Westerbeke 4.2 SBCG-50HZ, Operator'S Manual

Page 1: ...OPERATORS MANUAL MARINE GASOLINE GENERATORS 6 5 SBCG 60HZ 5 4 SBCG 50HZ 5 0 SBCG OHZ 4 2 SBCG 50HZ Single T U It r a L o w C a r b o n _M o n oxide Em is s i o fJ_ s ...

Page 2: ...ess Nausea Headache Weakness andSleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONEELSEEXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY Ifsymptoms persist seekmedicalattention Shut down the unitand do notrestart until it has been inspected andrepaired A WARNING DECAL is providedby WESTERBEKE and shouldbe fixed to abulkheadnea...

Page 3: ...Gasoline with an ETHANOL content higher than 10 o E10 is not ai O Ated and may yoid warranty TM Engines Generators ...

Page 4: ...Blank page ...

Page 5: ...al sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel lines or fuel filters Do not operate with the air cleaner silencer removed Backfire can cause severe injury or death Do not smolce or permit flames or sparks to occur near the fuel system KeeiJ the compartment and the engine clean and free of debris to minimize the chances of fire Wipe up al...

Page 6: ...lyte caps A WARNING Carbon monoxide CO is a dea dly gas E nsure 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 water injected elbow is securely attached Be sure the unit and its surr pundings are well ventilated Run blowers when running the generator set or engine Do not run the generato...

Page 7: ...and follow ai1 safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin with a thorough examination of the American Boat and Yacht Council s ABYC standards These standards are from a combination of sources lncJuding the USCG and the NFPA Sections of the ABYC standards of particular interest are H 2 VentilatioQ_for Boats using...

Page 8: ...he vessel s waterline under the vessel s various operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphon break can result in catastrophic engine damage Consult the siphon break manufacturerfor proper maintenance EXHAUST SYSTEM AVAILABLE FROM YOUR WESTERBEKE DEALER SIPHON BifEAfw iit S...

Page 9: ...ning continuously down hill Observe the usually translucent tubing between the probe and the analyzer and be sure no water is being ingested Ifany water is ingested into the analyzer it must be repaired or replaced and recalibrated When measuring CO at the exhaust outlet be aware of the ambient CO level by also measuring CO away from and upwind of the exhaust outlet especially in marinas the CO le...

Page 10: ...al 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 Federal Emissions requirements Catagory C 250 hrs B 500 hrs m A lOOO hrs EMISSIONS CONTROL INFORMATION TABLE The California emissions control wan anty statement is located in the same Emissions Warranty Information p...

Page 11: ...Bectronic Fuel Injector EFI 16 Engine Oil 17 Engine Oil Change Engine Oil Pressure I8 Testing Oil Pressure 18 Engine Adjustments 20 Timing Belt 20 21 22 23 Battery Care 23 Valve Clearance Adjustment 24 Injection Timing 24 Torquing the Cylinder Head Bolts 24 Spark Plugs 25 Drive Belt Adjustment 25 Starter Motor Testlng 26 27 Engine Troubleshooting Chart 28 Generator Information 29 Changing Voltage ...

Page 12: ...RATURE SWITCH EXHAUST CONNECTION FAULT SCHRADER VALVE SBCG PARTS IDENTIFICATION FRESHWATER DRAIN 2 SUMP CHARGER BUS FUSE GENERATOR BACK ENO AIR BLEED PETCOCK LEFT SIDE c JI ffi RAW WATER PUMP FUEL FILTER RIGHT SIDE ...

Page 13: ...ate available WESTERBEKE Engines Generators Customer Identification WESTERBEKE OWNER MAIN STREET____ HOMETOWN USA __________________ Model _____ Ser ________ Expires _________________ NOTES CAUTIONS AND WARNINGS As this manual takes you through the operating procedures maintenance schedules and troubleshooting Critical information will be highlightetl byNOTES CAUTIONS and WARNINGS An explanation f...

Page 14: ...e at the factory during assembly and thorough testing have resulted in a WES1ERBEKE generator capable of many thousands of hours ofdependable service However the manufacturer cannot control how or where the generator is installed in the vessel or the manner in which the unit is operated and serviced in the field This is up to the buyer owner operator NOTE Six important steps tO ensure long generat...

Page 15: ...rove the use of synthetic oils If synthetic oils are used engine break in MUST be performed using conventional oil Oil change intervals must be as listed in the MAINTENANCE SCHEDULE section in this manual and not to be extended if synthetic oils are tised NOTE The information above supercedes all previous statements regarding synthetic oil usage ENGINE COOLANT WESTERBEKE recommends a mixture of 50...

