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OPERATORS MANUAL
20.0 KW SBEG and SBEGA • 60 HZ
16.0 KW SBEG and SBEGA • 50 HZ
22.5 KW SBEG and SBEGA • 60 HZ
18.7KW SBEG and SBEGA • 50 HZ
. MARINE GASOLINE GENERATORS
I
SINGL
TH
E PHASE
.:
:
NO. 049800
REVISIONS
DECEMBER 2009
Ultra-Low Carbon Monoxide Emissions
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Table of Contents
Related Manuals for Westerbeke 20.0KW sbeg
Summary of Contents for Westerbeke 20.0KW sbeg
- Page 1 -( £ ft lit. .;: . . '" <) . . iiI. D~' OPERATORS MANUAL 20.0 KW SBEG and SBEGA • 60 HZ 16.0 KW SBEG and SBEGA • 50 HZ 22.5 KW SBEG and SBEGA • 60 HZ 18.7KW SBEG and SBEGA • 50 HZ .
- Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
- Page 3 Shut dllwn the unit and dll nllt restart until It has been Inspected and TIJfIIIlred. A WARNING DECAL is provided by WESTERBEKE and shlluld be fixed til bulkhead near Yllur engine generatllT. WESTERBEKE afstJ recllmmends installing CARBON MONOXIDE DETECTORS In the livfnJ!sleeplng quarters lit Yllur vessel.
- Page 4 SAFETY INSTRUCTIONS ImODUCTION • Do not operate with the air cleaner/silencer removed. Backfire can cause severe injury or death. Retul this safety manual carefully. Most accidents are • Do not smoke or permit flames or sparks to occur near caused failure to follow fundamentol rules and precau- the fuel system.
- Page 5 SAFETY INSTRUCTIONS BATTERY EXPLOSION WARNING: Carbon monoxide (CO) is an invisible WARNING: Battery explosion can cause injury odorless gas. fnhalation produces flu-like symptoms, death! nausea or death! • Do not smoke or allow an open flame near the battery • Do not use copper tubing in diesel exhaust systems.
- Page 6 E-9 DC Electrical Systems Avon Industrial Park All installations must comply with the Federal Code of Avon, MA 02322 Regulations (FCR). USCG (United States Coast Guard) "USCG 33CFR183" Order from: U.S. Government Printing Office Washington, D.C. 20404 WESTERBEKE Engines & Generators...
- Page 7 EPA andCARB. Even though Westerbeke Safe·CO generators are designed to Maintenance of any components affecting the flow of air or reduce normal levels of CO in the engine exhaust by...
- Page 8 The other location is the boat's exhaust outlet, which Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI, Teledyne and others. Westerbeke recommends analyzers with contains entrained cooling water (except dry stack exhaust a probe connected to the analyzer by a length of transparent systems).
- Page 9 Califomia users of this genset should be aware that maintenance or service of your genset is authorized, you unauthorized modifications or replacement of fuel, exhaust, should seek assistance from an approved WESTERBEKE intake, or speed control system components that affect dealer.
- Page 10 The Westerbeke generator that you purchased is certified for constant-speed operation only. The use ofany Westerbeke product in any manner inconsistent with its intended use could be a violation of Federal Law. "Iryou install the engine in a way that makes the engine's emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105".
- Page 11 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid the following infonnation: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
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Page 12: Table Of Contents
TABLE OF CONTENTS 20KW SBEG/22.5KW SBEG Parts Identification ..... Introduction ..............3,4 Fuel, Engine 011 and Engine Coolant ......Preparations for Initial Start·Up ........Operating Instructions ............ 7 Generator Control Panel .......... 7 Remote Control Start/Stop Panel......7 Break·ln ProcedureJDaily Operation ......Shutdown Sensors/Switches ....... -
Page 13: 20Kw Sbeg/22.5Kw Sbeg Parts Identification
... ~~~~~tl--:;:lkLll.~@?), SEIISOR IWI) -\li~hl- EXHAUST TEMPERATURE FRONT SWITCH EXHAUST CONNECTION MOUNT LEFT SIDE COOLANT FILL AIR BLEED (MANIFOLD PRESSURE CAP) FILL CAP BREAK }HERMIOSTAT ASSEMBLY COIfTROL FRONT REAR WATER RAIL IN-LINE RIGHT SIDE FUR FILTER WESTERBEKE Engines & Generators... -
Page 14: Introduction
USE OF SUCH SOFTWARE. manual carefully and observe all the safety precautions throughout. Should your generator require servicing, contact WESTERBEKE customers should also keep in mind the your nearest WESTERBEKE dealer for assistance. time span between printings of WESTERBEKE product... - Page 15 Also insist upon WESTERBEKE packaged parts the way. WESTERBEKE will provide you with a suggested because will or generic parts are frequently not made to the spares and accessories brochure to assist you in preparing an same specifications as original equipment.
