumich depressed
2. Inspect the linkage for binding or sticking
a. M there i= no signal or 2 weak signal from the
WIRE a ea tu Sa wie
and biack'whit wire leads from the MPU on the controler
terminal block. Whiz cranking the engine or with the engine
running at idle. voltage should be 1.5-2 5 VAC.
NOTE: The AC input impedance of meter mist be
2000 ohwmsAvolts or greater ;
ROTE: When making this test pr discal units, dab
the preheat solencao by disconnecting the “S- ела!
connection 50 às not lo damage the glow pings.
4. Checx the actuator with the preheaton switch depressed.
This provides DC voltage to fre controller. Mezsare the
DE voltage between the actuator connections on the
System appears dead
(No actusior movement)
Engine runs, but at ¡die speed
à Purple lead to Black DC (-).
В. Purple iead/purple/white lead to Black DC (+).
MOTE: Continue thés test (ONLY) 7 the battery
voltage = not present.
E The following checks ère performed between the
connections at the actuator and the Black DC (-) connection
on the controller termina! block. This is to determine rd there
& à break in the fine between the controllers minal block
connection and the actuator connections or the actuator
leads themseives
NOTE The actuator should fully extend and retract when the
1) Low voltage (1.0-2.0 VOC) àt either actuetor connections
2) Battery volage al both actuator connections.
3) Battery voliage & one actuator connection but
mot at the second.
Check the controller by removing the two. purple leads
ona af a ime that come from the actuator off the controSar
terminal block. Litt one actustor lead and depress the
preheation switch. Reconnect and do the same with the second.
NOTE: Eariy controllers had two solid purple leads for the
actusior connections Later model controles have one solid
lever goes to full 1.
when the preheat
ES depressed and says
4
Correct
1. inspect the DC circuit back to the Staring battery
2. Free up the Enis and clean and lubricate the linkage.
3. Check for damage to or improper adjustment of
magnetic pick-up. Replace of re-adjust
4. Low voltage (1.0-2.0 VDC) el either actuator connections.
b. Replace the controBier if battery voltage is not present ai
both the Purple leads.
1) Broken actuator lead, repair.
2) Broken actuator lead, repa or replace actusioc
3) Check actuator winding for open. Replace actuator
1. Check for à shorted actuzior lead Replace Me
controBer because it Should not cause the actuator
lever to go to full fuel when fe engine is not running.
pirrpie and 3 purpladwhite stripe for the actuator connection
The purpleMtil sad is designatad (+) and le specii amy in
gasoëne DC circus
a Actuator 10 tul extension (Diesel) & Check for shorted actuator load.
Does fot retract (Gasoline).
E Actuator does not extend (Diesel). b Replace controller _
Actuator funts éuring operation 1. Linkage or rod end bearings are sticking or binding 1. Lubricate or replace.
2 Improper governor adjustment z Reañus! the calibration.
3. LEAS PRET LAN VAE à i actuator doesn't fully edend (diesels) or retract
a Connect a DC voltmeter to Red (+) and Black (-) leads (A SEE pl
at the controlizr terminal block. the voltage is less than specified, check for
b. Disconnect both leads coming from actuator from юо5е or poor connections in the DC circuit back to
Controller terminal block. Me bañery, check the K2 relay and its connections.
E Connect one lead from the actuator to the Red (+)
on the terminal block and the other actualor lead to
the Black (-lon the terminal block.
d Mementariy the
should extend and sky extended extenden (diese) ans
retract (gasoline) 35 long as the switch te
ads wae performing is Is across the fied {+ } nd Back €)
leads whis this test be greater
than 60% OC velo: mentar поро чей „ареной
24 VIC E 60% = 19.2 VDC
12 VDC & 80% = 36 VOC
NOTE: Reconnect Me actusior lesds propeniy after completing this hast
& MPU positioned marginafiy too tar away from fiywfes!
teeth giving erraic AC input 10 controler.
e Check te position of the MPU.
If problems continue to persist, contact your WESTERBEXE dealer for additional assistance.
y
34
GenRemote CALIBRATION лодок,
The unit consists of a Power Logic Module, Display Panel and six conductor shielded Display
Cable. The shielded cable links the display to the module and can be up to 300 feet long. Two
display panels can be daisy chained to one (1) module output. The module supports two display
cable outputs allowing for a total of four (4) displays per module. Total allowed cable length per
module, including both display cable outputs, is six-hundred (600') feet
The logic module is powered directly from the generator’s cranking battery and consumes less
than 70 milli amps (70/1000 of an amp) when the generator is idle. DC operating voltage can be
12 or 24 volts. The AC generator output can be 115V, 240V, 50/60 Hz, single phase (1) or
three (3 ©) phase.
Generator and Engine Monitoring
1. DC Voltage
Cil Pressure
Water Temperature
AC Voltage
AC Current L-1
AC Current 1-2
Line Frequency Hz
Engine Hours Up to 10,000 Hours
E 307 NN A Y NN
Exhaust Over Temperature Alarm
GenRemote is designed to safely interface with the existing engine sensors. The
digital display is easily calibrated to match the readings of the manufacturer supplied
mechanical gauge package.
The GenRemote circuitry is isolated from the generators OEM electrical system. This
assures that GenRemote will not interfere with the manufacturers supplied gauge
package. Electrical isolation also allows normal generator operation should the GenRe-
mote be accidentally disconnected from the generator.
Electrical Hook-Up
Electrical hookup includes interconnecting with both the generators AC and DC systems.
The AC wires Required: The 115 volt Line One [L-1 Jis Black Line Two [1-2] is White. The 220 volt
Line-2[L-2]is Black witha Red Stripe. The 220 VAC Neutral connection is White and is Not connected
to the GenRemote,
The 220 VAC Generator Neutral is the same as Green Ground wire. The 115/220 VAC Neutral [White
Color] is connected to the generator frame.
The DC Wire Harness Supplied Color Code as follows: Green is Ground, White is ESS [Emergency Stop
Switch], White/Black is the Stop Switch, Black is Preheat, Orange is Oil Pressure, Red is Water
Temperature, Yellow is the Exhaust High Temperature Alarm [marine applications only] and Black/Red
is the Start Button.
IMPORTANT ! The Exhaust High Temp terminal is connected to the ESS terminal when it isnotused.
Cv] WESTERBERE
Engines E Generators
39
GenRemote CONTROL STATION
IMPORTANT! The generator must be running and the system fully operational before the
calibration mode can be accessed
Enter the Calibration Mode: Press and holding the Mode Button for 10 seconds. Entry 1s
indicated when the hundreds place decimal of the 3-digit, 7-scgment display turns on.
Calibration Button Functions
Mode Button: Press and hold the mode button to enter the calibration mode.
Preheat Button: Use the Preheat Button to manually advance through the AutoGauge
Scroll functions until the desired gauge is reached
Stop Button: Use the Stop Button to decrement or reduce the gauge value.
