Westerbeke 20.0KW sbeg, Operator'S Manual

Page 1: ...ERATORS MANUAL 20 0KW SBEG and SBEGA 60HZ 22 5KW SBEG and SBEGA 60HZ MARINE GASOLINE GENERATORS Single and Three Phase PUBLICATION NO 049800 THIRD EDITION MARCH 2008 Ultra Low Carbon Monoxide Emission...

Page 2: ...MEDIATELY Ifsymptomspersist seekmedicalattention Shut down the unitand do not restart untilit has been inspected andrepaired A WARNING DECAL is providedby WESTERBEKE andshouldbe fixed to a bulkheadnea...

Page 3: ...rburetor or fuel filters Do not operate with the air cleaner silencer removed Backfire can cause severe injury or death Do not smoke or permit flames or sparks to occur near the fuel system Keep the c...

Page 4: ...bow and exhaust pipe nipple Be sure the unit and its surroundings are well ventilated In addition to routine inspection of the exhaust system install a carbon monoxide detector Consult your boat build...

Page 5: ...erest are H 2 Ventilation H 24 Gasoline Fuel Systems P l Exhaust Systems P 4 Inboard Engines E 9 DC Electrical Systems All installations must comply with the Federal Code of Regulations FCR ABYC NFPA...

Page 6: ...the exhaust to provide a margin of safety Westerbeke Safe CO generators achieve an approximate 99 reduction of typical CO by precise control control of the engine s air fuel ration coupled with after...

Page 7: ...ously down hill Observe the usually trdIlslucent tubing between the probe and the analyzer and be sure no water is being ingested If any water is ingested into the analyzer it must be repaired or repl...

Page 8: ...ntrol Federal Emissions Compliance Period The Federal Emissions Compliance Period referred to on the nameplate indicates the number of operating hours for which the engine has been shown to meet Feder...

Page 9: ...l EMISSION RELATED INSTALLATION INSTRUCTIONS AVAILABLE FROM YOUR WESTERBEKE DEALER Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates fede...

Page 10: ...18 Remote Oil filter Optional 19 Timing Belt Inspection lnstallation 20 21 Engine Adjustments 22 Spark Plugs 22 Drive Belt Adjustment 22 Engine Compression Test 23 Valy Cl ce Adjustment 24 IgnItIOn t...

Page 11: ...L PANEL GEIIERATOR 8ACKENO HOUR METER fAULT lEO LIGHTS RAll lEFT SIDE OIL SUMP AIR BLEED PETCOCK SYPHON BREAK CONNECTION RAIL COIIJBALLAST REGISTER COOLANT FILL MANIFOLD PRESSURE CAP Oil Fill CAP I RI...

Page 12: ...fifth numbers represent the month of manufacturer PRODUCT SOFTWARE Product software tech data parts lists manuals brochures and catalogs provided from sources other than WESTERBEKE are not within WES...

Page 13: ...e highlighted by NOTES CAUTIONS and WARNINGS An explanation follows NOTE An operating procedure essential to note A CAUTION Procedures which ifnotstrictly observed can result in the damage or destruct...

Page 14: ...rand contains its own additives additives ofdifferent brands couldreact in the mixture toproduce properties harmful toyour engine ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50...

Page 15: ...the purged air Before subsequent operation ofthe generator the engine s manifold should be topped offand the coolant recovery tank s level brought to 114 full MANIFOLD PRESSURE CAP OIL DIPSTICK AIR B...

Page 16: ...the fuel system or changing the fuel filter air can accumulate in the fuel line or the throttle body and prevent starting The Schrader valves on the throttle body and the fuel cell are used to remove...

Page 17: ...eter reading in your log engine hours relate to the maintenance schedule Visually inspect the generator for fuel oil or water leaks Check the oil level dipstick Check the coolant level in the coolant...

Page 18: ...Pressure Sensor An oil pressure sensor is located off the engines oil gallery Oil pressure on the sensor affects the DC voltage through the sensor to the ECU Should the voltage reach a preset value t...

Page 19: ...Filter Inlet fuel Filter CAUTION When servicing or replacing DC components tum offthe 20 amp DC circuit breaker 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1010 0 DID 0 0 0 0 0 J 0 0 0 0 0 0 0 0 0 0 0 10 0 0 0 0 0...

