Westerbeke 10.0KW-60Hz User manual

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Readthis

safety

manual carefully.

Most

accidents

are

caused

failure

follow fundamenfLll

ruks

and

precautions.

Know

when dangerous conditions exist and

fLliaJ

the

necessary precautions

protectyourself, yourpersonnel,

andyour machinery.

The

following safety instructions

are

in complimlce

with

the

American Boat and

Yacht

Council (ABYC)

standards.

PREVENT

ELECTRIC

SHOCK

WARNING:

not

touch

electrical

connections

while

engine

running,

when

connected

shore

power.

Lethal

voltage

present

these

connections!

•

not operate this machinery without electrical

enclosures

and

covers

place.

• Shut offelectrical power before accessing electrical

equipment.

•

Use

insulated mats whenever working

electrical

equipment.

• Make sure your clothing

and

skin

are

dry,

not

damp

(particularly shoes)

when

handling electrical equipment.

•

Remove

wristwatch

and

all jewelry

when

working

electrical equipment.

•

not connect utility shore power

vessel's

circuits, except through a ship-ta-shore double

throw

transfer switch. Damage

vessel's

generator

may

result if this procedure

not

followed.

• Electrical shock results

from

handling a charged capacitor.

Discharge capacitor

shorting terminals

together.

PREVENT

BURNS

HOT

ENGINE

WARNING:

not

touch

hot

engine

parts

exhaust

system

components_

running

engine

gets

very

hot!

•

Always

check

the

engine coolant

level

the

coolant

recovery

tank.

WARNING:

steam

can

cause

Injury

death!

•

case of

engine overheat,

allow

the

engine

cool

before touching

the

engine or checking

the

coolant.

PREVENT

BURNS

FIRE

WARNING:

Fire

can

cause

injury

death!

• Prevent

flash

fires.

not

smoke

or pennit

flames

sparks to occur

near

the

carburetor,

fuel

line,

filter,

fuel

pump,

other potential

sources

of spilled

fuel

vapors.

Use

a suitable container

catch

all

fuel

when

removing

the

fuel

line,

carburetor,

fuel

filters.

•

not operate

with

Coast

Guard

Approved

flame

arrester

removed.

Backfire

can

cause

severe

injury

death.

•

not

operate

with

the

air

cleaner/silencer

removed.

Backfire

can

cause

severe

injury

death.

• Do not

smoke

or permit

flames

sparks

occur

near

the

fuel

system.

Keep

the compartment

and

the engine/gener-

ator clean

and

free

ofdebris

minintize the chances of

fire.

Wipe

all spilled

fuel

and

engine

oil.

• Be

aware

diesel

fuel

will

bum.

PREVENT

BURNS

EXPLOSION

WARNING:

Explosions

from

fuel

vapors

can

cause

Injury

death!

•

re-fueling safety instructions.

Keep

the

vessel's

hatches

closed

when

fueling.

Open

and

ventilate

cabin

after

fueling.

Check

below

for

fumeslvapor before

running

the

blower.

Run

the

blower

for

four

ntinutes before start-

ing

your

engine.

•

All

fuel

vapors

are

highly

explosive.

Use

extreme

care

when

handling

and

storing

fuels.

Store

fuel

a well-ventilated

area

away

from

spark-producing equipment

and

out

the

reach ofchildren.

• Do

not

fill

the

fuel

tank(s)

while

the engine

running.

• Shut off

the

fuel

service

valve

the

engine

when

servicing

the

fuel

system.

Take

care

catching

any

fuel

that ntight

spill.

NOT

allow

any

smoking,

open

flames, or other

sources

fire

near

the

fuel

system

engine

when

servicing.

Ensure proper ventilation

exists

when

servicing

the

fuel

system.

• Do

not

alter or modify the

fuel

system.

• Be sure

all

fuel

supplies

have

a positive shutoff

valve.

•

certain

fuel

line fittings are

adequately

tightened

and

free

leaks.

• Make

sure

fire

extinguisher

installed nearby

and

properly maintained.

familiar

with

its

proper

use.

Extinguishers

rated

ABC

the

NFPA

are appropriate

for

all

applications

encountered

this

environment.

...v-

WESTERBEKE

Engines &

Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

STARTING

WARNING:

Accidental

starting

can

cause

injury

death!

