Westerbeke 12.0 BTDAR 50 HERTZ, Operation And Maintenance Manual

Page 1: ...5 0 BTDAR 20 0 BEDR 25 0 BEDR 32 0 BEDR 60 HERTZ MODEL 12 0 BTDAR 16 0 BEDR 20 0 BEDR 25 0 BEDR 50 HERTZ SINGLE THREE PHASE GENERATORS Publication 039835 Edition Two May 1993 r v WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 ...

Page 2: ...ngine It covers initial service operation maintenance and troubleshooting in depth It also contains important safety information key specifications and a wiring diagram No manual can provide for every possible question or contingency Ifyou should need further assistance please contact the Westerbeke Master Distributor located nearest you for technical advice Again thank you for choosing a Westerbe...

Page 3: ...ppropriate blocks in the illustration below These will provide quick reference when ordering spares repair parts or when seeking technical information 79ELI 1 6 0 1 6 0 I I jO 220 1 I II l I i CClN r 0 0 I 6 l II 0 The engine serial number can also be found stamped into the engine block on a smooth rectangular surface above the injection pump The generator serial number is stamped into the generat...

Page 4: ...DON TS DO S DO visual inspections before starting your generator DO check your engine once a day Keep eyes open and be alert to people and obstacles 3 DON TS DON T touch any moving part on your engine during operation DON T touch hot engine parts such as exhaust manifolds Westerbeke Generators ...

Page 5: ...and a wad ofcloth in between sling and unit Westerbeke Generators 4 DON T remove radiator filler cap immediately after shutting down engme DON T smoke near the battery Never use an open flame as a light anywhere on or around the battery Battery gas is highly flammable Sulfuric acid is destructive Ifit comes in contact with your skin wash it offat once with water ...

Page 6: ...t is necessary to check the engine while running use caution and beware of moving parts and the presence of AC voltage DON T touch AC electrical connections while the unit is running Lethal voltage is present at these connections Westerbeke Generators ...

Page 7: ...TION Operating procedures practices etc which if not strictly observed will result in damage or destruction to your engine WARNING Operating procedures practices etc which if not correctly followed will result in personal injury or loss of life DEFINITION OF LOCAL TERMS The words leftside rightside front and rear are used in the senses illustrated below Front Radiator End Westerbeke Generators Rig...

Page 8: ...EL FUEL ENGINE OIL COOLING WATER OPERATING YOUR GENERATOR STARTING WARMING UP STOPPING ROUTINE SERVICE SERVICE ITEMS GENERAL RULES SAFETY RULES SERVICE SCHEDULE ENGINE OIL FILTER CYLINDER HEAD BOLTS AND VALVE ADJUSTMENTS 15 0 BTDAR 20 0 BEDR 25 0 32 0 BEDR INJECTOR SERVICING AIR FILTRATION SYSTEM FAN BELT PAGE 9 17 22 27 32 38 40 41 42 44 44 45 45 46 46 46 47 50 50 51 52 52 53 54 54 55 7 Westerbek...

Page 9: ...CHEMATIC 65 20 0 25 0 32 0 BEDR SINGLE PHASE INTERNAL WIRING SINGLE 66 BTDAR BEDR INTERNAL WIRING SCHEMATIC THREE PHASE ONLY 67 VOLTAGE REGULATOR ADJUSTMENTS 20 25 32 BEDR 68 15 BTDAR NO LOAD VOLTAGE ADJUSTMENT SINGLE PHASE ONLY 69 AC VOLTAGE CONNECTIONS ALL MODELS 70 15 BTDAR OPTIONAL VOLTAGE REGULATOR SINGLE PHASE ONLY 71 ENGINE TROUBLESHOOTING 72 TORQUE SPECIFICATIONS 77 78 Westerbeke Generator...