Page 20: ...ricate the starter motor pinion drive Check ignition timing Check condition of distributor cap and rotor Incorrect valve clearance will result in poor engine performance check compression pressure and...

Page 21: ...e external portion of the cooling system Coolant Recovery Tank The coolant recovery tank allows for engine coolant expansion and contraction during engine operation without the introduction of air int...

Page 22: ...oss from possibly tearing offthe exchanger shell After removing the zinc note the condition of it If the zinc is in poor condition there are probably a lot of zinc flakes within the exchanger Remove t...

Page 23: ...p with a non ferrous housing and a Neoprene impeller The impeller has flexible blades which wipe against a curved cam plate within the impeller housing producing the pumping action On no account shoul...

Page 24: ...he MAINTENANCE SCHEDULE OWNER INSTALLED FUEL WATER SEPERATOR WESTERBEKE PART 49602 ELEMENT O RING Changing Filter Element 1 Shut off the fuel supply 2 Ensure there is no pressure in the fuel system by...

Page 25: ...e at the throttle 4 Open the valve on the fuel pressure gauge line Do not prime system without the fuel gauge purge valve open or air can be forced back into fuel cell If this happens repeat steps 1 2...

Page 26: ...ttle opening position A high pressure fuel pump supplies fuel to the area around the injector and regulator maintains the fuel pressure in that area at 35 40 PSI COOLANT RETURN FUEL PRESSURE REGULATOR...

Page 27: ...contact Clean skin andnails thoroughly usingsoap and water Launder or discard clothing orrags containing used oil Discard used oilproperly REPLACING THE OIL FILTER When removing the used oil filter yo...

Page 28: ...the engine set the engine speed at 1800 rpm and read the oil pressure gauge Oil Pressure Between 55 and 16 psi at 1800 rpm Note A newly started cold engine may have an oil pressure up to 70 or 80 psi...

Page 29: ...UT MARKINGS ON THE ADAPTER WHEN THE HOSES ARE REMOVED FOR INSTALLATIONS SO THEY WILL BE RECONNECTED CORRECTLY To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filte...

Page 30: ...NSPECTION 1 Replace the timing belt if there is any oil grease or moisture on it 2 Check for damage wear peeling cracks and hardening Replace if necessary Check the timing belt tensioner and idler pul...

Page 31: ...e timing belt on the crankshaft pulley and the camshaft pulley from the tension side the right side as viewed from the front of the engine so that tension is retained 6 Loosen the tensioner lock bolt...

Page 32: ...ring A slack belt or the presence of oil on the belt can cause belt slipping resulting in high operating temperatures The 22 5Kw and 20Kw SBEG generators have two drive belts one drives the governor a...

Page 33: ...ADAPTER COMPRESSION GAUGE TYPICAL rt jj I 6 Measure the compression pressure for all the cylinders Ensure that compression pressure differential for each cylinder is within the specified unit Compres...

Page 34: ...timing groove and the timing mark on the scale embossed on the engine s front cover timing mark rl4 J m li TIMING GROOVE CRANKSHAFT PUllEY 2 Start the engine and warm the engine to its normal operatin...

Page 35: ...r ampmeter is not installed to monitor voltage and load check it with a pOltable meter and amp probe NOTE When the area in which the generatO r is installed contains AC equipment O f120 volts only it...

Page 36: ...the main stator and is in turn supplied to a voltage regulator The regulator produces a DC voltage to further excite the exciter stator windings enabling the generator to produce a rated AC output The...

Page 37: ...Volt 0 0 FUSE REO U1 V1 GREEN RED BLUE YELLOW THREE PHASE EXCITER I I I I 6 WIRE RECONNECTABLE 1 1 I STATOR I _ rn K T __ Bl K______ V2 ULft I I VI I I I I I I I I ROTOR I I I I V2 _ IG iiiRE EiENr t...

Page 38: ...ite with a green strip It connects between the neutral stud and the generator frame BE SINtiLE PHASE 120 240V 60HZ 120V 60HZ AVR AVR AVR AVR z r ___ a J Ci o 0 Xl L1 L2 N N Generator Frequency Frequen...

Page 39: ...copper wire sizedfor the average ratingfrom the hot lead connection L1 0 L1 2 3 1 3 L2 0 L2 0 5 6 7 5 7 6 8 L3 0 N L3 N 9 10 11 9 11 10 12 0 24 8 12 SERIES YII PARALLEL Y 480V 60 Hz 208V 60 Hz N L1 L...