• Disconnect the battery cables before servicing

the

engine!

generator. Remove

the

negative

lead

first

and

reconnect

it last.

• Make certain

all

personnel are clear of

the

engine before

starting.

• Make certain all covers, guards,

and

hatches

are

re-

installed before starting

the

engine.

BAnERY

EXPLOSION

WARNING:

Battery

explosion

can

cause

injury

«death!

• Donot smoke

allow

open

flame

near

the

battery

being serviced. Lead

acid

batteries

emit

hydrogen,

highly explosive gas,

which

can

ignited by

elec~cal

arcing or

lit tobacco

products.

Shut off

all

electncal

equipment in the

vicinity

prevent

electrical

arcing

dur-

ing servicing.

• Never connect the negative (-)

battery

cable

the

posi-

tive (+) connection ternrinal

the

starter

solenoid.

not test the battery condition

shorting the

terminals

together. Sparks could ignite battery gases or

fuel

vapors.

Ventilate any compartment containing batteries to prevent

accumulation

explosive gases.

avoid

sparks,

not

disturb

the battery charger connections while the battery

is being charged.

•

Avoid

conlllcting the

ternrinals

with

tools,

etc.,

prevent

burns or sparks that could cause

explosion.

Remove

wristwatch, rings, and

any

otherjewelry before handling

the

battery.

• Always tum the battery charger offbefore disconnecting

the battery connections.

Remove

the negative

lead

first

and reconnect it last whenservicing

the

battery.

BAMRYACID

WARNING:

Sulfuric

acid

batteries

can

cause

SIWBI8

injury

death!

• When servicing the

battery

orchecking

the

electrolyte

level, wear rubber

gloves,

a rubber

apron,

and

eye

protec-

tion. Batteries conlllin sulfuric

acid

which

destructive.

itcomes in

conlllCt

with

your

skin,

wash

it off

once

with

water.

Acid

may

splash

the

skin

or into

the

eyes

inadvertently when

removing

electrolyte caps.

TOXIC

EXHAUST

GASES

WARNING:

Carbon

monoxide

(CO)

deadly

gas!

• Ensure that

the

exhaust system

adequate

expel

gases

discharged

from

the

engine.

Check

the

exhaust

system

regularly

for

leaks

and

make

sure

the

exhaust

manifold!

water-injected

elbow

securely

attached.

•

sure

the

unit

and

its

surroundings

are

well

ventilated.

Run

blowers

when

running

the

generator

set

engine.

• Don't

run

the

generalor sel

engine

unless

the

boat

equipped

with

a functioning

marine

carbon

monoxide

detector

that

complies

with

ABYCA-24.

Consult

your

boat

builder

dealer

for

installation of

approved

detectors.

•

For

additional

information refer

ABYC

T-22

(educational

information

Carbon

Monoxide).

WARNING:

Carbon

monoxide

(CO)

invisible

odorless

gas.

Inhalation

produces

flu·like

symptoms,

nausea

death!

•

not

use

copper

tubing

diesel

exhaust

systems.

Diesel

fumes

can

rapidly

destroy

copper

tubing

exhaust

systems.

Exhaust sulfur causes

rapid

deterioration

copper

tubing

resulting

exhaust/water

leakage.

•

not

install

exhaust outlet-where exhaust

can

drawn

through

portholes,

vents,

air conditioners.

the

engine

exhaust

discharge

outlet

near

the

waterlme,

water

could

enter

the

exhaust

discharge

outlet

and

restrict

the

flow

exhaust.

Avoid

overloading

the

craft.

• Although

diesel

engine exhaust

gases

are

not

toxic

exhaust

fumes

from

gasoline

engines,

carbon

monoxide

gas

present

diesel exhaust

fumes.

Some

the

symptoms

signs of

carbon

monoxide

inhalation

poisoning

are:

Vomiting

Dizziness

Headache

Nausea

AVOID

MOVING

PARTS

Inability

think

coherently

Throbbing

temples

Muscular

twitching

Weakness

and

sleepiness

WARNING:

Rotating

parts

can

cause

Injury

death!

•

not

service

the

engine

while

running.

a situation

arises

which

absolutely

necessary

make

operat-

ing

adjustments,

use

extreme

care

avoid

touching

mov-

ing

parts

and

hot

exhaust

system

components.