Start Button: Use the Start Button to increment or increase the gauge value,
Mode Button: Press the mode button to exit the calibration mode. Not pressing
any button for 30 seconds will also exit the calibration mode.
Firmware LD. The firmware identification number will appear in the display when the
calibration mode is exited. A typical firmware identification number is
Calibration Method A
Calibrate the AutoGangeScroll by using the values derived from 9% PRESSURE Es
the mechanical gange package supplied with the generator. Tr т 518
Calibrate the AC Volt and Current Meter with à standard Amp ef mts fms
and Voltmeter normally carried by most service technicians.
No calibration of the Frequency Meter is required or allowed. The Frequency Meter 1s factory
calibrated to = one (1) Hz.
NOTE: The unit will automatically exit the Calibration Mode if no buttons are pressed for thirty
(30) seconds.
Firmware identification
When calling for service or warranty repair it is useful to have the firmware Fret
identification number. The unit's age, software revision level and the systems [ (7 aC
hardware can be identified from this number. The firmware identification {| Ol
number is also placed on the 28 pin microprocessor located in the control module
assembly. The firmware number appears in the display when the calibration
mode 1s exited `
FAIL SAFE PROCEDURES
The fail-safe system is setup to display potential failures approximately 10% lower than the OEM
settings. This allows time for the operator to manually shut down the generator before serious damage
OCCUTS.
Failures are displayed by turning on the appropriate warning LED. For Example, the high coolant
temperature alarm will appear at 195 * F and the OEM safety switch will stop the generator at 210 °F.
The alarm LED will remain lit after the generator shuts down to provide indication as to why the unit
stopped.
The alarm LED can be cleared by pressing the stop button or by restarting the amt
The Fail-Safe Protocols include: 1 - Oil Pressure
2 - Coolant Temperature
3 - Exhaust Over temperature KLIXON
JWESTERBEXE
36
GenRemote WIRING DIAGRAM
Figure - 20 Westerbeke Wiring
for Westemeke Homess cnd Plug Assy.
Federal and Local Electrical Code
requirements for Proper Wie Sting.
Important |
Neutral Connection to Gentemote Is
Not Required for 220 Voit Applications
For 115 Volt sysiems L2 ls Neutral,
this is usuoily the white wire.
LT OUTPUT TO LOAD ol = —
Distribution fonel ad —
WESTERBEKE
Engines & Generalors
37
GenRemote INSTALLATION DIAGRAM
Hole:
GenRemote uses engine Oil pressure
ond AC vollage to recogrèe he
Cenremote | engine sunning
Hectical Box | Without AC nputihe generator wil in
and GenRemoie will only moniiorn the
Battery, Water Temp ond Oil Pressure.
Mo AC readings will be displayed and the
Run Indicator wil not um on
1
Socio
* AC Lood con be comecied
снесту Юю generotor, however,
the L1 ond L2 curent reacings
Westetbeke AC Output LI & L2 uit est fe Covi
Neutral Not Required The AC signal MUST be wired
— for 220 Voi Appicalors to GenRemote,
STOP/START ROCKER SWITCH
The One Iuminated Burton Start / Stop Rocker Switch is provided for areas where remote start stop
fmetions are reguired and no spece Es available for the standard display panel
Startthe generator by pressing and releasing the upper rocker once. The lamp will fiacker repidhy winle
the generator is starting. The indicator lamp will remain on and steady while the generator is running.
Stop the generator by pressing and releasing the lower rocker once.
Trouble Indicator: The indicator lamp will flicker siowiy whil= the generator iS operating ifa service
problem is developing Possible problems include, High Coolant Water Temperature, Low Oil Pressure
and High Exhaust Temperature Safety Switch
GenRemote SPECIFICATIONS
DC OPERATING VOLTAGES «ori cacssiisrsnsisistsssassmnrsnessssssess ts sossstnnmssassnss 12 or 24 VDC
DC Current REouremeNT MODULE e.======0==mneretooscaaticacicao teria roce 50 ma
DC CURRENT REQUIREMENT —IISPLAY ...cemmrmmrsersrrrrsrssssssssssssssssnrensssnsensnsnsnssasss .. 20 MA
DC CURRENT EACH ADDITIONAL DiSPLAY 5 15 ma
DV TOO rte tree te 2222222222" 120 / 240 VAC
PHASE ....cosrmenoos Td in" 19003 ©
STANDARD CURRENT METER sssreerrrreere rer e Ire os oa 60 amps
REMOTE CURRENT METER FEN va .200 amps
START RELAY occncarerressssssssosesssossimmmnmeanssssmssnssesssssrersssitomennmisnnes sess essere res ssssss 7 AMPS
Stop RELAY m..... EEE EEE À AMPS
Presa REG em E 7 AMPS
Maomum $ or DispLAYs PER MODULE ceecesnccononenoas mem meta aan ЙЕ
Maxomum # or DispLays Daisy CHAINED Lecvrussers da in in 2
Maamum DispLay CABLE LENGTH (ONE DIRECTION) cov…ouscensansannameanennaresenansessunnes 300 FT
TortAL AuLoweo DispLay CanuE LENGTH ..………10…0sresserstansansmnnnenmensansessssssassnnaane 600 FT
TEMPERATURE RANGE Cecaacemccner 0° F THROUGH 180° F
NOTE: Each module will support a maximum of four displays. No more than two (2) displays
should be dom chained to ont module output. The m e supports two (2) separate display
output lines
Cv ]MWESTERBEKE.
Engines £ Generators
39
GENERATOR INFORMATION
USE OF ELECTRIC MOTORS
The power required to start an electric motor is considerably
more than is required to keep it running after it is started.
Some motors require much more current to start them than
others. Split-phase (AC) motors require more current to start,
monly used on easy-starting loads, such as washing
machines, or where loads are applied after the motor is
started, such as small power tools. Because they require 5 to
7 times as much current to start as to run, their use should be
avoided, whenever possible, if the electric motor 15 to be dri-
ven by a small generator. Capacitor and repulsion- induction
motors require from 2 to 4 times as much current to start as
to run. The current required to start any motor vanes with the
load connected to it. An electric motor connected to an air
compressor, for example, will require more current than a
motor to which no load is connected.
In general, the current required to start 115-Volt motors connected
to medium starting loads will be approximately as follows:
MOTOR SIZE AMPS FOR AMPS FoR FOR
(HF) | RUNNING
_ (AMPERES) (AMPERES)
16 | 32 6410224"
1/4 45 9210327"
13 52 10.4 to 725"
1/2 72 14.410292"
au _ 102 | _ 20410408"
1 13 | 26 to 52
"NOTE: In the above table the maximum Amps for Siarting is
more for some small motors than for larger ones. The reason
for this is thar the hardest starting rypes (split-phase) are not
made in larger sizes.