Page 10: ...t l t po o Ul Preheat Solenoid Breaker Emergency Shut off Switch Engine Oil Fill Speed Sensor DC Alternator Shield Circuit Breaker Box Fan Belt Guard A C Connections Outlet Exhaust Manifold 15 0 BTDAR GENERATOR RIGHT SIDE ...

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Page 12: ...ator _ Fan I Belt Guard Injection Pump Water Temperature Switch Fuel Filter Fuel Lift Pump Oil Pressure Sender Lube Oil Filter 15 0 BTDAR GENERATOR LEFT SIDE Start Stop Panel LED Lights Unit Data Tag DC Battery Ground Starter with Solenoid ...

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Page 14: ... do s o en Preheat Solenoid Emergency Stop Switch Control Panel LED Lights DC Battery Ground Connection 20 0 BEDR RIGHT SIDE Radia or Fill Cap DC Charging Alternator Lube Oil Drain Hose ...

Page 15: ...v Top Engine Oil Fill Air Intake Silencer Fuel Lift Pump Actuator Radiator Fuel Injection Pump Oil Pressure Sender 20 0 BEDR LEFT SIDE Filter Breaker Control Panel AC Connections Outlet Fresh Water Block Drain Lube Oil Filter ...

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Page 20: ...liters FIRING ORDER 1 3 4 2 DIRECTION OF ROTATION Clockwise when viewed from the front MAXIMUM TORQUE AT 1800 RPM 1171b ft 16 18 kg m COMPRESSION RATIO 21 1 COMPRESSION PRESSURE 427 psi 30 kglcm2 at 250 rpm Limit ofdifference between cylinders 47 2 psi 3 0 kglcm2 VALVE TIMING Intake Opens 17 BTDC Intake Closes 47 ABDC VALVE SEAT ANGLE VALVE CLEARANCE Engine Cold ENGINE SPEED 17 Exhaust Opens 51 BB...

Page 21: ...T FUEL CONSUMPTION INCLINATION Westerbeke Generators Height 28 50 inches 723 nun Width 24 8 inches 530 mm Length 49 6 inches 1260 nun 870 lbs 395 kgs 2 0 gph 7 571ph at full rated output approximate Continuous 150 Temporary 200 not to exceed 20 min 18 ...

Page 22: ... Water LUBRICATIONSYSTEM GENERAL OIL FILTER 19 Open flow totally self priming 1 bleed point No 2 Diesel oil cetane rating of45 or higher Bosch Model VE Distributor 0 TDC Top Dead Center Throttle type Spin on type full flow Replaceable element 70 0 dIn l 9 cmm Closed fresh water cooled block thermostatically controlled with radiator Centrifugal type metal impeller belt driven 11 5 quarts 10 88 lite...

Page 23: ... RPM 15KW 50 Hertz 1500 RPM 12KW Westerbeke Generators 12 volt 170 A H negative ground recommended 200 A H in cold areas 400 600 cold cranking amps 51 amp rated belt driven Glow plug sheathed type 12 volt 3 KW reduction type 2 ofrated Amps 250 300 amps engine cold Brushless four pole revolving field Sealed lubricated single bearing design Reconnectable single phase for 120 240 volts with solid sta...

Page 24: ...Pressure Engine Timing 21 Brushiess six pole revolving field Sealed lubricated single bearing design 12 lead reconnectable for low voltage WYE high voltage Delta Solid State voltage regulator with protection circuitry Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA 208 volts 480 volts 240 volts 380 volts 220 volts 52 1 Amp...

Page 25: ...ers FIRING ORDER 1 3 4 2 DIRECTION OF ROTATION Clockwise when viewed from the front MAXIMUM TORQUE AT 1800 RPM 1171b ft 16 18 kg m COMPRESSION RATIO 21 1 COMPRESSION PRESSURE 427 psi 30 kglcm2 at 250 rpm Limit ofdifference between cylinders 47 2 psi 3 0 kglcm2 VALVE TIMING Intake Opens 17 BTDC Intake Closes 47 ABDC VALVE SEAT ANGLE VALVE CLEARANCE Engine Cold ENGINE SPEED Westerbeke Generators Exh...