Page 16: ... not as coolant loss will occur AIR BLEED PETCOCK MAX FULL MANIFOLD PRESSURE CAP THERMOSTAT HOUSING RAW WATER DRAIN Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check threaded connections Search for any gasoline leaks Check load leads for correct connections as specified in the wiring diagrams Examine the air inlet and outlet for air flow obstru...

Page 17: ...cally terminate if the unit fails to start after 6 seconds approximately of cranking time The fault LED for Underspeed will illuminate and flash To initiate another another crank cycle the panel DC breaker must be turned OFF and then backON REMOTE START STOP PANEL The components on the panel are 1 Athree position start stop rocker switch 2 Agreen LED run indicator light on the rocker switch 3 Afou...

Page 18: ...5 times normal running amperage See GENERATOR INFORMATION in this manual CHECK LIST Follow this checklist each day before starting your generator Record the hourrneter reading in your log engine hours relate to the maintenance schedule Visually inspect the engine for fuel oil or water leaks Check the oil level dipstick Check the coolant level in the coolant recovery tank Check your fuel supply Che...

Page 19: ...e ECU will shut the engine down and will illuminate the over temp fault LED light on the control panel WATER TEMPERATURE SENSOR WIPE SURFACE CLEAN BEFORE INSTALLING Low Oil Pressure Sensor FILTER GASKET APPLY CLEAN OIL WHEN ASSEMBLING NEW FILTER A low oil pressure sensor is ocated adjacent to the lube oil filter It sends a DC voltage to the ECU that is interpreted as oil pressure Should this DC vo...

Page 20: ...ossible corrosion Clean re gap Initial engine oil and filter change at 50 hours then change both every 100 hours Initial check at 50 hours then every 250 hours or once ayear Carefully inspect for leaks Check that the exhaust hoses are properly attached and that the securing clamps are tight Check the integrity mounting security of the water injected exhaust elbow Remove clean and re install screen...

Page 21: ... for wear especially cam and wear plates Replace the impeller and gasket Lubricate the impeller when re assembling Inspect for proper operation Replace at 2000 operating hours Inspect for deterioration Test resistance Drain flush and re fill the cooling system with appropriate antifreeze mix Replace the thermostat and coolant pressure cap Adjust valves Incorrect valve clearance will result in poor...

Page 22: ...lant must be changed according to the MAINTENANCE SCHEDULE If the coolant is allowed to become contaminated it can lead to overheating problems A CAUTION Proper cooling systemmaintenance is critical asubstantialnumber ofengine failures can be tracedback to cooling systsm corrosion Drain the engine coolant by removing the drain plug and opening the manifold pressure cap Flush the system with fresh ...

Page 23: ...UT DEBRIS ZINC ANODE DO NOT USE SEALANT NOTE Operating in silty antJ or tropical waters may require that a heat exchanger cleaning be performed TfK re often then every 1000 hours ZINC ANODE A zinc anode or pencil is located in the raw water cooling circuit within the heat exchanger The purpose of the zinc anode is to sacrifice itself to electrolysis action taking place in the raw water cooling cir...

Page 24: ...th and cooling the exhaust gases This mixture ofexhaust gas and raw water is discharged overboard by the engine s exhaust gas discharge pressure RAW WATER PUMP The raw water pump is a self priming rotary pump 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 accoun...

Page 25: ...LED Periodically check the fuel connections to d out of the pump and make sure that no leakage is present and that the fittings are tight and secure The engine mounted fuel pump is maintenance free FUEL PUMP INLET FUEL FILTER 1 Shut off the fuel supply to the genemtor Disconnect the fuel supply line tothe inlet filter and unscrew the filter from the pump inlet Take care to catch any fuel that may ...

Page 26: ...e set from the fuel cell and connect it to the Schrader valve on the throttle body 5 Connect the fuel cell to the wiring harness _ 6 Open the valve on the fuel pressure gauge purge line Do not prime the system without the fuel gauge purge valve open or air can be forced back into the fuel cell If this happens repeat steps 1 2 and 3 to remove the trapped air from the fuel cell A WARNING Take care t...

Page 27: ...el pump supplies fuel to the area around the injector and the regulator maintains the fuel pressure in that area at 35 40 PSI maximum STEPPER MOJOR AND THROTTLE SHAFT ASSEMBLY FUEL REGULATOR The injector is a solenoid operated pintle valve that meters fuel o the intake manifold depending on engine operating conditions and generator amperage load as determined by the ECU Air flow into the intake ma...

Page 28: ...r when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Keep your engine clean Inspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes off with the old oil filter If this rubber sealing gasket remains sealed against the filter bracket gently remove it When installing the new oil filter ...

Page 29: ...ION HOSE MUST ATTACH TO THE IN CONNECTION AT THE REMOTE OIL FILTER INSTALLATION This popular accessory is used to relocate the engine s oil filter from the engine to a more convenient location such as an el gine room bulkhead NOTE Refer to ENGiNE OIL CHANGE in this manualfor instructions on removing the oilfilter To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil ...