Because the heavy surge of current needed for starting
motors is required for only an mstant, the generator will not
be damaged if it can bring the motor up to speed in a few
seconds. If difficulty is expenenced in starting motors, tum
off all other electrical loads and, if possible, reduce the load
on the electric motor.
REQUIRED OPERATING SPEED
Run the generator first with no load applied, then at half the
generators capacity, and finally loaded to 1s full capacity as
indicted on the generators data plate. The output voltage
should be checked periodically to ensure proper operation of
the generating plant and the appliances it supplies. If an AC
voltmeter or ampmeter is not installed to monitor voltage and
load, check it with a portable meter and amp probe.
NOTE: When the area in which the generator is installed
contains AC equipment of 120 volts only, it is recommended
that the generators AC terminal block be configured to
provide one 120 vol: AC hot leg for the distribution panel.
This will ensure good motor starting response from the
generator.
Generator Maintenance
Ш Мана! ble clean ei
Connections of terminal boards and rectifiers may become
corroded, and insulation surfaces may start conducting if
salts, dust, engine exhaust, carbon, etc. are allowed ©
build up. Clogged ventilation openings may cause
excessive heating and reduced life of windings.
E For unusually severe conditions, thin rust-inhibiting
petroleum-base coatings, should be sprayed or brushed
over all surfaces to reduce rusting and corrosion.
HM In addition to periodic cleaning, the generator should be
pestes METE Ae SE ANOS OA
overheated terminals and loose or damaged wires.
E The drive discs on single bearing generators should be
checked periodically if possible for tightness of screws
and for any evidence of incipient cracking failure. Discs
should not be allowed to become rusty because rust may
accelerate cracking. The bolts which fasten the dnve disc
to the generator shaft must be hardened steel SAE grade
8, identified by 6 radial marks, one at each of the 6
comers of the head. .
Bl The rear armature bearing is lubricated and sealed; no
maintenance is required. However, if the beanng becomes
noisy or rough-sounding, have it replaced.
I Examine bearing at periodic intervals. No side movement
of shaft should be detected when force is applied If side
motion is detectable, inspect the bearing and shaft for
wear. Repair must be made quickly or major components
will rub and cause major damage to generator.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the living quarters. Carbon Monoxide, even in
small amounts is deadly.
The presence of carbon monoxide indicates an exhaust leak
from the engine or generator or from the exhaust
elbow/exhaust hose, or that fumes from a nearby generator
are lealane in your area.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
e
POWER TAKE OFF SYSTEMS
POWER TAKE OFF ADAPTER
A power take off adapter can be attached to the generator
backend. This adapter allows access to the full power of the
engine for à variety of hydraulic and electrical accessories.
Contact vour WESTERBEKE COMMERCIAL GENERATOR
SUPPLIER for additional information.
XRT POWER SYSTEM
The XRT power system combined with a Westerbeke
generator provides electrical and hydraulic power for
fire/emergency apparatus The system generates electrical
power for auxillary lighting and provides continuous.
operation of up to three extrication tools at the same time.
SPECIFICATIONS
Components Dual stage continuous duty pump, stainless
high pressure fithings, three gallon reservoir
with filter, pump enclosure with integral control
blogk assemblies.
System Avalabiity 5.000 psi phosphate ester fluid and mineral
fluid systems up to 1050051
Dimensions COMB! pump in shroud.
10m x WHS" x Hed” x 42 Tbs
Reservoir HE 177 x W:177 xD: 65
Open Center Vaives
LATS" xW 275" xH 40."
For additional information, contact XRT POWER
me Cm or call (800) 343-0480.
XRT POWER SYSTEMS
32 Tioga Way
Marblehead MA 01945
Engines 5 Generators
41
BT GENERATOR
This generator is a four-pole, brushless, self-excited generator
which requires only the driving force of the engine to pro-
duce AC output. The copper and laminated iron in the exciter
stator are responsible for the self-exciting feature of this gen-
erator. The magnetic field produced causes an AC voltage to
be induced into the related exciter rotor windings during rota-
tion. Diodes located in the exciter rotor recufy dus voltage to
DC and supply it to the windings of the rotating field. This
creates an electromagnetic field which rotates through the
windings of the main stator, inducing an AC voltage which 15
supplied to a load. A step down transformer is connected in
parallel to the AC output of the main stator. An AC voltage is
produced in the auxiliary windings of the transformer and the
main stator and is, in turn, supplied to a full-wave bridge rec-
tifier. The rectifier produces a DC voltage to further excite
the exciter stator windings, enabling the generator to produce
a rated AC output. An optional solid-state voltage regulator is
available to work in tandem with the transformer regulator to
A circuit breaker is installed on all WESTERBEKE genera-
tors. This circuit breaker will automatically disconnect gener-
ator power in case of an electrical overload. The circuit
breaker can be manually shut off when servicing the genera-
tor to ensure no power is coming into the boat
NOTE: This circuit breaker is available as a WESTERBEKE
add-on kit for earlier model generations; contact your
WESTERBEKE dealer.
BREAKER 7
re
BLACK LI = 8.0KW - 42707 =)
> 10.0KW - 42698 =
WHTEN _ “E 12.50W-42709 (<. Ps
BT GENERATOR / SINGLE PHASE [SIX STUD]
A. EXCITER STATOR WINDINGS 1& 2
INTERNAL WIRING SCHEMATIC (SIX STUD)
W/OPTIONAL VOLTAGE REGULATOR
A-1 and A - 2 Exciter Stator Windings
(Selector in COMP position)
B. EXCITER ROTOR and FIELD
|. Auxiliary Windings (A - B - C)
2. Diodes (6)
3. Rotating Field Windmes
4. Pos] Resistor
C. MAIN STATOR
1. Main Stator Windings
2 Mazin Stator Windines
3. Main Stator Auxiliary Windings
D. COMPOUND TRANSFORMER
1. Compound Transformer Windings
2. Compound Transformer Windings
3. Compound Transformer Auxiliary Windmes
Resistance readines and voltage checks can be accessed
easily for the components in the exciter circuit A, G, C-3 and
D-3 by locating the color coded wires at the connection
points shown on the above schematic. When checking
winding resistance values be sure to Lift both of the
component's electrical connections.
G. BRIDGE RECTIFIER
A.VR
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Optional Automatic Voltage Regulator Plug (6 Prong).
IWESTERBEKE
43
BT GENERATOR SINGLE PHASE
OPTIONAL AUTOMATIC VOLTAGE REGULATOR (AVR)
BT 6 STUD MODELS ONLY
An optional solid-state voltage regulator (board #34410)
is available for use with the BT series generators. When
installed, and the regulation switch is moved to the ELEC
- pound transformer regulator to regulate the generator’s volt-
age output. In the EL EC mode, the regulator provides
excitation to the group] exciter windings, and the trans-
former provides excitation to the group 2 exciter windings.
|. The regulator is mounted using existing tapped holes In
the generator's case. Use two (2) M4 x 0.7mm screws,
each 15mm long, with lock washers to mount the regula-
tor board.