Page 26: ...UEL CONSUMPTION INCLINATION 23 Height 28 50 inches 723 9 mm Width 22 0 inches 546 1 mm Length 45 79 inches 1163 3 mm 7971bs 361 5 kgs 2 0 gph 7 571ph at full rated output approximate Continuous 15 Temporary 20 not to exceed 20 min Westerbeke Generators ...

Page 27: ...ATIONSYSTEM GENERAL OIL FILTER Westerbeke Generators Open flow totally self priming 1 bleed point No 2 Diesel oil cetane rating of45 or higher Bosch Model VB Distributor 00 TDC Top Dead Center Throttle type Spin on type full flow Replaceable element 81 0 cfin 2 29 cmm Closed fresh water cooled block thermostatically controlled with radiator 1700 1900 F 770 880 C Centrifugal type metal impeller bel...

Page 28: ...5 API SPECIFICATION OF CF OR CG 4 SAE 30 or 10W 30 15W 40 12 volt negative ground 400 600 cold cranking amps 51 amp rated belt driven Glow plug sheathed type 12 volt 3 KW reduction type 2 ofrated Amps 250 300 amps engine cold Brushless four pole revolving field Sealed lubricated single bearing design Reconnectable single phase for 1201240 volts with solid state voltage regulator 120 OR 120 240 vol...

Page 29: ...sure Engine Timing Westerbeke Generators Brushless six pole revolving field Sealed lubricated single bearing design 12 lead reconnectable for low voltage WYE high voltage Delta Solid State voltage regulator with protection circuitry Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA 208 volts 480 volts 240 volts 380 volts 220...

Page 30: ...ers FIRING ORDER 1 3 4 2 DIRECTION OF ROTATION Clockwise when viewed from the front MAXIMUM TORQUE AT 1800 RPM 1481b ft 20 46 kg m COMPRESSION RATIO 21 1 COMPRESSION PRESSURE 427 psi 30 kg cm2 at 250 rpm Limit ofdifference between cylinders 47 2 psi 3 0 kg cm2 VALVB TIMING Intake Opens 17 BTDC Intake Closes 47 ABDC Exhaust Opens 510 BBDC Exhaust Closes 13 ATDC VALVB SEAT ANGLE VALVB CLEARANCE Engi...

Page 31: ... FUEL CONSUMPTION INCLINATION Westerbeke Generators Height 28 6 inches 726 4 mm Width 23 3 inches 591 8 mm Length 49 9 inches 1140 5 mm 752 Ibs 345 kgs 2 9 gph 10 9Iph at full rated output approximate Continuous 15 Temporary 20 not to exceed 20 min 28 ...

Page 32: ... Water LUBRICATIONSYSTEM GENERAL OIL FILTER 29 Open flow self priming 1 bleed point No 2 Diesel oil cetane rating of45 or higher Bosch Model VB Distributor 0 TDC Top Dead Center Throttle type Spin on type full flow Metal screen type clean able 94 6 cfin 2 7 cmm Closed fresh water cooled block thermostatically controlled with radiator Centrifugal type metal impeller belt driven 11 5 quarts 10 88 li...

Page 33: ...20 0 KW Westerbeke Generators API SPECIFICATION OF CF OR CG 4 SAE 30W or 10W 30 lSW 40 12 volt negative ground 400 600 cold cranking amps 51 Amp rated belt driven Glow plug sheathed type 12 volt reduction type 2 ofrated Amps 250 300 amps engine cold Brushless four pole revolving field Pre lubricated single bearing design Reconnectable single phase for 120 240 volts with solid state voltage regulat...

Page 34: ...age WYE and for DELTA Solid state voltage regulation with protection circuitry Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA 208 volts 480 volts 240 volts 380 volts 220 volts 86 6 amps 37 6 amps 75 2 amps 38 0 amps 65 5 amps 1 0 Power Factor 450 din 12 74 cmm NOTE Increase air supply 15 for 50 hertz operation 1500 rpm TU...