Page 30: ...rger put a multimeter between the positive and negative leads to the battery It should indicate 13 0V to 13 4V with the engine running If only the battery voltage is indicated check that the battery charger terminal connections are tight With the unit running test between the and terminals for 13 0V to 13 4V If no charge is indi cated replace the charger TERMINAL TO BRIDGE RECTIFIER RED TO CIRCUIT...

Page 31: ...tum the crankshaft clockwise TIMING MARK 2 Remove the plug on the left surface of the cylinder block and insert a rod with a diameter of 8mm 0 3iin to lock the counterbalance shaft NOTE Be sure to use an inserting rod with a diameter pf 8mm 0 31 in 2 6 IN 65MM ROD CYLINDER BLOCK 3 Loosen the timing belt tensioner nut 4 Move the timing belt tensioner toward the water pump and temporarily tighten th...

Page 32: ... peeling of canvas 4 Cracks on tooth bottom 5 Cracks on belt 6 Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife 7 Abnormal wem on teeth 8 Tooth missing and canvas fiber exposed 5 6 RUBBER EXPOSED a 7 8 Te ioner Inspection 1 Reptace the tensioner if the pulley binds rattles or is noisy when turned Crankshaft Bolt Installation 1 Lock the crankshaft NOTE Do not ...

Page 33: ...CKET At this time check that the moveable range of teeth on the oil pump sprocket is according to specifications Standard value 4to 5teeth In forward direction 1to 2teeth In reverse direction OIL PUMP SPROCKET 4 If the movable range ofthe oil pump sprocket exceeds the specified range correct as follows a Pull out the round bar from the plug hole in the left side of the cylinder block b Thm the oil...

Page 34: ...ant Then tighten the plug to the specified torque Specified sealant value 3M A1D P8rt No 8660 or equivaient Tightening torque 15 22 Nm 11 16ft lbs BAnERYCARE Battery Maintenance The minimum recommended capacity ofthe battery used in the engine s 12 volt DC control circuit is 800 1000 Cold Cranking Amps CCA Review the manufacturer s recommendations and then establish a systematic maintenanCe schedu...

Page 35: ...4 Replace the rocker cover and the rocker cover gasket ROCKER COVER TORQUE 2 9 5 11b fl 0 4 0 7 kg m VALVE CLEARANCE Valve Clearance Intake 0 20mm 008 inches Exhaust 0 30mm 012 inches IGNITION TIMING 1 Attach a timing light to the 1 spark plug and mark the front timing pointer to indicate 15 Locate the timing mark on the crankshaft pulley and mark it with white chalk or a crayon 2 Start the engine...

Page 36: ...40 PSI DRIVE BELT ADJUSTMENT The drive belt must be properly tensioned Excessive drive belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pump s bearing A slack belt or the presence ofoil on the belt can cause belt slipping resulting in high operating temperatures The generator have two drive belts one drives the governor and alternator and the other drive...

Page 37: ...k and measure the return stroke called pinion gap 3 Ifthe pinion gap is not within the standard range 0 5 to 2 0 mm adjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the number of shims increases PINION GAP No Load Test 1 Connect the ammeter voltmeter and battery to the starter as illustrated 2 When the switch is closed the pinion must protrude and t...

Page 38: ... and remove the center bracket At the same time the washers for the pinion shaft end play adjustment will come off STARTER MOTOR PINION SHAFT INSPECT FOR WEAR CHIPPING 4 Return test With a battery connected to the solenoid ter minal M and to the starter body manually pull out the pinion fully The pinion must return to its original position when released from holding by hand RETURN TEST 7 Pull out ...

Page 39: ...e engine 2 Relief valve is stuck 5 Cankcase breather hose is clogged Poor Performance 1 Fuel injector not functioning properly at Qenerator speed 2 Fuel pump clogged Remove and replace 3 Throttle body filter scre en dirty Remove and clean ENGINE TROUBLESHOOTING SOFTWARE DIAGNOSTICS DIAGNOSTIC SOFTWARE KIT 055410 This Diagnostic Software Kit is designed to aide the technician in monitoring and trou...

Page 40: ...only it is recommended that the generator s AC terminal block be configured to provide one 120 volt AC hot legfor the vessel s distribution panel This will ensure good motor staning responsefrom the generator GENERATOR FREQUENCY ADJUSTMENT l e9uency is a direct result ofengine generator speed as mdicated by the following When the generator is run at 1800 RPM the AC voltage output frequency is 60 H...

