Westerbeke 5.7 KW BTD 50 Hz, Operator'S Manual

Page 1: ...E WESTERBEKE 7 6 KW BTD 60 Hertz 5 7 KW BTD 50 Hertz MARINE DIESEL GENERATOR SET Publication 040457 Edition One April 1994 WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A ...

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Page 3: ...ted mats whenever working on electrical equipment Make sure your clothing is dry not damp particularly shoes and keep your skin surfaces dry when handling electrical equipment Remove wristwatch and jewelry when working on electrical equipment Do not connect utility shore power to vessel s AC circuits except through a ship ta shore double throw transfer switch Damage to vessel s AC generator may re...

Page 4: ...low an open flame near the battery being serviced Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing Avoid Moving Parts Do not service the unit while it is running If a situation arises in which it is absolutely necessary to make operating adjustments use extreme care to avoid moving parts and hot exhaust system components Do not wear loose clothing or ...

Page 5: ...facturers with their own software and Westerbeke must depend on such software for the design of Westerbeke s own product software Such software may be outdated and no longer accurate Routine changes made by Westerbeke s suppliers of which Westerbeke rarely bas notice in advance are frequently not reflected in the supplier s software until after such changes take place Westerbeke customers should a...

Page 6: ... checks system descriptions and minor adjustment procedures are included herein so you can operate your equipment safely and properly maintain the equipment at a high level of efficiency and ex pecl dependable performance and long service life in return Should your unit require special attention contact your Westerbeke dealer for assistance The Westerbeke Service Organization is trained to provide...

Page 7: ...D 7 5 10 0BTD S 3 11 0BTD 9 4 12 5BTDA 12 0 15 0BTDB 16 0 20 0BEDA 20 0 25 0BED 25 0 32 0BEDA All 1 The equipment listed is only for use in Marine Applications aboard boats 2 The equipment listed must be located below decks on the vessel and permanently installed in its location 3 The equipment listed must be wired to the grounding system of the vessel I the undersigned hereby declare that the equ...

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Page 9: ... 38 7 6 BID CONTROL CIRCUIT WIRING DIAGRAM 039284 39 COOLING SYSTEM 43 LUBRICATION SYSTEM 49 BT GENERATOR 51 GENERAL INFORMATION AND CARE OF THE GENERATOR 57 YOUR NOTES 59 ENGINE TROUBLESHOOTING 60 MAINTENANCE AND ADJUSTMENTS 63 LAY UP AND RECOMMISSIONING 70 REMOTE LUBE OIL FILTER KIT PN 040078 73 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 74 SPARE PARTS 76 SOUND GUARD INSTALLATION INSTRUCTIONS...

Page 10: ...uit Breaker i l Pre heat Solenoid 0 A C Connections Outlet Fuel Lift Pum Air Intake Silencer Lube Oil Filter 7 6 KW BTD RIGHT SIDE Top Engine Oil Fill Water Temperature Switch Lube Oil Dipstick Oil Fill Oil Pressure Sender Oil Pressure Switch ...

Page 11: ...ure Sender Water Temperature Switch DC Charging Alternator Belt Guard Heat Exchang Starter with Solenoid 7 6 KW BTD LEFT SIDE Unit I D Plate 45 0 Exhaust Elbow Emergency Shut off Switch Unit Data Tag DC Battery Ground Connection ...

Page 12: ...iesel engine does differ from the gasoline engine however in its handling and firing of fuel The carburetor and ignition systems are done away with and in their place are two components the fuel injection pump and the fuel injectors Ordering Parts Whenever replacement parts are needed always provide the generator model number designation i e 7 6 KW BID engine serial number and generator serial num...

Page 13: ...800 rpm 42 lb ft 5 8 kg m Compression Ratio Compression Pressure Valve Timing Valve Seat Angle Valve Clearance engine cold Engine Speed Dimensions Weight Fuel Consumption Inclination 23 1 398 psi 28 kg cm2 at 280 rpm Intake Opens 19 BIDC Intake Closes 51 ABDC Exhaust Opens 51 BBDC Exhaust Closes 19 AIDC Intake 45 Exhaust 45 Intake 0 0098 inches 0 25 mm Exhaust 0 0098 inches 0 25 mm 1800 rpm 60 her...