2. Connect the 6-prong generator plug to the receptacie on
the regulator board.
NOTE: The plug is keyed to engage the regulator receptacle in
one direction. Check this and insert it correctly.
=
Before moving the selector switch to the ELEC position,
the NO-Load voltage produced by the generator when in
the COMP position will have to be adjusted. The NO-
Load voltage should be admsted down between 114 - 118
volts (60Hz) or 224 - 228 volts (50Hz) following the
procedures as explained earlier in tins manual.
. With the generators no load voltage properly adjusted,
the regulator board potentiometer to set NO-Load voltage
at 120 - 122 volts at 61.5 - 62.0 Hertz (230 - 234 volts at
51.5 - 52.0 Hertz). The regulator board is operating In par-
voltage output within +5 per cent from NO-Load to
FULL-Load
NOTE: Do not use the regulator to force NO-Load voliage
down. Use the compound transformer for this function. Using
the regulator to perform this causes the regulator to use more
for loaded conditions.
SL
GENERATOR VOLTAGE ADJUSTMENT
tests and adjustments be performed by a quailified technician
Generator Frequency
1. Frequency is a direct result of engine/generalor speed:
1800 rpm = 60 hertz
1500 rpm = 50 hertz.
2. To change generator frequency follow the steps below.
a Connect the AC output leads to the AC terminal block,
following the illustrations on this page.
b. If an AVR is installed, reposition the blue or blue/white
lead to correspond to the hertz selected on the
Voltace/Hertz Connection Bar.
H there is no automatic voltage regulator (AVR
Voltage/Hertz Connection Bar. Simply reconfigure the
AC terminal for the hertz change.
e Start the engine, monitor voltage and adjust engine
no-load speed. Adjust diesel units by the linkage
between the throttle arm and fuel solenoid or the
throttle lever on the injection pump..
G hertz no-load speed, 61.5-62.0henz
0 her no-load speed, 515-520 henz
d. After the no-load hertz adjustment is made, the no-load
voltage may need to be readjusted. In most cases, if the
generator was producing the comect no-load voltage at
the previous hertz setting, it would be correct at the
changed hertz setting.
In the event it needs adjustment, adjust the shim thack-
ness under the laminated steel bar of the transformer.
60 hertz: no-load voltage, 121-124 volts.
50 hertz no-load voltage, 232-236 volts.
e. Load the generator to the rated amperage output
corresponding to the hertz speed of the generator.
Rated Loaded Speed
60 bertz: loaded speed, 58.5 - 59.0 hertz
50 hertz: loaded speed, 48.5 - 49.0 hertz
The lowest acceptable voltage at full rated output
(amps)
60 hertz: 108 - 110 volts
50 hertzz 205-210 volts
be moved when changng +
from 115 vois and 1107220 ë
volts 50 hertr to 230 volts =
50 nartz. From maidng con- 6
nechons to the AC terminal
biock, use terminal endsior |
14 ch studs hai wi
accent muit-stand copper
wire sed {rhe amperage
rating from the hot lead con-
nection. The frame ground
wie © while or white with 2
green sinp. it Connecs
bewee the neutral sid
and the generator frame.
GENERATOR VOLTAGE ADJUSTMENT
NOTE: WESTERBEKE recommends that the following generator
tests and adjustments be performed by a quailified technician.
NO-LOAD VOLTAGE ADJUSTMENT
Voltage adjustment is made with the generator regulation
being governed by the compound transformer.
1. The selector switch, if installed, must be in the COMP
position.
To confirm no-load voltage, start the generator and apply
a momentary (moderate) load to excite the transformer.
The voltage produced by the generator after the momen-
tary load is removed is no-load voltage. Note the voltage
output from the generators 120 volt legís) (230 volt 50
heriz). The no-load voltage should be between 121-124
volts at 61.5-62 hertz (232- 236 volts at 51 5-52 hertz).
NOTE: The no-load voltage should be adjusted to the voltage
produced by the generator once started and a momentary
load should be applied to excite the transformer and then
removed. The voliage produced by the generator after this
momentary load is removed is no-load voltage.
3. To raise or lower the voltage, shims of varying thickness
(non-conductive material) are placed or removed from
under the steel laminated bar on top of the compound
soften at temperatures in the 176° F (80° C) range. A
small reduction in no-load voltage (1 to 3 volts) can some
times be accomplished by gently tapping the top of the
laminated steel bar to reduce the gap between the existing
shims and the transformer core.
=
NOTE: No-load voltage may be effected needing readjustment
with the compound transformer. Do not use these
adjustments to compensate for overload conditions being
placed on the generator/engine {inductive-motor type loads).
Loss of generator hertz/speed, the result of overload, will
cause à drop in voltage oufpul.
Shim thickness of 0.001 inch will change the no-load
voltage by approximately 4 - 6 volts. Adding shim
material raises the no-load voltage. Removing shim
material lowers no-load voltage.
FULL-LOAD VOLTAGE ADJUSTMENT
The voltage hertz connection bar that is used when changing
from 60Hz to-50Hz can also be used to increase or decrease
the generators full-load output.
Fine voltage adjustments can be performed by repositioning
wires A to leads #1, #2, and #3 increasing the loaded voltage
progressively in that order. A no-load voltage adjustment will
have to be made as well.
Should full-load output fall below 108 volts-60Hz
(210 volz-50Hz), the voltage should be adjusted.
NOTE: When the optional voltage regulator is installed
and if the Blue/White (Blue) lead is not correctly positioned
to correspond to the Hertz the unit is operating at, the
regulator will sense incorrect voltage and cause the generator
to produce abnormaily high output voltage.
a =
46
BT GENERATOR VOLTAGE REGULATOR ADJUSTMENTS [THREE PHASE]
Descrinti
The voltage regulator is an advanced design which ensures
optimum AC generator performance. It is equipped with
complete protection circuitry 10 guard against operating
conditions that could be detrimental to the AC generator.
This potentiometer 15 used to adjust output voltage. Al proper
engine operating speed the output voliage should be held at
+1% from a no-load condition to a full rated generator output
and from power factor 1.0 - 0.8 with engine drive speed
variations up to -6%. Prior to starting the engine, tum the
VOLT and STAB wimmers (using a mini phillips screw-
driver) fullv in a counter clockwise (Mimimum) direction
until you feel them hit their stops. Tum the AMP and
HERTZ mmmers completely clockwise (Maximum) in the
same manner. With the generator moning at no-load, at
normal speed, and with VOLT adjust at minimum, it is
possible that output voltage will oscillate. Slowly rotate the
VOLT adjust clockwise. The voltage output will increase and
stabilize Increase the voltage to the desired value. In this
situation, only the green LED will stay lit.