Page 41: ... The DC circllit Rev Limiter must be changed 60 hertz mOdels use pn 052854 antl 50 hertz models use pn 053082 8 Open the generators AV breaker and start the engine Monitor the AC voltage and hertz NOTE No Load AC voltage output can be adjusted using the capacitor connections 7 8 or 9 One ofeither on each capacitor Change these connections only with the generator STOPPED 9 Close the AC breaker and ...

Page 42: ...or can result if utilityshore powerandgenerator output are connected at the same time This type ofgenerator damage is not coveredunder the warranty it is the installer s responsibility to makB sure allAC connections are correct 31 Q z I 0 a CI GENERATOR N L1 w U GENERATOR SHORE 5 SWITCH ID 1 L1 I I r r rl 3 2 I _ 5 i NEUTRAL 1 1 7 6 I _ SHORE GROUND SHORE POWER SHIP S LOAD SHIP S GROUND Switching ...

Page 43: ...H 91t I IJ l l l e l OIL _ ij U 8 I W __j i LL ltJ_ r R r t rLJJ NH M SflHM 0 t 0311911 OIA91t t oo o o o o o IW ololo o o o Q Q Q Q 0 Q l It 0 6 0 Q 0 QOQQQ I I Q 001 NH9 11t 13A lii 1HM 02t 9 2 Q3H Wl911HM91t J e t s_Nnll dOH HI IGlHIII 1HJ 03Ytll l c 0 rp r fp I r fp f fp 1 si 0 ...

Page 44: ...100 Pn 049669 REMOTE STOP START PANEL WIRING DIAGRAM SCHEMATIC 49209 118 ORG 118 GRN 118 WHT BLK REO 1118 WHTIBLK BLU UJ ll j 120 WHT BLKIBRN Q flq f C P W T T O S 10 YI W O FROM WIA SID 3POSITION START STOP SW STOP START ICATOR z 118 WHTIBLK REO n I 1 1 1 l t CENTER OFF ll I 2 3 t 4 5 6 7 8 9 I 120 WHTIBLK GRY _ _ 0 a _ _ o w 2 a c a _ _ 120 WHT RLK GRN l l r a J 2 w 0 o Engines Generators 33 ...

Page 45: ...m Note Forr ed ventilation should be provided to maintain generators compartment temperature below 120 F 50 C General Fresh Water Pump Raw Water Pump Raw Water Flow Cooling Water Capacity Operating Temperature COOLING SYSTEM Fresh water cooled block through raw water cooled heat exchanger circuit Centrifugal type metal impeller belt driven Positive displacement rubber impeller belt driven 4 9 US g...

Page 46: ...be provided to maintain qenet tors compartment temperature below 12o F so c 35 General Fresh Water Pump Raw Water Pump Raw Water Row Cooling Water Capacity Operating Temperature COOLING SYSTEM Fresh water cooled block through raw water cooled heat exchanger circuit Centrifugal type metal impeller belt driven Positive displacement rubber impeller belt driven 4 9 US gpm 18 51iters 1800 rpm approx me...

Page 47: ...Piston and Connecting Rod Camshaft thrust plate bolt 10 12 7 9 Connecting rod cap nut 15 90 tum 11 90 tum Rocker arm adjust nut 8 10 6 7 Crankshaft Bearing Cylinder Head Valve Oil seal case bolts 10 12 7 9 Cylinder head bolt cold engine 60 70 43 51 Bearing cap bolts 5Q 55 36 40 Spark plug 15 2 10 8 Cylinder Block Rocket cover 12 13 9 10 Taper plug 1 16 8 12 6 9 Miscellaneous Taper plug 1 8 15 22 1...

Page 48: ...Top off your fuel tanks with unleaded gasoline of 89 octane or higher Afuel conditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any spilled fuel Fuel System Diesel Top off your fuel tanks with No 2 diesel fuel Fuel additives such as BioBor and Diesel Klee...

Page 49: ... If batteries are to be left on board during the lay up period make sure they are fully charged and will remain that way to prevent them from freezing If there exists any doubt that the batteries will not remain fully charged or that they will be subjected to severe environmental conditions remove the batteries and store them in a warmer more compatible environment 38 SPARE PARTS Lay up time provi...

Page 50: ...fresh air to dilute the exhaust gas Therefore one should never rely on dilution of 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 treatment in a special catalyst CO emissions are not the same for every model because each engine is different Also c...

Page 51: ...ALSO AGALLON OF PREMIXED_ COOLANT FOR THE COOLING SYST M WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged rust free toolbox KIT A includes the basic spares KIT B is for more extensive off shore cruising Kit A Impeller Kit Heat Exchanger Gasket Oil Filter Drive Belt Zinc Anodes Spark Plugs Fuel Filters 40 Kit B Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Compl...

Page 52: ......

Page 53: ......

Page 54: ...1177 4 2015 WESTERBEKE CORPORATION 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 westerbeke com ...