Page 35: ...s FIRING ORDER 1 5 3 6 4 2 DIRECTION OF ROTATION Clockwise when viewed from the front MAXIMUM TORQUE AT 1800 RPM 1951b ft 26 97 kg m CO MJ RESSION RATIO 21 1 CO MJ RESSION PRESSURE 427 psi 30 kg cm2 at 250 rpm Limit ofdifference between cylinders 47 2 psi 3 0 kg cm2 VALVE TIMING Intake Opens 14 BIDC Intake Closes 44 ABDC Exhaust Opens 48 BBDC Exhaust Closes 10 AIDC VALVE SEAT ANGLE Intake 45 Exhau...

Page 36: ...EL CONSUMPTION INCLINATION 33 Height 31 0 inches 787 4 nun Width 25 2 inches 640 3 nun Length 57 5 inches 1460 5 nun 1250 Ibs 567 kgs 3 1 gph 11 73 Iph at full rated output approximate Continuous 15 Temporary 20 not to exceed 20 min Westerbeke Generators ...

Page 37: ...low selfpriming 1 bleed point No 2 Diesel oil cetane rating of45 or higher Bosch Model VE Distributor 0 TDC Top Dead Center Throttle type Spin on type full flow Metal screen type clean able 128 0 cfin 3 7 cmm Closed fresh water cooled block thermostatically controlled with radiator Centrifugal type metal impeller belt driven 18 5 quarts 17 5 liters approximately GENERAL Pressure fed system OIL FIL...

Page 38: ...E 30W or 10W 30 15W 40 12 volt negative ground 900 1000 COLD CRANKING AMPS 51 Amp rated belt driven Glow plug sheathed type 12 volt reduction type 2 ofrated Amps 350 400 AMPS ENGINE COLD Brushiess four pole revolving field Pre lubricated single bearing design Reconnectable single phase for 1201240 volts with solid state voltage regulation 120 OR 120 240 volts 60 Hertz 220 volts 50 Hertz Voltage re...

Page 39: ...age WYE and for DELTA Solid state voltage regulation with protection circuitry Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA Low voltage WYE High voltage WYE DELTA High voltage WYE DELTA 208 volts 480 volts 240 volts 380 volts 220 volts 111 0 amps 48 1 amps 96 2 amps 47 5 amps 82 0 amps 1 0 Power Factor 480 din 13 59 cmm NOTE Increase air supply 15 for 50 hertz operation 1500 rpm T...

Page 40: ...YOUR NOTES 37 Westerbeke Generators ...

Page 41: ...rgizes the engine s glow plugs activates the electric fuel pump bypasses the engine s oil pressure switch and activates the fuel run solenoid This switch also feeds power to the START switch 2 START The START switch when pressed energizes the starter s solenoids which cranks the engine This switch will not operate electrically unless the PREHEAT switch is pressed and held at the same time 3 STOP P...

Page 42: ...ofengine coolant During operation it should be indicating 175 F 195 F 80 91 C 39 ENGINE OIL PRESSURE 0 0 0 e 0 Indicates the pressure of lube oil The needle should indicate 40 50 PSI 2 8 3 5 kg cm HOUR METER o o The hour meter registers elapsed time and should be used as a guide for scheduled maintenance Westerbeke Generators ...

Page 43: ... any sign ofdamage Lubrication System Check oil level in oil pan Check for leaks Cooling System Check coolant level in radiator Vent air out of system Westerbeke Generators Electrical System DC Check battery electrolyte level Check connections for tightness and instruments for operation 40 Fuel System Check fuel level in tank Check piping for leaks Prime fuel system ...