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Page 16: Fuel, Engine 011 And Engine Coolant
FUEL, ENGINE OIL AND ENGINE COOLANT ENGINE COOLANT GASOUNE WESTERBEKE recommends a mixture of 50% antifreeze and Only use unleaded gasoline with an 50% distilled water. Distilled water is free from the chemicals . . CAUTION: Oetane rating of#89 or higher. A that can corrode internal engine surfaces . -
Page 17: Preparations For Initial Start-Up
PREPARATIONS FOR INITIAL START-UP ~P:LA~cS;DTliiECliCyOOLANT TANK MANIFOLO PRESSURE CAP I BLEED THIS LINE RETURNS COOLANT TO THE ENGINE OIL DIPSTICK EXHAUST MANIFOLO PRESTARTINSPECTION Before starting your generator for the first time or after a • Visually examine unit. Look for loose or ntissing prolonged layoff, check the following items: parts, disconnected wires, unattached hoses, and check threaded connections. -
Page 18: Operating Instructions
The Schrader valves on the throttle body and the fuel cell are used to remove trapped air. This air is mixed with fuel and under high pressure. Follow the BLEEDING THE FUEL SYSTEM instructions in this manual. , . WESTERBEKE Engines & Generators... - Page 19 • Check drive belts for wear and proper tension (weekly). • Confirm exhaust smoke: When the engine is cold - white smoke. When the engine is wann - almost smokeless. When the engine is overloaded - some black smoke. WESTERBEKE "S¥ Engines & Generators...
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Page 20: Safety Shutdown Sensors/Switches
SAFETY SHUTDOWN SENSORS AND SWITCHES SAFm SHUTDOWN SWITCH/SENSORS Oil Pressure Sensor The engine is protected by four automatic shutdown circuits. An oil pressure sensor is located off the engines oil gallery. Oil pressure on the sensor affects the DC voltage through the Should a shutdown occur, attempt to resflJtt without sensor to the ECU. -
Page 21: Maintenance Schedule
MAINTENANCE SCHEDULE WARNING: Never a/tempt to perform any service while the engine is running, Wear the proper safety equipment such as goggles and gloves, and use the consct tools for each Job, When servlclng/rtlplaclng DC components, turn off the 20 amp DC circuit breaker on the control panel, or disconnect the battery IBrmlnals, SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE... - Page 22 'Oxygen Sensor Remove and replace exhaust oxygen sensor. EVERY 5000 OPERATING HOURS 'Calalysl Remove and replace exhaust catalyst. 'WESTERBEKE recommends Ihis service be performed by an authorized mechanic. Revised November 2009 Test run unit and verity no exhaust leakage. EXJIi~UST...
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Page 23: Cooling System
COOLING SYSTEM DESCRIPTION CHANGING COOLANT Westerbeke marine engines are designed and equipped for The engine's coolant must be changed according to the fresh water cooling. Heat produced in the engine by combus- MAINTENANCE SCHEDULE. If the coolant is allowed to tion and friction is transferred to fresh water coolant which become contaminated, it can lead to overheating problems. -
Page 24: Thermostat
Operating in silty and/or tropical waters may require that a heat exchanger cleaning be peiformed more often thall NOTE: Electrolysis is the result of each particular installation every 1000 hours. vessel location, not that of the generator..v: WESTERBEKE Engines & Generators... -
Page 25: Raw Water Intake Strainer
COOLING SYSTEM RAW WATER INTAKE STRAINER RAW WATER PUMP The raw water pump is a self-priming, rotary pump with a IIOTE: Always install the strainer at or below the waterline so non-ferrous housing and a Neoprene impeller. The impeller strainer will always be self-priming. has flexible blades which wipe against a curved cam plate A clean raw water intake strainer is a vital component of the within the impeller housing, producing the pumping action. -
Page 26: Fuel System
Take care in catching any fuel that may spill . • TO FUELINJECTOR SCHRADER TEST FUEL PORT PUMP OWNER INSTALLED FUEL CELL ELEMENT FUEL WATER (FUEL PUMP/FILTER) SEPERATOR (WESTERBEKE PART 149602) D·RING BOWL ENGINE FUEL FILTER & Generators Engines... -
Page 27: Bleeding The Fuel System
FUEL SYSTEM BLEEDING THE FUEL SYSTEM the engine cranks but fails to start or starts and then shuts 5. Repeat step 2, this time purging the air completely from down, there may be air in the fuel system. Use the following the throttle body. -
Page 28: Electronic Fuel Injection (Efi)
The ECU interprets this information to determine the appropriate injector pulse mte and throttle 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. WESTERBEKE Engines & Generators... -
Page 29: Engine Lubrication Oil
Call a competent mechanic if water NOTE: Use genuine WESTERBEKE oil filters. Generic filters is present in the oil. Raw water present in the oil can are not recommended. be the result of a fault in the exhaust system attached to the... -
Page 30: Testing Oil Pressure
OIL PRESSURE NOTE: WESTERBEKE recommends that the following engine adjustments be pet/armed by a competent engine mechanic. The information below is provided to assist the mechanic. DESCRIPTION LOW OIL PRESSURE The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 15.0 - 10.0 psi... - Page 31 Contact your WESTERBEKE dealer for more information. NOTE: Refer to ENGINE OIL CHANGE in this manual for NOTE: Westerbeke is not responsible for engine failure due to instructions on removing the oil filter. incorrect installation of the Remote Oil Filter.