Stability
This potentiometer permits variation of the regulator's
response to generator load changes so as to lmit overcom-
pensation and obtain a minimum recovery tume to the normal
voltage outpul
In order to adjust the regulator stability the generator must be
running at no-load and the output must be monitored.
Turn the STAB adjust slowly clockwise until the voltage
starts to fluctuate. At this point rotate the STAB adjust coun-
terclockwise until the voltage is stable within 1 or 2 tenths of
a volo
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Amp-Hertz
These two adjustments are used in conjunction with the two
protection circuits in the voltage regulator that are indicated
by the illumination of colored LED lights.
1. Delaved overload protection (yellow LED).
2 Low speed protection (red LED).
Both systems have an intervention threshold winch can be
adjusted using the respective potentiometer. Each of the two
circuits are able to cause an adequate reduction in excitor
valtage to safeguard the excitor windings and prevent their
overheating.
The overlosd protection system has a delay which permits
temporary overloading of the generator dunng times such as
motor start-up or other similar load surge demands. The regu-
lator also has a third LED (green), that glows dunng genera
tor operation to indicate correct operation of the regulator
with the generator.
Setting the Overload Protection
In order to set the AMP overload protection, the generator
must be loaded to its full output rang.
1. Load the generator to its rating, then decrease the speed of
the engine by 10.10% (54 Hertz on 60 hertz units, 45
hertz on 50 hertz units).
2 Rotate the AMP adjustment counterclockwise until it ints
its stop. Wait about 15-20 seconds after which the AC out-
put of the generator should drop and the yellow LED hight
should come on.
3. Slowly rotate the AMP adjustment clockwise until the
output voltage increases to approximately 97% of the volt-
age output at the start of the adjustment. At thus point the
yellow LED light should come on.
4. Return to nominal speed, the yellow LED will tum off
and the generator voltage will nse to its normal valve.
Should this not happen, repeat the adjustment.
NOTE: When changing from 60 hertz to 50 hertz operation,
remove the 60 hertz jumper bar from the regulator board
Setting the Underspeed Protection
NOTE: If the unit is operating ar 60 Hertz ensure that the
jumper strap is in place on the regulator board between the
two 60 Hertz terminals. In order to adjust the underspeed
setting, the generator should be running at no-load
1. To adjust the underspeed (low frequency) protection circuit,
lower the engine speed at 90% of its normal running speed
(54 hertz on 60 hertz units, 45 hertz on 50 hertz units.
2. Rotate the Hertz adjustment counterclockwise slowly until
the generators AC output voltage starts to decrease and at
the same time the red “LED” light comes on.
3. Increase the engine speed to ¡ts normal speed (frequency).
The red “LED” light will go out and the AC voltage out-
put will return to normal.
With the above adjustments made, the regulator should func-
поп normally.
IWESTERBEKE
47
| Dsraton
p--=————
=-------—-——- 0e
BT GENERATOR INTERNAL WIRING
3 PHASE TWELVE WIRE RECONNECTABLE
maim mel EEE
MOVIE
5.3 BUS FUSE
y
E VOLTAGE REGULATOR
HITT,
ALL
8071
ame =:
MOTIJA
HET
yh
REGULATOR SENSING 3 PHASE WYE-DELTA CONFIGURATIONS
NOTE: WESTERBEKE recommends that the following generator [ests
and adjustments be performed by a qualified rechmician.
Description
The regulator is equipped with seven numbered terminals
(0 to 6) and their related brass jumpers. The illustrations
shown connection points and jumpers for the 3 phase config-
uration of the generator. The sensing leads connect between
pin #1 and pin #2 on the AC terminal block and connection
#7 and #0 on the voltage regulator board.
NOTE: Series Delta requires the installation of a jumper on
the regulator board between terminal B and J.
L 208 VAC 130 60 Hertz
N 120 VAC 10 60 Hertz
-L 1920 VAC 30 50 Herz
N 115 VAC 1 50 Hertz
SERIES WYE (STAR)
L2 L3,-N 120 МАС
L-L 230-VAC
L2,L3,-N ПЗ МАС
10 60 Hertz
30 50 Hertz
1 50 Hertz
BT GENERATOR TROUBLESHOOTING CHART
NOTE: WESTERBEKE recommends that the following generator fests
and adjustments be performed by a qualified technician.
~ Problem I Probable Cause — Verification Remedy
| Low voltage at N/T and F/L No 1. Regulator board detective. 1. Replace the reguiator board. Adjust AVL voltage with
adjustment from regulator potentiometer transiormer, then switch lo ELEC ang adjust with
| AMP. polenbomeler.
2. Exciter stator winding A-1 open. 2. Check resistance values of C-3 and D-3 windings and
я a their connections
Low voltage af NL and voltage drops 1. Diode(s) in exciter rotor shorted (B-2) 1. Check the diodes in the exciter rotor.
further a5 a load is apphed.
2. Audiary windings in exciter 2. Check the resistance values and continuity to ground
| rotor shored (B-2).
Voltage OK at NA and low at FL 1. Audiary windings in the exciter rotoc 1. Check the resistance values and confinufty to ground.
| stator compound winding 2. Check the continuity and the connection of the winging.
| E open
3. Awaizry windings D-3 or C-3 open. 3. Check the continuity and the connection of the winging.
Voltage unstable 1. Defective regutator board. | 4. Check the stability of DC voltage from the reguiztor to the
exciter stzior windings. Operaie the unit on COMP. Replace the
| reguiator board.
2. Engine E hunting. 2. Check the engine operation and the fuel system.
3. Electrical connections. 3. Check for clean and secure connections
Engines & Generators
50
SPECIFICATIONS 10.0KW/8.0KW BTDA
GENERAL CS ОАО
Engine Type Diesel. four-cycle, three-cylinder, fresh water- | General Open flow, seif priming.
|
mechanism me ne Fuel No. 2 diesel ol (cetane rating of 45 or higher).
Displacement 80.4 cubic inches (1.318 Ber) Fuel Injection Pump ee (055
Imecton Timi o
Aspiration Naturally aspirated Fuel imecton Timing (Top Dead Canter)
| Combustion Chamber Swirl type. Nozzle Troie type:
Bore & Stroke 3.07 x 362 inches (78 x 92 mm) fect me Spin regiacesiie (PFO2E06Y),
ys 30 | |: en ото
Re Аг Виз 1 {3.9 cmm) at 3600 rpm.