Engines & Generators

SAFETY

INSTRUCTIONS

•

not

wear

loose clothing or jewelry

when

servicing

equipment;

avoid

wearing

loose

jackets,

shirts,

sleev~.

rings,

necklaces or bracelets that could

caught

moving

parts.

•

Make

sure

all

attaching hardware

properly tightened.

Keep

protective shields

and

guards

their respective

places

all

times.

•

not

check

fluid

levels

the

drive belts'

tension

while

the

engine/generator

operating.

•

Stay

clear of

the

drive

shaft

and

the

transmission coupling

when

the

engine

running; hair

and

clothing

can

easily

caught

these rotating

parts.

HAZARDOUS

NOISE

WARNING:

High

noise

levels

can

cause

hearing

loss!

•

Never

operate a generator without

its

muffler installed.

•

not

run

engine with

the

air intake (silencer)

removed.

•

not

run

engines or generators

for

long periods with

their enclosures

open.

WARNING:

not

work

machInery

when

you

mentally

physically

Incapacitated

fatigue!

OPERATORS

MANUAL

Many

the

preceding safety

tips

and

warnings are repeated

your Operators Manual along with other cautions

and

notes

highlight critical information.

Read

your manual

carefully,

maintain your equipment,

and

all

safety

procedures.

GASOLINE

ENGINE

AND

GENERATOR

INSTALLATIONS

Preparations

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 ofsources including

the

USCG

and

the

NFPA.

Sections

the

ABYC standards ofparticular interest

are:

H-2

Ventilation

H-24

Gasoline

fuel

systems

P-I Exhaust systems

P-4

Inboard engines

E-9

Electrical systems

All

installations must comply with

the

Federal Code of

Regulations

(FCR).

ABYC,

NFPA

AND

USCG

PUBLICATIONS

FOR

INSTALLING

GASOLINE

AND

DIESEL

ENGINES

AND

GENERATORS

Read

the

following ABYC,

NFPA

and

USCG

publications

for

safety codes

and

standards. Follow their recommenda-

tions

when

installing your WESTERBEKE engine/generator.

ABYC (American Boat and

Yacht

Council)

"Safety Standards

for

Small Craft"

Order

From:

ABYC

3069

Solomon's Island

Rd.

Edgewater,

21037

NFPA (National Fire Protection Association)

"Fire Protection Standard

for

Motor Craft"

Order

From:

NFPA

1Batterymarch Park

P.O.

Box

9101

Quincy,

02269-9101

USCG (United States Coast Guard)

"USCG 33CFR183"

Order

From:

U.S.

Government Printing Office

Washington,

D.C. 20404

....

WESTERBEKE

Engines & Generators

iii

)

TABLE

CONTENTS

Engine

Specifications

............................................

Testing

for

Overhaul

...............................................

Troubleshooting

Guide

.......................................

Safety

Shutdown

Switches

..................................

High

RPM

Shutdown

Switch

................................

Disassembly

and

Assembly

Procedures

.............

Bolt

Tightening

Methods

.....................................

Engine

Disassembly,

Inspection

Assembly

...

Timing Belt Inspection & Replacement.........

Removing Exterior Assemblies......................

Engine

Disassembly,

Inspection

Assembly

...

Distributor

..........................................................

Testing

the

Igniter

.............................................

Electrical

System

..........................................

.31

AlternatorTroubleshooting ............................

Generator Schematic ......................................

Wiring Diagram............................................:.34

Remote Start Diagram....................................

Remote Instrument Panel Diagram..........

.36-37

Engine

AdJustments

..........................................

.38

Oil Pressure ...................................................

.38

Ignition Timing..............................................

.39

Valve Clearance.............................................

.39

Compression Test ..........................................

.39

Drive Belt .......................................................40

Spark Plugs.....................................................40

High Tension Cords........................................40

Carburetor......................................................

.41

Governor.........................................................42

Mando

Alternator

........................................

.43-49

Starter

Motor

........................................................

Generator

......................................................

52-60

Service

Specifications

......................................

Torque

Speciflcations

.....................................

63-66

Sealants

and

Lubricants

...................................

Metric

Conversions

......................................

65~67

Special

Tools

....................................................

Index

..................................................................