Page 14: ...RBEKE GENERATORS Open flow totally self bleeding No 2 Diesel cetane 45 or better In line plunger type Bosch type Throttle type 12 volt DC electric Plastic Intake Silencer 30 2 cfm 0 85 cmm Fresh water cooled block thermostatically controlled with heat exchanger 170 1900 F 77 880 C Centrifugal type metal impeller belt driven Positive displacement rubber impeller mechanically driven 6 5 7 0 U S gpm ...

Page 15: ...olts 175 200 Amps engine cold 12 Volt DC 40 amps Brushless four pole revolving field transformer regulation Prelubricated single bearing design Reconnectable 120 volts or 1201240 volts single phase 120 or 1201240 volts 60 Hertz 220 volts 50 Hertz Voltage regulation 5 no load to full load Frequency regulation 3 Hertz no load to full load 120 volts 120 240 volts 220 volts 63 3 Amps 63 3 31 6 Amps 26...

Page 16: ...M SPECIFICATIONS continued TUNE UP SPECIFICATIONS Injector Pressure Engine Timing Spill Timing EMISSION CONTROL SYSTEMS WESTERBEKE GENERATORS 1988 psi 142 psi 140 kg cm2 10 kg cm2 16 1 BIDe Static 12 Smoke PuffLimiter ...

Page 17: ... on the engine II CAUTION II For safety reasons the generator s engine is not filled with lubricating oil for shipment Before leaving the factory however each generator set is thoroughly tested with oil in its engine This testing among other things provides all internal parts with a coating of oil This oil acts as a preservative providing reliable protection against corrosion for at least one year...

Page 18: ... its crankshaft position Certain situations exist by which the engine must be lowered endwise through a small hatchway which cannot be made larger Under these conditions ifthe opeuingofthe hatchway is extremely small it is possible to reduce to some e ent the outside dimensions of the generator by removing external components such as the cooling system s accessory equipment should be removed by a ...

Page 19: ...he generator or drive engine The drive engine and generator must be accessible for minor servicing and repairs Access for major repairs should be given consideration as well The generator set must be properly ventilated to provide fresh cooling air for the generator end for engine combustion needs and to remove heat produced by the engine while operating The generator set needs fresh cool air in w...

Page 20: ...t type exhaust system is used the exhaust muflIer should be mounted as close to the engine as practical The exhaust discharge should always drop downward into the exhaust muflIer Loops in the exhaust hose between the water injected exhaust elbow and the water lift muflIer should be avoided as these will trap and hold water For installations where the exhaust manifoldlwater injected exhaust elbow i...

Page 21: ...e s back pressure at the exhaust elbow while the generator is under a full load Refer to the pressure specifications listed below Dimension A cannot exceed 39 inches of water Back pressure as measured by a gauge instrument should not exceed the following specifications 2 inches of mercury 27 inches of water in a water column 15 6 ounces PSI 1 0 PSI Mercury Manometer Exhaust Elbow Exhaust Excessive...

Page 22: ...essively If excessive heat is present correct the situation immediately If you notice a change in the sound or appearance of the exhaust system shut down the unit immediately and have the system inspected and repaired at once by a qualified mechanic Make sure there are no unnecessary objects suspended from any portion of the exhaust lines Rigidly constructed exhaust risers installed off the exbaus...

Page 23: ...Tighten the clamp just enough so the exhaust elbow can remain attached to the manifold and still be rotated The exhaust elbow discharge must be directed downward so the mixture of raw water and exhaust gases will flow fall downward into the exhaust mnlller which must be positioned below the exhaust elbow There shonld be no loops or rises in the exhaust hose connected between the exhaust elbow and ...

Page 24: ...l tanks are installed below the engine s fuel system and will help prevent air from entering the fuel system when the engine is shut down Ensure that the fuel tank filler is properly sealed to prevent water entry should it become awash The fuel tank s vent should be located so that its discharge route cannot allow water to enter through to the fuel tank s Moisture must no be allowed to accumulate ...

Page 25: ...ng the generator s operation suction from the pump may collapse a non reinforced hose Raw water strainers should be mounted at or below the water line to make sure the raw water line remains primed after shutdown II CAUTION II Do not use a scoop type through hull fitting as a means of supplying raw water to the generator Water pressure against this type fitting while the vessel is under way can pu...