TRENT Clockwise, when viewed from the front. | im bustion)
ни te Fuel Lit Pump 12 voit DC Et capacity of 5 (15 mm) sobd state |
Wacht (Enge Only) 276 lbs (276 kos) without transmession. |
inclination Continuous 15° ELECTRICAL SYSTEM
Temporary 25° {not to exceed 30 min.) В 12 Vol. 3
TUNE-UP SPECIFICATIONS Batey Copey 400 — 600 Cold Cranking Amps (CCA)
Compression Pressure 427 psi (30 kg/m”) at 280 pm DC Charging Atemator 57 Amp rated, belt-driven
354 psi (27 kg/cm") Starting Aid Giow plugs. sheathed type
Valve Timing Intake Opens Starter 12 Volt, reduction gear
ка Closes
$T 1750 IS
Valve Seat Angia 45° General Fresh water-cooled block, Thermostatically-
Engine Timing 17" BTDC controlied with heat exchanger
injector Pressure 1991 + 71 - 0 psi (140 + 5 - 0 kyon?) Operating Temperature TEC |
Valve Seat Angie Intake 45° Fresh Water Pump Centrifugal type, metal mpeñar, beit-drrven.
| Exhaust 30° System Capacity 1.9 LS ots (1.5 Mers)
Valve Clearance 0.0098 inches 0.25 mm | (Fresh Water)
| (engine Cold) г :
LUBRICATION SYSTEM
| General Pressure led system.
СЯ Filter Full flow, paper element. spm-0n type.
Sump Capacity 3905. ats (37 liters)
(not including filter)
Operating Où Pressure 50-60 ры (35-42 к/ст)
(engine hot)
Os Grade API Specification CF or CG=4,
SAF 30, 10-30, 1777-40
CA WESTERBEKE
91
SPECIFICATIONS 15KW BTDC/12.5KW BTDB
ama
Engine Type Diesel. four-oycie. four-cyinder, fresh water- — |
cooled, vertical in-Ene overhzad valve
Mechas
Displacement 107.3 cubic inches (1.755 Mer)
Aspiration Naturally aspirated
Combestion Chamber Swirl type.
Bore & тоже 3.07 x 362 inches (78 x 92 mm)
ring Order 1-3-4-2
[erection of Rotation Cloclowrse, when viewed from the front
Compression Ratio 771
Dimensions - inches (mm) Height 24.0 inches (609.6 mm)
Engine Only Width: 19.0 inches (482.6 mm)
Length: 34.6 inches (878.8 mim)
Weight (dry) 569 bs (258.10 kgs)
Fusl Consumption 1.42 gir (5.38 ltrhr)al 1800 rpm
HF @ 1800 RPM 25 НР
| Compression | at 780
Spilled Timing (Static) 17" (spill)
Valve Seat Angle Intake 45°
Exhaust 30°
o
| Valve Seat Angle Intake 45%
Exhaust 30°
Valve Clearance 0.0098 inches ( 0.25 mm)
injector Pressure 1991 + 71 - 0 psi (140 + 5 = О крат)
Engine Timing 17° BTDC
Starting Battery 12 Volt, {-) negative ground
Battery Capacity 400 — 600 Cold Cranking Amps (CCA)
DC Charging Altemator 51 Amp rated, beit-drven
Starting Aid Glow plugs. sheathed type
Starter 12 Volt, reduction gear
92
Fuel
Fuel injection Pump
Nozde
Fuel Filter
Air cieaner
Fuel Lift Pump
Genera Open flow, salf priming. |
No. 2 diesel où (cetane rating of 45 or higher). |
in-iine plunger type (BOSCH)
Throttle type.
Spm-on reptaceable (FMA0Z4365)_
Replaceable paper filter cartridge.
12 volt DC 6 capacity of 5° (1.5 mm) soñd state
IVE
General
Operating Temperature
Fresh Water Pump
System Capacity
(Fresh Water)
General
Ou Filter
Sump Capacity
(not including filter)
Operating 0d Pressure
{engine hot)
O Grade
Fresh water-cooled block, thermostatcally-
controded with heat exchanger
170-190" F(77—86" C)
8.0 US gis (7.5 Hers)
LUBRICATION SYSTEM
Pressure fed system.
Рый flow, paper element, spañ-on type
5515 gis (5.2 Rers)
50 — 60 psi (3.54.2 kg/cm)
AP Specification CF or C54
WESTERBEKE
Engines & Generalors
SPECIFICATION 10.0KW BTDA
SPECIFICATION 8.0KW BTDA
AC GENERATOR (Single Phase)
Single Phase Brushiess, tour-pole, revolving field. | General - 3 Phase Brushiess sic pole, revolving field. Sealed
Pre-lubricated, singis bearing design 10.0 KW - 60 Hertz lubricatad single besnng design, 12 Lead
Reconnectable, single phase transionmer | 75 KW-50 Hertr reconnectable for low voltage WYE, high
regulation (optional sobd-5tzte voltage | voltage Delia. Sold State voltage regulalor
regulation}. wich protection circuitry
Voltage 120 or 1207240 Volts - 60 Hertz Voltage - 3 Phase Low voltage WYE 208 voës
220 Volts - 50 Hartz (60 Hartz) High vañage WYE 480 volts
| Voltage regulation: + 5% no load to full load. oe “0
ЧН Voltage - 3 Phase High voltage WYE 360 volts
Rating (Volks AL) Amperane-3 Phase — Low voltage WYE 35 Amps
10.060 120/240 Volls 83.341.6 Amps DELTA 30 Amps
50 Hertz [1500 mm) 220 Volts 3.1 Amps
7.5XW Amperage - 3 Phase High voltage WYE A.
Generator Cooling 225 - 250 dim (5.66 - 6.37 emm) | AM e
Air Requirements | Engine Combustion 32 cim (806 cm)
(62 Hertz! at 1800 mm MOTE: increase ar supply 15% for 50 Hertz Air Reguirements
орегайоп (1508) грип) (60 Hertz) at 1800 rpm
| Single Phase Brushless. four-pole. revolving field
Heconnectable, Singe phase tansiormer
reguiabon (optional Sobo-Stais vomege
regulation).