Page 44: ...System Is coolant up to level in radiator filler Do not remove filler cap when engine is hot Others Are electrical connections OK Are you sure there are no oil or water leaks Are bolts and nuts tight Engine Oil Battery Are cables tight on terminal posts Is there enough fuel for the day s operation Is the oil level up to the FULL mark on the dipstick 41 Westerbeke Generators ...

Page 45: ...n and pure the following practice is advisable Purchase a well known brand of fuel Install and regularly service a good visual type filter water separator between the fuel tank and the generator drive engine Raycor 220 or 225 is a good example ofsuch a filter ENGINE LUBRICATING OIL Use a heavy duty engine oil with API classification ofCC or better Change the engine oil after an initial 50 hours of...

Page 46: ... be deterimental to the aluminum engine and cooling system components An antifreeze mixture will aid in cooling and protect against unexpected freeze Antifreeze mixtures are beneficial to the engine s cooling system in that they retard rust and scale formation and are beneficial to the service life ofthe freshwater circulating pump seal ANTIFREEZE PROTECTION CHART Antifreeze Concentration 13 23 30...

Page 47: ... Approx 10 seconds Approx 20 seconds Approx 30 seconds One minute While still depressing the PREHEAT switch depress the START switch This will engage the start solenoid Panel power and the fuel solenoid will be activated Upon engine firing 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...

Page 48: ...gine generator are operating without any abnormal noise or vibration STOPPING Remove the AC electrical load from the generator and allow the generator to run for 3 to 5 minutes to stabilize its operating temperatures Depress the STOP switch and hold it until the generator is completely stopped Now release the STOP switch 45 Apply a light amperage load to the generator and allow the engine operatin...

Page 49: ...hen a load is applied Note DO NOT operate the generator unit for lengthy periods oftime without a load being placed on the generator 5 Loading Apply loads systematically not all 4t once Allow the unit to adjust to each load before applying the next bad 6 Stopping Remove major loads f nr the gene or one at a time Allow the unit to run loaded for approximate R mi 1utes to stabilize engine temperatur...

Page 50: ... needed Check electrolyte level and make sure cables have tight clean connections FIRST 50 OPERATING HOURS 1 Lube Oil 2 Lube oil filter 3 Generator 4 Fuel filter element 5 Engine no load speed 6 Fan Belt 7 Air cleaner 47 Initial lube oil change should be performed Initial oil filter change should be performed Check that AC connections are clean and secure Check that AC leads are not chaffing Initi...

Page 51: ...ctric fuel pump if applicable and in engine mounted cartridge filter Clean any obstructions from radiator fins Check radiator hoses and tighten clamps EVERY 500 OPERATING HOURS 1 Cylinder Head Maintenance Retorque cylinder head and rocker shaft hold down bolts and adjust valve clearances 2 Cooling System 3 Starter Motor 4 Preheat circuit Westerbeke Generators Check antifreeze water mixture Add ant...

Page 52: ...injectors as needed Check engine compression pressure Check DC charge from alternator Check pulley mounting and attachment of alternator to engine Check security and tightness of nuts bolts and wire connections EVERY 1000 OPERATING HOURS 49 Remove radiator have professionally cleaned and pressure tested Repair or replace as needed Replace coolant mixture if needed Westerbeke Generators ...

Page 53: ...lled oil to be collected cleanly without spilling oil on the engine Oil or any other fluid on the engine reduces the engine s cooling ability Please keep your generator s engine clean o Receiver OIL PRESSURE SWITCH The replaceable cartridge type oil filter requires no cleaning inside OlL P ESSu E SENDER When installing the oil filter element apply a thin coat of clean engine oil to OIL DIU H SYSTE...

Page 54: ...ty ofoil with the dipstick Fill to but not over the high mark on the dipstick ifthe engine requires additional oil 4 Torquing Cylinderhead Bolts UPPER LIMIT HoNHnL L un LOWER LIMIT Tighten the cylinder head bolts according to the sequence shown in the illustration below Make sure the engine is cold when this is done and loosen one head bolt one halfturn and then tighten it between 85 to 90 Ib ft 1...