Page 26: ... switch resets at 195 F 107 C Low Oil Pressure Shutdown Switch normally open A low oil pressure shutdown switch is located off tbe engine s oil gallery The switch s sensor monitors tbe engine s oil pressure Should the engine s oil pressure fall to 5 10 psi the switch will open and turn the generator off Generator AC Output Make sure tbat tbe AC output connections within tbe generator s AC terntina...

Page 27: ...ing air is required for the generator end and also for removing the heat produced by the generator s engine during operation and ventilating air is required to clear the bilges below the generator as well as the compartment in which the generator is located of potentially toxic and flammable diesel vapors Keep in mind that hot air rises so heated air should be removed from the upper area of the ge...

Page 28: ...NOTES WESTERBEKE GENERATORS 24 ...

Page 29: ...plugs activates the electric fuel pump bypasses the engine s oil pressure switch and activates the fuel run solenoid In addition this switch energizes the START switch 2 START The START switch when pressed energizes the starter s solenoid which cranks the engine This switch will not operate electrically unless the PREHEAT switch is pressed and held at the same time 3 STOP Through the STOP switch p...

Page 30: ...RED WKIH r T ___________ _ ___________ R E J rh I j PREHEAT SW ITCH U 3 A RI ll REO r I i I 114 RED 1 4 RED i 114 RED 1 WHlH L _____________________________________________________ r i L __________________________________________________ P N 24943 AU MODEL V T H TWO ELUS Ta 1 2 Te I GROUND T82 1 TB2 2 HII l T81 S Refer to the control circuit wiring diagram when installing the remote start stop pan...

Page 31: ... 2 7 37 eo 50 240 40 7 7 103 26D 21 7 32 7 52 7 82 7 31 210 35 3 58 3 89 6 227 19 3 28 7 S 7 73 3 11 18 300 31 7 SQ 3 70 27 202 321 17 3 26 2 66 os 271 28 3 5 3 7 8 2 7 3 2 70 112 80 2 5 3D 7 12 3 3D6 33 52 7 03 7 135 211 22 7 3 57 9 230 22 3 58 90 3 60 7 96 3 53 2 3 306 26 3 7 3 07 2 3 5 3 72 2 23D 2 33 7 54 1S 3 23 36 3 57 7 92 14 84 30 7 4 77 7 33 2 3 83 3 133 67 45 7 3 76 3 121 53 36 57 7 3 38...

Page 32: ...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 Combustion Chamber GLOW PLUG Glow Plug BODY CENTER JJ I SHAFT rllt _ CAP TUBE NOTE The START sw...

Page 33: ...it 24977 as standard equipment which must be installed and the following applies A Remove the pressure cap from the engine s exhaust manifold and slowly fill the engine s cooling system with a mixture of water and antifreeze suitable for your temperature zone Operate the engine and observe the coolant level in the manifold Maintain this level to the base of the filler neck Once the engine reaches ...

Page 34: ... attempt to engage the starter while the engine is running NOTE Some unstable running may occur in a cold engine but this condition should smooth out as the operating temperature of 130 1500 F 55 560 C is reached Proper glow plug function is indicated by a voltmeter drop when the PREHEAT switch is depressed This drop will be slight but discernible If no voltage drop is noted it may indicate defect...

Page 35: ...ng the piston rings to the cylinder walls Excessive oil consumption and smoky operation indicate that the cylinder walls are scored which is caused by overloading the generator during the break in period As indicated above operate the generator with a moderate load during the 50 hour break in period On one hand don t baby the engine but on the other hand don t abuse it Remote Starting Procedure Th...

Page 36: ...rdance with the STARTING PROCEDURE instructions in this manual and allow the engine s operating temperature to reach 140 1500 F before placing a load on it Starting Under Cold Conditions Under extremely cold temperatures the following conditions can occur Follow the instructions listed below when operating your engine in cold weather Lubricating Oil Turns Viscous Make certain that the lubricating ...

Page 37: ...sed B path for voltage to the engine s run circuit The bright green LED will go dim faint when the generator slows and stops Then it will go out indicating the engine has stopped The STOP switch must be held open until the generator comes to a complete stop Remote start panels may be connected to the generator set as indicated A jumper has to be removed between the T 1 and T 2 connections at the p...

Page 38: ...NOTES WESTERBEKE GENERATORS 34 ...