Voltage 120 or 120/240 Vois - 60 Hertz
220 Vois - 50 Hertz
Voltage requiation = 5% no load to fol load
| Frequency regulation: +3 Hertz [55) no load to full load
Rating (Volts AL)
60 Hertz (1800 rpm) 120 Volts E5 Amps
E.0KW 120/24) Volts — 6633 Amps
50 Hertz {1300 rpm) 220 Vols ZT Amps
BLOW
Generator Cooling 175-200 cfm (4.95 - 5.66 cmm)
Air Requirements
[60 Hertz) at 1800 rpm NOTE Increase air supply 12% for 50 Herz
operation (1500 rpm)
Engine Combusaon 32 cim (.506 cmm)
Ал Requirements
(60 Hertz} ai 1800 rm
Engine Compartments 100-200 dm (253 - 5.55 cmm)
WESTERBEKE
ee
93
SPECIFICATIONS 15KW BTDC
AC GENERATOR (Single Phase)
Three Phase Brushiess, sor-pole, resohang field Sealed
15.0 Kw - 60 Hertr lubricaled, single bearing desgn 17 Lead
12.0 Kw - 50 Hertz reconneciable Tor low voltage WYE, high |
voltage Deñz Solid state volle requistor with
protection circuftry
Voltage 120 ог 120/240 Volts - 60 Hertz | Voltage - 3 phase 60 Hertz. Low Voltage WYE 208 Volts
| 230 Volts - 50 Hertr High Voltage WYE 480 Voits
| I DELTA 240 Volts
| Voltage regulation: +5% no load 10 full load. 3 Phase50 Hertz Hioh Vokage WYE 380 Volts
Frequency regulation: 3 Hertz (5%) no load to full load DELTA 230 Volts
Rating (Volts AC) 60 Hertz (1800 rpm) 120 Vols 125 Amps | = Low Voltage WYE 52 Amps
60 Hertz (1500 rpm) 1207240 Vols 125/62 5 Amps | ee ei High Voltage WYE 22 Amos
50 Hertz [1500 mm) — 730 Volts 60 Amps DELTA 45 Ames
| A 225 - 250 cim (6.37 - 7.08 cmm) Amperage - High Voltage WYE 22 AMOS
Remarements DELTA 33
(60 Hertz) at 1800 rpm MOTE: Increase air supply 15% dor 50 Hertz LA | so
| operation (1500 pm). SCPE 104°F (40°C) maxımum
Engine ñ Comi sion 41 cim (1.16 cmm) ir NOTE: Foster ventilation should be provided
Air Requirements lo maintain génerstor
(60 Hertz), at 1800 rpm | temperatures below 104 07).
Generator Compartment 104°F (40°C) maximum
Ambient Temperature
Recommendations NOTE: Forted ventilation should be provigad
lo meintar) generator
temperatures below 104" (OC)
SPECIFICATIONS 12.5KW BTDB
AC GENERATOR (Singe Phase
Single Phase Brushless, four-pode, revolving fisid Three Phase Brushiess, sor-pole, revohang field. Seed
Pre-lubricated, single-bearing design. 12.5 Kw - 60 Hertz lnbricated, singie-bearing design. 12 Lead
Reconnecishls single-phase transformer 8.3 Kw - 50 Hertz reconnectable for low voitage WYE, hagh
requistion (optional sobid-state voltage voitage Defiz. Sod state voltage reguistor with
) protection circuitry
Voltage 120 or 120/240 Vols - 60 Hertz Voltage - 3 phase 60 Hertz Low Voltage WYE 203 Volts
230 Vol - 50 Hertz. High Voltage WYE 450 Vots
| Voltage regulation: 25% no inad to full load. | DELTA 205
Voliage - 3 Phase 50 Hartz High Voltage WYE 380 Volts
Frequency regulation: à Hertz (5%) по icad to fui icad DELTA 730) Vols
Rating (Volts AC) | | Amperage- Low Voltage WYE 43 Amps
60 Herz (1800 rpm) 120 Voits 104 Amps 3 phase 60 Hartz High Voltage WYE 18 Amps
12-5KW 120/240 Vois 10452 Amps DELTA 37 Amps
50 Hertz (1300 rpm) 230 Volts 60 Amps
| Generator Cookng 200- 225 cim (6.37 - 7.08 cmm) > puse 20 A
Air Requirements Engine Combustion 41 cim (1.16 emm)
(60 Hartz) at 1800 rpm NOTE: increase air supply 15% for 50 Hertz Air Requirements
opersbon (1500 rpm) (50 Hertz), at 1800 mm
Generator Compartment 104°F (40°C) mæadmum | | Generator Compartiment = 104°F (40°C) mædmum
Ambien! Temperature | | Ambient Temperature |
Recommendations NOTE: Forced ventilation should be provideo | Recommendations BOTE: Forced vention should be provided
ip maintain generar compartment Io Mantas) generator compattment
temperatures Delow 104" (40°C). temperivres below 104F (40°C)
WESTERBEKE
[SV WESTERBEKE
94
Bolt or Nut
Altemator Bracket
Back Plate
Connecting Rod Cap
Coclant Pump
Coolant Pump Pulley
Coolant Temperature Sender
Coolant Temperature Switch
Crankshaft Pulley Nut
Cylinder Head Bolt
Delivery Valve Holder
Engine Mounts
Exhaust Manifold
Fiywheel Boit
Fuel Filter Assembiy
Fuel Injection Nozzle Holder
Fuel Injection Pipe Nut
Fuel Leak-Off Pipe Nut
Fuel Solenoid Locknut
Glow Plug |
Glow Plug Connection Plate
Intake Manifold
Main Bearing Cap Bolt
Oil Filter
Oil Pan Bolt
Dil Pan Drain Plug
Dil Pressure Sender
Dil Pressure Switch
Pressure Refief Valve
Rear Plate Bolt (stamping)
Rear Plate Bolt (standard)
Retaining Nut for Delivery
Valve Holder Body
Rocker Cover Bolt
Rocker Shaft Bracket Bolt
Sliding Sleeve Shaft
Special Nut for
Torque Spring Set
Starter B Terminal
Stor Solenoid
Thermostat Housing
Thermoswitch
ENGINE TORQUE SPECIFICATIONS
Mi6
M10
M12
MAJOR BOLTS AND NUTS
Width Clamp
Diameter Pitch acrossflats length
1.0 14 —
15 27 —
1.25 14 87
=== 19 —
1.25 19 29
1.5 21 —
15 - —
15 18
1.25 12 60
0.7 8 vom
1.25 17 Bi
15 — _—
1.25 12 25
15 22 10
— 26 1
1.5 22 33
1.25 12 16
1.25 17 28
0.75 19 =
1.25 12 40
1.25 12 581
1.25 14 295
1.0 17 —
1.25 12 —
15 36 —=
1.5 17 315
MIG
TORQUE
kg -m fi-lb
3.853 27-38
3348 24-35
3a5+025 7772
16+24 12-17
16+24 12-17
12+1.8 9-13
121.8 9-13
17525 12x18
+05 65 = 4
45+05 32x54
32+47 23-34
16x24 12-17
135+05 983+4
46+ 6.8 33-49
55+05 40+44
3+05 22 = 4
275+025 20+ 2
40x50 289+ 36.2
175+025 12-72
0.125—0.025 09+02
16x24 12-17
525+025 38=x2
12x01 8.7+ 0.7
28+03 203x232
40+5 29+4
12+1.8 9-13
1+02 T2+14
50+5 3a5+4
1.152015 B3+11
65+1 47+]
375+025 272
115015 83x11
15+05 114
36x06 26+4
2+05 14=4
1.1 x01 8047
4505 32+54
0.3-0.45 2-3
23x04 166 £3
STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt
Customary (inch) bolts zre identifed by markings two 10 grade ssi
(strongest). The marks correspond to two marks less than the actual grace,
Le: 2 grade seven bolt will desplay five embossed maris.