Page 55: ...3 and 6 valves see the illustration to the right Position the No 4 piston at TDC ofits compression stroke and adjust the 4 5 7 and 8 valves The valves are numbered 1 to 8 from the front ofthe engine to the back 6 Torquing Cylinderhead Bolts 32 BEDR Tighten the cylinder head bolts according to the sequence shown in the illustration Make sure the engine is cold when this is done Loosen one bolt at a...

Page 56: ...alve clearance Intake Valve Cylinder 1 2 and 4 Exhaust Valve Cylinder 1 3 and 5 Position the No 6 piston at the TOP DEAD CENTER TDC on its compression stroke and adjust the valve clearance Intake Valve Cylinder 3 5 and 6 Exhaust Valve Cylinder 2 4 and 6 Valve Clearance 15 BTDAR 20 BEDR 25 BEDR and 32 BEDR Adjust all valves to 012 inches 0 3 mm with the engine cold r I I J L J I I I I II 0 012 II O...

Page 57: ...50 RPM Standard 427 psi 30 kg cm2 Minimum 384 psi 27 kg cm2 Maximum difference between cylinders 42 7 psi 3 0 kg cm2 9 Air Cleaner Element r C1 1 I I POOR H ft i jJj GOOD Various air filtration systems may be incorporated with your generator depending on the application Proper servicing is imperative Check the air filtration system frequently NOTE DO NOT OPERATE THE UNIT WITHOUT THE AIR CLEANER EL...

Page 58: ...olant recovery tank Open the engine block drain petcock located behind the lube oil filter When the system is drained flush with clean water Once flushed and drained close the two petcocks securely Fill the radiator with a 50 50 mixture of clean water and antifreeze NOTE Mix before adding Start the engine and observe the coolant mixture in the radiator Add coolant as air is expelled Observe engine...

Page 59: ...ear 3 Actuator Mounted at the front ofthe engine and attached with linkage to the throttle arm ofthe injection pump Controller Adjustments Typical Wiring e Diagram all units ID t o 1 Speed This adjustment is used to raise or lower engine speed to the desired hertz COlo code on 11 0111 01 Onlrtlue g m t J i t 2 Gain This adjustment affects the reaction time ofthe actuator to the generator engine lo...

Page 60: ...ve 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 drive disc to the generator shaft must be hardened steel SAE grade 8 identified by 6 radial marks one at each ofthe 6 comers ofthe head ...

Page 61: ...UGS __________ r _ ______ __________ r 1 EMERGENCY STOP t _JSWITCH I I ____ J START SWITCH j I ____ oJ i i PREHEAT L _ SWITCH K L __ ____________ 87 STOP SWITCH _ J O P SW r IOAI 1 C aL _J W T SW ALTERNATOR SPEED ACTUATOR SPEED SENSOR FUEL SOL K ________ ____________ ________ __ 8 5 8 __ o P SNDR Westerbeke Generators W T SNDR 58 ...

Page 62: ...f r I U L EL SOLENOID r eve WATER TEMP SE R GLOWP UGS n u Jll D II ftl Lk oJ L rostED rOREC o I II 9W f I I 1M t 4O y J III I 140Aw 59 I II IO T OIL PRESSURE SW I U 7 OIL PRESS G RNQ9 C Ro STANDARD INSTRUMENT PANEL Westerbeke Generators i ...

Page 63: ...TO TB I I ____ 0 GREEN I TO TBI GND STOP SWITCH i I 10 BLACK i I A PURPLE r TO TB2 2 START SWITCH PREljEAT SWITCH 55 A SURGE 15 A START _____________ i _3__ A_ ______________R_Ep__ RED REO i RED n mg t l 3 A RUN WHITE L ______________________________________________________________________ ________________________ _ ______________________________________________________________J P N 2490 Westerbek...