Page 39: ...l pump engine filter and injection equipment The owner operator 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 filtration separation system In addition any gasoline in the fuel system will damage the engine s fuel injection pump assembly and injectors as gasoline does not...

Page 40: ...rried on board at all times Select the parts for your engine from the Parts List and purchase spares from your local Westerbeke Dealer or Distributor For example filter kit 30200 includes replacement elements with gaskets items 21 and 20 If a leak should develop at a fuel banjo or sealing washer location that cannot be remedied by a slight tightening the sealing washers and banjo bolts contained i...

Page 41: ...adjustments the servicing dealer can perform on the injection pump Other types of adjustments or repairs must be performed by a qualified injection service shop FUEL INJECTION PUMP FUEL SOLENOID r _ FUEL RETURN t FUEL LINE OIL FILTER FUEL LINE FUEL FilTER ELECTRIC FUEL PUMP FUEL SUPPLY To obtain long and satisfactory service from the injection pump always use fuel which is free from impurities and...

Page 42: ...it is 350 400 cold cranking amps Fuel Pump The engine mounted fuel pump requires little or no maintenance Ensure fuel being supplied to this pump is free ofwater or other types of contaminants that will hinder the pump s operation 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 connecti...

Page 43: ...V It 9 _pD llUil pD OJ PBESs 1fT PUMP g r I I jl W 011 m SATT RY SWITCH rJ y r llQB EXHA EBeI JBE 1 lllliJi 1 1 1 1 I 1 1 1_______ 1 TO 1 81 1 TO 1 10 I 1 0 1 l ie tfP wT _________________ J lOA CIBpliI C r U llEillWi FIIFI SOl ftIQlQ Itf r IIF Ug r I I r J ri J i L i I ID O C_ o 5 o l I 1 I VCLT IIIKT8II _ L___________________________________ J 39 WESTERBEKE GENERATORS ...

Page 44: ...R LOCATED tI 1I THE SUIITEP 1 10 AS CLOSE TO THf eURIIEtlT SOURCE AS POSSIBLE EXCESSIVE CURREtlT DRAW ANYWI1ERE IN TI E ItiSTRUMENT PAtlEL WIIIlNG 011 ENGINE WILL CAUSE THE SREAKEiI TO TIIIP IN THIS VENT OST GEtlERATORS WILL SHUT DOWN BECAUSE THE OPENED BREAKlR OISCOtlN CTS THE ruEL SUPPLY T lEREFOIlE THE O NER BUILOER IotUST SE SUIIE THAT THE NSTRUIoIEtI PANEL 1111 110 AND ENGINE liE lWST LLEO TO...

Page 45: ...ircuit DC Wiring Diagram 044121 Two Relays EO QII PRESS 011 PRfSSltR n U 1 tc RED I l YELiRCO I I I II n l31 0 II PREHEAT L UI START SMTa1 S MTOi __________ __ __ J ___ 1 TO Tal I TO rBr o 1 8 1 Of T ONAI HC f MITEB a _ jE O E JU ral T let 5 B1 151 I TEgNATOR 51A o o r II cow filE SO ENOID 41 WESTERBEKE GENERATORS PIIMI ...

Page 46: ...1 1 t I I L__ J PREHEAT SOLENOID GLOWPLUGS l i I I I L __ J AL TERNATOR 87 KI START B 30 K2 RUN pm I FUEL SOL 30 I 187 HOlD r FUEL PUNP EXHAUST TEMP WATER TEMP OIL PRESS U H H AUX OIL PRESS H zy z9 K2 RUN RELAY IN I02 8S 85 VI PREHEAT START KI START RELAY rWIT rWIT 8S 85 l J l J OIL PRESS SENDER J 7 WATER TE SENDER T81 2 T81 3 T81 4 T82 2 TBI 5 T62 1 T82 3 T82 8 TB2 4 T82 5 7 T6 I I 0 CD WESTERBEK...

Page 47: ...hen passes through the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned to the engine block through the suction side of the fresh water circulating pump When the engine is started cold external fresh water flow is prevented by the closed thermostat although some fresh water flow is bypassed around the thermostat to prevent the exhaust manifold from...

Page 48: ...d and where coolant can be easily added if needed see the figure below A stainless steel mounting bracket is supplied with each kit along with a 30 inch length of clear plastic hose and clamps to connect the hose between the engine s manifold fitting to the hose spud on the base of the recovery tank FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tank COOLANT RETRACTION COOLANT EXPANSION Coolant fr...