WESTERBEKE

Engines & Generators

WESTERBEKE

8.0KW

15KW

BEG

ENGINE

SPECIFICATIONS

Engine

Type

Governor

Combustion

Chamber

Bore

Stroke

Piston

Displacement

Aring

Onter

Direcllon

Rolation

Compression

Ratio

Weight

GENERAL

Gasoline,

four-cycle,four-cyJinder,

fresh

water-cooled,

vertical

in-line

overhead

mechanism,

Hoof,

flybaJ

type,<i%

speed

reduction,

Semi-spherical

type,

2,97

3,23

cu,in,

(75,5

82,Omm)

89,6

cubic

Inches

(1468

cubic

centimeters),

1-3-4-2

Clockwise,

when

viewed

from

the

front.

9:0:1

8.OKw

10.OKw

12.5Kw

15.0

440

lbs

(199

Kg)

466

Lbs

(211

Kg)

497

Lbs

(497

Kg)

525

Lbs

(238

Kg)

TUNE-UP

SPECIFICATIONS

Compression

Pressure

(11mK

difference

between

cylinders)

Valve

Seal

Angle

vaJvo

Clealance

(engine

hot)

Engine

Timing

General

Oil

FIller

SUmp

Gapacity

(not

Including

fiKer)

Operating

Oil

Pressure

(engine

hot)

Oil

Glade

165psi

300

rpm

14psi

Inlake45°

Exhaust

Iniake

0.08

inchas

(0.20

mm)

Exhaust

0.09

inches

(025

mm)

20"

BlDC

1800

rpm

Forced

lubrication

geared

pump.

Full

flow,

spin-on

replaceable

type.

3.5

U.S.

qts

(3.3IKers)

plus

llKer

50-60

psi

API

Specification

class.

ELECTRICAL

SYSTEMQ

StaJlMotor

Starting

BatleIY

CCA

BaileIY

Gapacity

General

Distributor

Spark

Plug

Thread

Size

Volt,

reduction

gear/solenoid,

Volt,

(-)

negative

ground

3O(Hj()()

Amps

150

Cold

Cranking

Amps

(CCA).

IGNITION

SYSTEM

BatleIY

Ignitionl2V

negative

ground,

Distributor

with

Ignhion

module

and

ignher.

Ignition

coli

and

spark

plugs,

Equipped

with

auto

timing

controller,

ignition

coil

buih-in

breake~ess

type.

14mm

1.25

pitch

IGNITION

SYSTEM

(CONT.)

Carburetor

(STD

Typ!)

Spark

Plug

Gap

General

Fuel

Lift

Pump

Fuel

Consumption

(approximate)

Fuel

Rher

(on

engine)

I'jr

cleaner

(ilame

arrester)

I'jr

Row

(engine

combustion)

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

Row

1800

rpm,

System

Capacity

(coolant)

Down

draft

type.

single

barrel.

U,S,C.G.

approved

flame

arrester,

,030

inches

(0.8

mm)

FUEL

SYSTEM

Conventional

carburetor

type

with

electric

fuel

~ump,

Regular

unleaded

gasoline

with

octane

rating

better,

Electric-lift

capability

ft,

(18mm)

8.0Kw

1,1

gph

10.0Kw

1.25

gph

12.5Kw

1,45

gph

15.0

1.7

gph

Replaceable

cartridge-screw

on,

Metal

screen

type

•

cleanable,

46,6

elm

(1.3

cmm),

COOLING

SYSTEM

Fresh

water-cooled

block,

thermostatically-

controlled

whh

heat

exchanger,

140

-1600 F(61-710

Centrifugal

type,

metal

impeller,

beh-driven,

Positive

displacement,

rubber

impeller,

beh-driven,

5,5

gpm

(5.20

Ipm),

5,5

qts

(5,20

liters)

GENERATOR

(SINGLE

PHASE)

Single

Phase

Vohage

regulation:

Frequency

regulation:

Rating

(Voks

AC)

8.0Kw

10.0Kw

12.5Kw

15.0

Generator

Cooling

I'jr

Requirements

(60

Hertz

1800

rpm)

Engine

Combustion

Air

Requirements

(60

Hertzat

1800

rpm)

Brushless

Six-pole,

revoMng

field,

Sealed

lubricated

Single-bearing

design,

Reconnactable,

single·phase

transformer

whh

solid-state

vohage

regulation,

120

1201240

Voks

Hertz

230

Volts

Hertz.