Page 64: ...R 12 VDC SENSOR ACTUATOR ELECTRONIC GOVERNOR CIRCUIT TERMINAL BLOCK MOUNTED INSIDE UNIT CONTROL PANEL DC RED RED DC BLACK BLACK BLACK WIRE BLACK WHI or TE RED WHITE PURPLE I PURPLE PURPLE PURPLE 61 Westerbeke Generators n 0 z i J 0 r r rl J ...

Page 65: ...THIS PAGE LEFT BLANK INTENTIONALLY Westerbeke Generators 62 ...

Page 66: ...led Cooling Air Requirements 15 KW 20 KW 25 KW 450 500 CFM 32 KW 525 550 CFM Ambient Temp Max Insulation Number ofPoles Stator Leads 3 Phase 1 Phase Class F 4 or 6 6 or 12 3 or 4 Voltage and KW are 5 6 ofrating at 1800 RPM At 1500 RPM any given generator will provide a voltage and KW rating equal to 5 6 the rating at 1800 RPM Consult manufacturer if a higher voltage of KW rating is needed at 50 HZ...

Page 67: ...THIS PAGE IS LEFT BLANK INTENTIONALLY Westerbeke Generators 64 ...

Page 68: ...elector in COMP position C MAIN STATOR 1 Main Stator Windings 2 Main Stator Windings 3 Main Stator Auxiliary Windings F SELECTOR SWITCH F Switch in Compound Position F 2 Switch in Electronic and Compound Position 65 81aclc WhJ t A V R PLUG B EXCITER ROTOR T I Sw e l t Y ll_ 1I laU T S lecl S Uca 1 Auxiliary Windings A B C 2 Diodes 6 J 3 Rotating Field Windings 4 Pozi Resistor D COMPOUND TRANSFORME...

Page 69: ...SCHEMATIC SINGLE PHASE r N M r 0 0 l cc l I L ___ N N N x 1 I r I 1 I I I g I I I UJ I 1 0 I c u I I 1 CIl I I WI I J 9 l ole M IA c 0 1 z UJ c J J r L Q I __ 1 I l C W 0 c UJ 0 I 0 I U X I V J c J I 1 o J I 1 0 1 I UI I I I xo L c I I _ _ _ _ _ _ _ _ _ _ _ J J I I I I Westerbeke Generators 66 ...

Page 70: ...2 0 BEDR GENERATOR INTERNAL WIRING SCHEMATIC THREE PHASE ONLY r cz o I ex I I 0 1 l __ _ I t _ J 03 NO CD CD NV lIns r I I I Cl I 1 L J 1 I I I I Cl I I 0 _ I g I 0 Cl I l o UJ cr 0 r L _1 ___ 1 I l I 0 II 0 0 l e I I 0 UJ I u x UJ 1 I I I I I I I I I L ___ _2 _____ II J lj 4j 4 IY I I I r 1010113 1 l _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J 67 Westerbeke Generators ...

Page 71: ...he illumination ofa colored LED 1 Delayed overload protection yellow LED 2 Low speed protection red LED Each system has an intervention threshold which can be adjusted using a potentiometer Each ofthe two circuits reduces excitor voltage to safeguard the excitor windings and prevent overheating The overload protection system has a delay which permits temporary overloading ofthe generator during ti...

Page 72: ...ad to excite the transformer The voltage produced by the generator after this momentary load is removed is no load voltage If this voltage does not fall within the specified range shut down the engine and adjust the voltage 3 To raise or lower the voltage shims ofvarying thickeness nonconductive material are placed or removed from under the steel laminated bar on top ofthe compound transformer The...