Page 49: ...cape Close the petcock securely 4 Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway between the ADD mark and the MAX mark Replace the plastic cap 5 Run the engine and observe the coolant s expansion flow into the plastic recovery tank 6 Check for leaks between the pressure cap filler neck and the plastic recovery tank Stop the engine and allow it ...

Page 50: ...as this debris lays in front of these tube ends and blocks them 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 circuit thereby reducing the effects of electrolysis on other components of the system The condition of the zinc anode...

Page 51: ...t in the drive shaft Move the blades to conform to the curved cam plate and push the impeller into the pump s housing Water Pump Drive Belt Tension Generator models COme equipped with belt guards that cover over the belt s on the front of the engine OUt of sight out of mind The belt guard is not installed for that purpose Operators are advised that the inspection service and maintenance spoken ofb...

Page 52: ...dent cooling circuits Refer to your generator s Parts List for part numbers and part descriptions ifyou need to order cooling system parts for your engine PRESSURE CAP INJECTED ELBOW _ INCOMING RAW WATER FRESH WATER RAW WATER WESTERBEKE GENERATORS 48 EXHAUST MANIFOLD WATER TEMPERATURE SWITCH HEAT A nAA ZINC FRESH WATER DRAIN WATER DRAIN ...

Page 53: ...l range between 35 and 55 psi NOTE A newly started cold engine can have an oil pressure reading upwards of60 psi A warmed engine can have an oil pressure reading as low as 35 psi These readings will vary depending upon the temperature ofthe engine and the load placed on the generator Engine Oil Change to include filter I Draining the Oil Sump Discharge the old oil through the sump drain hose attac...

Page 54: ... gasket 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 filter stub and then tighten the filter firmly by hand NOTE Generic filters are not recommended as the material standards or diameters of important items on generic parts might be entirely different from genuine parts ...

Page 55: ... 5 62 Hertz Ill 113 Volts at 51 5 52 Hertz NOTE The no load voltage should be adjusted to the voltage produced by the generator when the generator is started a momentary load is applied to excite the transformer and then removed The voltage produced by the generator after this momentary load is removed is the no load voltage 2 To raise or lower the voltage non onductive shims ofvarying thickness a...

Page 56: ...side from the transformer and a single lead on the other routed to the bridge rectifier The single lead can be pOSitioned at either of the three connections These connections are used to change the output voltage of the generator under load Should the voltage go below minimum Reposition this connection to increase output voltage under load 52 ...

Page 57: ...ID 7 6 KW Generator s Internal Wiring Diagram A EXCITER STATOR WINDINGS 1 Exciter Stator Windings B EXCITER ROTOR 1 Auxiliary Windings a b c 2 Diodes 6 3 Rotating Field Windings 4 Pozi Resistor C MAIN STATOR 1 Main Stator Windings 2 Main Stator Windings 3 Main Stator Auxiliary Windings 53 D COMPOUND TRANSFORMER 1 Compound Transformer Windings 2 Compound Transformer Windings 3 Compound Transformer ...

Page 58: ... to the inside of the louvered cover on the generator end A diagram of the various AC voltage connections is provided on the decal The information on the decal is similar to the figure shown on the following page The generator is a single phase reconnectable 120 volts AC two wire or 1201240 volts AC three wire at 60 Hertz or 110 volts AC two wire 1101220 volts AC three wire or 220 volts AC two wir...

Page 59: ... 0 0 0 0 0 0 c 0 N o 0 a 0 TO Fa C ilFt r o IQO 3 L n u l N N L AC Voltage Connections 12 Stud Terminal Block NOTE The frame ground wire must be moved when changing from 110 volts 50 Hertz to 220 volts 50 Hertz For making connections to the AC terminal block use terminal ends for 10 studs which will accept 6 or 8 multi strand wire 55 WESTERBEKE GENERATORS ...

Page 60: ...y to ensure that all AC connections are correct N G 1 ROf DHIGRllIII SHOWS COUEenONS FOR TWO G2 illitE 121 lOI T SYSHII FOR lHREE WIU t SYSTUC USE DOllED LINtS FOR TN DINU HOI LEGS L _ _ I I I I L i Gl I I SlIiP lO SHDR SlflTCH 3 rOl PM 32 8 41 AIoII S PDlO 12 Ll L l i 1j l l t I Noon II N ae IIHPS POLE 32111 C12S hIPSIPOl I ll ntH 218 liMPS POLE 52 t N NOTE OIAGRA SHOWS CONNECTIONS FOR A TWO WIRE...