.5%

load

full

load,

Hertz

(5%)

load

full

load,

1201240

voks

66133

'1201240

voks)

83/41

1201240

voks

-104152

1201240

voks

-125162

200-

225

elm

(5,6'

B.4

cmm)

NOTE:

Increase

air

supply

15%

for

Hertz

operaUon

(1500

tpm),

46,6

elm

(1.3

cmm)

Generator

Compartment

100-200

elm

(2,83-5,66

cmm),

Cooling

Requirements

....v'

WESTERBEKE

Engines & Generators

TESTING

FOR

OVERHAUL

HOW

DETERMINE

ENGINE

OVERHAUL

PERIOD

Cause

Low

Compression

Generally,

the

time

which

engine

should

overhauled

detennined

various conditions

such

lowered

engine

power

output, decreased compression

pressure,

and

increased

fuel

and

oil

consumption.

The

lowered

engine

power

output

not necessarily

due

trouble

with

the

engine

itself,

but

sometimes caused

wom

plugs or

fueVcarburetor

problems

The decrease

compression

pressure

caused

many

factors.

is,

therefore, necessary

detennine a

cause

or causes

the

basis

ofdata produced

periodic

inspection

and

maintenance.

Oil analysis

seasonal

basis

a good

means

of monitoring engine internal

wear.

When

caused

wom

cylinders or piston

rings,

the

following

symptoms

will

occur:

Low

engine power

output

2 Increased fuel consumption

3 Increased oil consumption

Hard

engine starting

5 Noisy engine operation

These symptoms

often

appear

together.

Symptoms

and

can

result also

from

carburetor performance

worn

plugs.

They

are

caused also

defective electrical

devices

such

the

battery,

alternator or

starter.

Therefore it

desirable

judge the optimum engine overhaul time

the

lowered

compression pressure

caused

worn cylinders

and

pistons

plus

increased oil

consumption.

Satisfactory combustion

obtained

only

under

sufficient

compression

pressure.

engine

lacks

compression pressure, incomplete combustion

fuel

will

take place

even

ifother parts ofthe

engine

are

operating

properly.

detennine the period of

engine

overhaul,

is important

measure the engine compression

pressure

regularly.

the

same

time,

the engine speed

which

the measurement ofcompression pressure

made

should be checked

because

the compression

pressure

varies

with

engine

rpm.

The

engine

rpm

can

measured

the

front

end ofthe crankshaft.

When

the decrease ofcompression pressure

reaches

the

repair limit, the engine

must

overhauled.

The

engine requires overhaul

when

oil

consumption

high,

blow-by

evident,

and

compression

valves

are

minimum

below.

NOTE:

Make

cenain

the engines valve clearances are

properly adjusted.

incorrect valve clearance

can

cause

symptoms that might, incorrectly, suggest an engine

overhaul (cylinder misfire, white smoke, noise, etc).

Before preparing

for

engine overhaul, adjust the valve

clearances

the

correct

specification.

install

new

cover

gasket

and

test the engine.

DISASSEMBLY

NOTE:

Before disassembly

and

cleaning, carefully check

for

defects which cannot befound after disassembly and

cleaning.

•

All

disassembled parts

should

carefully

arranged

the

order ofreassembly.

Mark

label

the

parts

needed

insure proper

mating

and

reassembly in

the

proper directions

and

positions.

• If

the

disassembly procedure

complex

requiring

many

parts

disassembled,

the

parts

should

disassembled

way

that

will

allow

them

efficiently

reassembled

without

any

change

the engine's extemal

appearance

its

performance.

•

not

remove

or disassemble

parts

that

require

disassembly.

• Carefully inspect each parts

after

removal

for

damage,

deformation,

and

other

problems.

•

Carefully

check

gaskets,

packings

and

oil

seals,

even

checking

not

specified.

Replace

with

new

ones

defective.

•

careful not

damage

the

disassembled

parts.

Keep

the

parts

clean.

•

Use

the

proper

tools.

Apply

oil

when

necessary.

Take

special care

keep the

fuel

system

parts

free

from

the

intrusion ofdust

and

dirt.

-..v:

WESTERBEKE

Engines & Generators

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