Page 73: ...EE PHASE 12 WIRE PARALLEL WYE STAR 12 10 11 9 CT O L1 8 6 7 5 J I L2 4 2 3 CL D L3 L _____________ N L l 208 VAC 3 60HZ L 120 VAC 1 J 60HZ L l 190 VAC 3 50HZ L 110 VAC 1 1 50HZ SERIES WYE STAR 12 10 11 A a D 8 6 7 5 a o 4 2 3 1 l a D 0 I L L 460 VAC 3 60HZ L 265 VAC 1 J 60HZ L L 380 VAC 3 50HZ L N 220 VAC 950HZ SERIES DELTA 9 Ll L2 Q L3 N L l 240VAC 3 60 HZ L2 l3 120VAC 1 J 60 HZ L L 220 VAC 3 50H...

Page 74: ... to mount the regulator board 2 Connect the 6 prong generator plug to the receptacle on the regulator board NOTE The plug is keyed to engage the regulator receptacle in one direction Check this and insert it correctly 3 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 b...

Page 75: ...fthe standard instrument panel depending upon the model PROBLEM PREHEAT switch is depressed no panel indications fuel solenoid electric fuel pump and preheat solenoid not energized START switch is depressed no starter engagement Westerbeke Generators PROBABLE CAUSE Battery switch not on 20 Amp circuit breaker tripped Connection to solenoid faulty Faulty START switch Faulty solenoid Loose battery c...

Page 76: ...on injection pump and connection Check that 12 Volts are present on the injection pump Remove solenoid from the pump and test separately 1 Check for fuel to generator engine 2 Check for air in fuel system Allow system to self bleed 3 Fuel lift pump faulty Check for 12VDC at pump Check ground connection 4 Filters clogged Replace filters and allow system to self bleed by depressing only the PREHEAT ...

Page 77: ... wiring 74 VERIFICATIONI REMEDY Check oil level check fresh water coolant Check gauge reading for indication of cause Check for satisfactory operation with switch bypassed Check with ohmmeter Check for satisfactory operation with switch bypassed Check with an ohmmeter Check for high DC amperage draw during operation Ensure switch is not overly sensitive to heat which would cause tripping Check ope...

Page 78: ...with voltmeter Ensure 12 Volts are present at EXC terminal Observe ifgauges and panel lights are activated when engine is not running Test the oil pressure switch Check wiring Insert sensitive 0 25 Amp meter in battery lines Do not start engine Remove connections and replace after short is located Check all wires for temperature rise to locate fault Disconnect alternator at output after a good bat...

Page 79: ...Generators PROBABLE CAUSE Fuel starvation DC Circuit Fault 76 VERIFICATION REMEDY Check fuel filter for contamination Check operation offuel pump Check fuel tank vent is clear Check for DC feed through DC charging regulator Disconnect exc led Then depress stop switch Check for faulty stop switch ...

Page 80: ... Bolts 6 9 6 9 6 9 6 9 Oil Pump Pipe 6 9 6 9 6 9 6 9 Fresh Water Pump Bolts 12 17 12 17 12 17 12 17 Crankshaft Pulley Nut 145 181 253 289 253 289 282 304 Glow Plug 7 11 7 11 7 11 7 11 Injector to Head Injection Nozzle to Body 58 72 29 36 58 72 29 36 Injection Pipe Flare Nut 18 22 18 22 18 22 18 22 Intake Manifold Nuts 12 17 12 17 12 17 18 22 Exhaust Manifold Nuts 12 17 12 17 20 24 20 24 Back Plate...

Page 81: ... 21 7 32 5 3 0 4 5 10 nun bolt head nut 1 5 19 5 30 4 2 7 4 2 12 nun bolt head nut 1 25 ISO 36 2 57 9 5 0 8 0 12 nun bolt head nut 1 5 36 2 50 6 5 0 7 0 12 nun bolt head nut 1 75 34 7 49 2 4 8 6 S Grade T 8T and 8 8 6nun bolt head nut 1 5 8 8 7 0 8 1 2 Snun bolt head nut 1 25 14 5 21 7 2 0 3 0 10 nun bolt head nut 1 25 2S 9 39 8 4 0 5 5 10 nun bolt head nut 1 5 26 8 37 6 3 7 5 2 12 nun bolt head n...

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