Page 61: ...tart lI5 Volt motors connected to medium starting loads will be approximately as follows MOTOR SIZE HP lI6 1 4 1 3 lI2 3 4 AMPS FOR RUNNING Amperes 3 2 4 6 5 2 7 2 10 2 13 AMPS FOR STARTING Amperes 6 4 to 22 4 9 2 to 32 2 10 4 to 72 8 14 4 to 29 2 20 4 to 40 8 26 to 52 NOTE In tbe above table the maximum Amps for Starting is more for some small motors tban for larger ones The reason for this is th...

Page 62: ...ble meter and amp probe Preventive Maintenance Generator Maintenance on the generator is minimal 1 Keep the generator clean dry and well ventilated 2 Ensure that all connections are clean and tight and that cables carrying AC voltage are properly supported and protected against chafing 3 The rear armature bearing is lubricated and sealed therefore no maintenance is required If the bearing becomes ...

Page 63: ...YOUR NOTES 59 WESTERBEKE GENERATORS ...

Page 64: ...tric fuel pump and preheat solenoid not 2 20 Amp circuit breaker 2 Reset breaker ifbreaker trips energized tripped again check preheat solenoid circuit and check circuit for shorts to ground START switch is depressed I Connection to solenoid I Check connection no starter engagement faulty 2 Faulty START switch 2 Check switch with ohmmeter 3 Faulty solenoid 3 Check that 12 volts are present at star...

Page 65: ...ee movement 3 Fuel injection pump failure Engine stops I Low oil pressure or 1 Check oil level check fresh and overheated sea water cooling 2 Low oil pressure switch 2 Check for satisfactory operation opens with switch bypassed Check with an ohmmeter 3 High temperature switch 3 Check for satisfactory operation opens at too Iowa temperature with switch bypassed Check with water temperature exhaust ...

Page 66: ...tivated when engine is not running Test the oil pressure switch 2 High resistance leak to 2 Check wiring Insert sensitive ground 0 25 Amp meter in battery lines Do not start engine Remove connections and replace after short is located 3 Low resistance leak 3 Check all wires for temperature rise to locate the fault 4 Alternator 4 Disconnect alternator at output after a good battery charging If leak...

Page 67: ...broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not properly secured 4 Check the fuel supply Fill tank s with a good grade ofNo 2 diesel fuel if required 5 Check the primary filter water separator Drain and service as required A primary filter water separator is optional but strongly recommended as damage to fuel equipment on the engine from fuel contaminant...

Page 68: ...mbly Servicing After Every 500 Hours of Operation 1 Adjust the valve clearances 2 Torque the cylinder head bolts 3 Drain flush and refill the fresh water cooling system There are two drain plugs for the fresh water system One on the lower side of the heat exchanger and the other behind the hose adjacent to the engine mounted fuel filter 4 Check the condition of the starter motor drive pinion lubri...

Page 69: ...tomotive radiator shop should be able to clean and test the heat exchanger NOTE Operating in silty and or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours 2 Check the injection pump s timing Static method spill time A Rotate the engine s crankshaft to position the 1 piston at the Top Dead Center of its compression stroke Observe the opening a...

Page 70: ...stration to the right Cylinder Head Bolt Tightening Sequence Bolts 1 2 and 3 12 mm socket 2 0 3 0 kg m 14 22 ft Ib Bolts 4 5 6 7 8 9 10 and 11 14 mm socket 7 5 8 5 kg m 54 61 ft Ib Rockershaft Hold Down Bolts 12 mm socket 1 5 2 2 kg m 11 16 ft Ib Valve Clearance Adjustment II CAUTION II Adjust the valve clearance when the engine is cold Valves are adjusted by cylinder in the firing order ofthe eng...

Page 71: ...ill flow from this line during the timing check RDJUST VALVES TO 0 010 INCHES 0 25 1 10 DELIYEiY YRLYE HOLDER DELIVERY V LVE SPRIN PlUJfHR cunOl PUIlO PlUN6ER SPIIN6 Fun CexUOl Rlicr Rotate the engine s crankshaft in its normal direction of rotation to position piston No I at the beginning of its compression stroke Move the throttle lever to its full open position and operate the electric lift pum...