Page 40: ...quires the installation ofajumper on the regulator board between terminal B and 10 170 270 V 180 160 V BLK AVR CASE GND BlK AVR CASE GND N GND U1 V1 L1 L2 L3 H i N GND Ul V1 L1 l2 l3 GRN GND BE THREE...

Page 41: ...1 Faulty voltage regulator UNSTABLE VOLTAGE OUTPUT 1 STB pod on regulator needs adjustment AC VOLTAGE DROP UNDER LOAD 60 100 VOLTS AC 1 Diode s on exciter rotor breaking down when load is applied indu...

Page 42: ...Hertz Jlinp E Slab Volt i5 n VOLTAGE REGULATOR DIAGRAM Stability This potentiometer permits variation of the regulator s response to generator load changes so as to limit overcompensation and obtain...

Page 43: ...generatordamage is not coveredunder the wa anty it is the installer s responsi bility to make sure allAC connections are co ect 120 VOLT 60 HZ THREE WIRE CONFIGURATION Notice the repositioning of the...

Page 44: ...20KW and 22 5KW SBEG GENERATOR WIRING DIAGRAM 49232 34...

Page 45: ...i j j a I i i L 20KW AND 22 5KW SBEGA GENERATOR WIRING DIAGRAM 53467 i i i i f l i u 3 I 0 1 ttlt Hi a l l 1rn Engines Generators 3 34A I I...

Page 46: ...BLK BLU 20 WHT BLK BRN 2 0 WHT BLK YEL 20 WHT BLK GRY 20 WHT BLK GRN PART NO 491 47 VIEWED FROM WIRE SIDE 18 WHT BLK RED AVAILABLE FROM YOUR WESTERBEKE DEALER WIRING HARNESS EXTENSIONS 15 fT PART NO 4...

Page 47: ...restricted 9 Exhaust restricted 10 Air in fuel system NOTE The engines control system electrical system is protected by a 8 Ampere manualfuse located on the control panel The generator has an AC circ...

Page 48: ...d 4 Piston rings are worn or unseated 5 Cankcase breather hose is clogged 3 Faulty DC alternator Poor Performance 1 Fuel pump clogged Remove and 4 Slipping alternator drive belt 5 Broken alternator dr...

Page 49: ...Test for B 12v at crank relay K1 terminal 86 If OK ItOK Test for B 12v at crank relay K1 terminal 85 Activate the start switch and after afew seconds the voltage should drop below 5 volts If OK Activ...

Page 50: ...lay NOTE For other possible causes failure to start such asfUel pump speed sensor MPU ignition etc refer to the these sections in this manual Engine starts runs but shuts down Test for voltage across...

Page 51: ...ditioner such as Sta Bil ga loline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any s...

Page 52: ...pling and the output flange with an anti corrosion coating Check that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Lay up time provides a good...

Page 53: ...n EXHAUST EMISSIONS SYSTEMS EmiSSion Control Systems EPA litle 40 part 1048 CARB Title 13 chapter 9 article 4 5 IGNITION SYSTEM General Battery ignition 12V negative ground Distributor with ignition m...

Page 54: ...100 cfm 2 83 cmm AC GENERATOR SINGLE PHASE General Single Phase Voltage Single Phase Voltage Regulation Frequency Regulation Rating Volts AC 2OKW 60 Hz 22 5KW 60 Hz Brushless six pole revolving field...

Page 55: ...Pulley 12 17 1 6 2 4 MB 10 7 15 4 1 6 2 3 Coolant Temperature Sendor 9 13 1 2 1 8 Rear Cover Assembly 5 3 8 0 8 0 12 0 Coolant Temperature Switch 9 13 1 2 1 8 Rocker Shaft Assembly 12 0 18 1 1 8 2 7...

Page 56: ...Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq 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...

Page 57: ...6168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 i 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER...

Page 58: ...OIL CHANGE 5 DTS AND A GALLON OF PREMIXED COOLANT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for mo...

Page 59: ...1204 w WESTERBEKE GENERATORS SAFE CO SERIES WESTERBEKE CORPORA TION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A TEL 508 823 7677 FAX 508 884 9688 Website www weste...