Metric bolt class numbers identify boîts by their strength with 10.9 the
strongest
Grade 8
NOTES: 1. Use the torque values listed below when specific torque values are not avaliable.
9. These torques are based on clean, dry threads. Reduce torque by 10% when engine od is used.
3.- Reduce torgues by 30% or more, when threading capscrews info aluminum.
METRIC BOLT & NUT TORQUE SPECIFICATIONS
| SAEGrades SA Graie6&7 | SAME Grades od
Capırew Body Size Torque Torque Torque Вой Grade df | Graded’ |Блайе 8-9. Grade 10.8
[Inches) - (Thread) АН (Ми) АЗЫ (№) | PH (Ма) Dia. | Wrench Sire | FHL (Nm) | Ab (Nm) | FHb{Mm) | АН (М)
| 14-20 8 (11) 10 (14) 12 (15) _
-28 10 (14) 14 (19) va 55 mm 0509 05 on 103 o
hal mm ; 1
nes nen 19 25) 7 an №5 | 8mm 1585 28 150 ES O)
35-16 a1 (42) 4 M6) 44 (60) Me | 10mm зы) 465) 7500) TU
-24 35 (47) ЭР MS | 13mm 785) | 10/19 18725) 509
16-14 45 (66) 5 79) 70 (25) MIO | 16mm 14 (18) 18 (25) 37 50) 55 (75)
% | 55 (75) 78 (106) | - =
12-13 75 102) 85 (115) 105 (14) | |MZ| Em | zB | 289 | SE | 909)
A Mid | 21mm 37 50 55 (75) 103 (140) | 151 (205)
2 5 (19) RMS wes | 2mm | Se | sas | 1975) | 27619 |
¥16- 12 110 (149) 120 155) 155 (210) = | |
== "e | ne Mis | 27mm ву (10) | 18060) | 225005) | 2s |
58-11 150 (203) 167 (225) 210 (285) м0 | 30mm 1180160) | 15725) | mes | 457 (620)
-18 170 231) 240 (325) ¡NO | Emm 15015) | 25(05) | 425520 | 62000) |
34-10 270 (365) 280 (380) 375 (508) | |
16 205 (400) 42071569) MO | Bw ee nd | ra 7
МТ men 1 (11 (1555)
ua a ón 440 (557) es MO | 44mm 402 545) | 568 (770) | 7103 (1405) | 1571 (2130)
1-8 90 (200) BEC (ES) 310 (1234) MES | 51mm 546 (740) | 77401050) | 1500 | 2129 (2000)
-W 650 (855) 0 (1347) NOS | Smm | 700650) | 992 (1345) ET 2744 (3720)
GASKETS/SEALANTS Use LIQUID TEFLON for sealing pipe plugs and filings that connect coolant
Où based PERMATEX #2 and its HIGH TACK equivalent are excellent all passages. Do not use tape sealants!
purpose sealers. They are effective in just about any joint in contact with
BOLTS & FASTENERS/ASSEMBLIES
coclant, raw water, of or fuel
Lightly oil head bolis and ciber fasieners assemble them. Bolts and
À light coating of OIL or LIQUID TEFLON can be used on rubber gaskets caos fal penstale the water jacket should be sealed with PERMATEN 22.
and O-rings. HIGH TACK.
+ ls да on od adapter hoses and the oil When assembiing the flywheel, coat the bolt threads with LOCTITE blue
Anti-seire compounds and thread locking adhesives such as LOCTITE protect
threaded components yet allows them to came apart when necessary
LOCTITE offers levels of locking according to the job.
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer
When installing gaskets that seal around water (coolent) passages, Cost both
sides with WHITE SILICONE grease. LITHIUM based grease is waterproci, ideal for water pump bearings and stuf
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position Gur- ing bes.
ing essembiy. Heavity où all sïiding and recprocaing components when assembling. Always
Specialized gasiet seslers such as HYLOMAR work wel in apolicafions requi- — use clean engine oil!
ing non-herdening properties. HYLOMAR is particiariy efectve on
copper cyiinder-head gaskets as it resists fuel, O8 and water
CATWESTERBEKE
Engines & Generators
26
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
Feet (ft) x .305 = Meters (m) x 3.281 = Feet
Miles x 1.809 = Kilometers (km) x .0621 = Miles
VOLUME
Cubic Inches (in*) x 16.387 = Cubic Centimeters x .061 =in
imperial Pints (IMP pt) x -568 = Liters (L) x 1.76 = IMP pt
imperial Quarts (IMP gt) x 1.137 = Liters (L) x.88 = IMP qt
Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = ¡MP gal
Imperial Quarts (IMP gt) x 1.201 = US Quarts (US qt) x .633 = IMP qt
Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
Fluid Ounces x 29.573 = Milliiiters x .034 = Ounces
US Pints (US pt) x .473 = Liters(L) x 2.113 = Pints
US Quarts {US gt) x .946 = Liters (L) x 1.057 = Quarts
US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons
MASS-WEIGHT
Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds
Pounds Per Sg In (psi) x 6.895 = Kilopascals (kPa) x 145 = psi
inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x 2961 = Hg
Inches of Water (H:0) x 07355 = inches of Mercury x 13.783 = H:0
inches of Water (H:0) x .03613 = psi x 27.684 = H:0
inches of Water (H:0) x 248 = Kilopascals (kPa) х 4.026 = №0
TORQUE
Pounds-Force Inches (in-ib) x .113 = Newton Meters (Nm) x 8.83 =in-ib
Pounds-Force Feet (ft-Ib} x 1.356 = Newton Meters (Nm) x 738 = fib
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
POWER
Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (KmJL)
Kilometers Per Liter (Km/L) x 2.352 = US MPG
TEMPERATURE
Degree Fahrenheit (°F) = (°C X 1.8) + 32
Degree Celsius (°C) = (°F - 32) x 56
JWESTEREERS
of
SUGGESTED SPARE PARTS
CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION
WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE у Е > AS is + (INA CANVAS
ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE $
AND A GALLON OF PREMIXED COOLANT.
SPARE PARTS KITS
WESTERBEKE also offers two Spare Parts Kits, [ KIT B
each packaged in à rugged hinged toolbox.
Kit “A” includes the basic spares. DRIVE BELTS
Kit “B™ is more extensive OIL FILTER
KIT À FUEL FILTER
INJECTOR
DRIVE BELTS OVERHAUL GASKET KIT
OIL FILTER AIR FILTER
FUEL FILTER GLOW PLUG
FUEL SYSTEM HARDWARE KIT FUEL SYSTEM HARDWARE KIT
FUEL PUMP INLET FILTER FUEL PUMP INLET FILTER