Page 72: ...equency is 50 Hertz Therefore to change the generator s frequency the engine speed must be changed To accomplish the frequency change perform the following 1 Connect the AC output leads to the AC terminal block in accordance with the AC voltage connections diagram specified for your generator set and change the hertz connection to the capacitor These connections are illustrated in the BC GENERATOR...

Page 73: ...pening Allow the plunger to contact the fuel rack and move it fully into the injection pump Do not thread further so as to push the plunger into the solenoid 4 Back the solenoid out 114 112 of a tum and secure it in position with the locknut 5 Properly connect the three electrical leads from the solenoid Two of the connections plug into the engine harness and the third grounds to the engine block ...

Page 74: ...protection is adequate Should more antifreeze be needed drain an appropriate amount from the engine block and add a more concentrated mixture Operate the engine to ensure a complete circulation and mixture of the antifreeze concentration throughout the cooling system Now recheck the antifreeze solution s strength Lubrication System With the engine warm drain all the lubricating oil from the oil su...

Page 75: ...ion slightly stronger than needed for winter freeze protection in your area Start the engine and allow all ofthis mixture to be drawn through the raw water system Once the bucket is empty stop the engine This antifreeze mil ture should protect the raw water circuit from freezing during the winter lay up as well as providing corrosion protection Remove the impeller from your raw water pump some ant...

Page 76: ...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 Recommissioning The recommissioning of your Westerbeke engine after a seasonal la...

Page 77: ... as either an end of season or recommissioning service to inspect the area that the zinc is located at in the heat exchanger and clear any and all zinc debris from that area 5 Start the engine in accordance with procedures in the PREPARATIONS FOR STARTING section of this manual REMOTE LUBE OIL FILTER KIT PN 040078 This kit allows you to remove the filter off the engine and with the mounting bracke...

Page 78: ... 21 7 32 5 3 0 4 5 10 mm bolt head nut 1 5 19 5 30 4 2 7 4 2 12 mm bolt head nut 1 25 ISO 36 2 57 9 5 0 8 0 12 mm 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 8 Grade 7T 8T and 8 8 6mm bolt head nut 1 5 8 8 7 0 8 1 2 8mm bolt head nut 1 25 14 5 21 7 2 0 3 0 10 nun bolt head nut 1 25 28 9 39 8 4 0 5 5 10 mm bolt head nut 1 5 26 8 37 6 3 7 5 2 12 mm bolt head nut 1 2...

Page 79: ...5 3 28 2 3 5 3 9 Injection pump All models Injector nozzle mounting M 20 21 mm 36 2 43 4 5 0 6 0 All models To Engine Fuel solenoid locknut M30 36 mm 28 9 36 2 4 0 5 0 Glow plug M 10 12 mm 10 8 14 5 1 5 2 0 All models Injector spray pressure 140 10 0 kglcm2 1990 psi 140 0 Cylinder compression pressure 28 kglm2 at 280 rpm 398 psi Tightening Torque for Common Bolts and Nuts Designation of screw Head...

Page 80: ...not be accurately predetermined should be carried on board in addition to those listed above especially if the vessel is to be taken on long ocean voyages I Fuel injectors 2 Glow plugs 3 Cooling system hoses 4 A starter 5 A 20 amp DC circuit breaker 6 An electric fuel pump 7 A sea water pump 8 Battery terminal connectors 9 A fuel run solenoid The spare parts listed directly above are those we reco...

Page 81: ...NOTES 77 WESTERBEKE GENERATORS ...

Page 82: ...he Sound Guard installation instructions required for your generator set please contact your local Westerbeke dealer A four page installation brochure is available which covers all current Sound Guard model assembly installations WESTERBEKE GENERATORS 78 ...

Page 83: ...uce 7 6 KW of AC electrical power and furnish horsepower to the PTO device simultaneously When mounting a PTO device using the optional adapter kit 34786 ensure good alignment of the device to the spline coupling and ensure that if additional support is needed it is added When in doubt provide extra support o CNERATOR HOUSINC P T O ADAPTER KIT BPLXME COUPLXNC AOAPTER CAPSCRE W 3 LOCK ACH R 3 I TUO...

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