- Page 32 Replace the timing belt if there is any oil, grease, or moisture on it. Inspect the timing belt covers for damage or cracks. Replace 2. Check for damage, wear, peeling, cracks, and hardening. if necessary. Replace if necessary..WESTERBEKE Engines & Generators...
- Page 33 Thess parts should nerer be cleaned. Replace If ssrlously contaminated with dirt oil. Is erident If 01/ on these parts, check the front case, oil pump seals, and camshaft oil ssals for a possible leak. WESTERBEKE ,.y: Engines & Generators...
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Page 34: Engine Adjustments
7. Replace the belt guard. the wires from the spark plugs, grasp and twist the moulded cap, then pull the cap off the spark plug. The resistance value 410 ohm per inch of wire. CHECKING RESISTANCE WESTERBEKE Engines & Generators... -
Page 35: Engine Compression Test
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. ENGINE COMPRESSION TEST 6. Measure the compression pressure for all the cylinders. Ensure that compression pressure differential for each 1. To check the engine's compression pressure, warm up the cylinder is within the specified unit. -
Page 36: Torquing The Cylinder Head Bolts
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. IGNITION TIMING VALVE CWUlANCE ADJUSTMENT 1. Attach a digital timing light to the #1 spark plug and mark NOTE: Retorque the cylinder head bolts before adjusting the... -
Page 37: Generator Information
(split-phase) are Iwt CARBON MONOXIDE DETECTOR made in larger sizes. WESTERBEKE recommends mounting a carbon monoxide Because the heavy surge of current needed for starting detector in the living quarters. Carbon Monoxide, even in motors is required for only an instant, the generator will not small amounts is deadly. - Page 38 DESCRIPTION CIRCUIT BREAKER This generator is a four-pole, brushless, self-excited generator A circuit breaker is installed on all WESTERBEKE which requires only the driving force of the engine to produce generators. This circuit breaker will automatically disconnect AC output. The copper and laminated iron in the exciter stator generator power in case of an electrical overload.
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Page 39: Internal Wiring Schematics (Single And Three Phase)
1:",0 -;-!- I I : :1- ..L_. _ _ _ _________ L-----r~ 6.3 AMP L _ _ _ _ _ _ _ _ - REGULATOR ",FUSE =1:~Lj:f::. ===t---' " " l~+~~====~=]======d----~ SO" BlUE yEtlO'N WESTERBEKE ...v' Engines Generators &... -
Page 40: Generator Ac Voltage Connections
120V-60HZ. ' " '" " -===- A JUMPER IS REQUIRED FOR 120V - 60 Hz 00 : L' ____ L ___ _ --Tt-- LED READOUT ~~""'1--REGULATOR POTENTIOMEtERS CIRCUIT BREAKER 2D KW BED SHOWN CIRCUIT BREAKER ...v: WESTERBEKE Engines & Generators... - Page 41 GENERATOR AC VOLTAGE CONNECTIONS BE THREE PHASE 6 STUD /12 WIRE TERMINAL BLOCKS NOTE: For output leads from the AC terminal block used terminal ends for 114" studs that accept multi-strand copper wire sizedfor the average rating from the hot lead connection. .
- Page 42 L2, L3-N - 120 VAC 1060 Hz BE THREE PHASE (TWELVE WIRE) A. SERIES DELTA - Note the repositioning 01 the ground lead Irom neutral to gener- ator housing. J. Jumper using 1110 AWG Wire. WESTERBEKE -.yo Engines & Generators...
- Page 43 SBEG TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ. --_________ ________________________ ______________ _ ~F~AU~~~J ~P~R=OB=A=B~LE~C~A=US~E~ NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the 4. Open in exciter main stator winding. stator winding.
- Page 44 VOLTAGE REGULATOR ADJUSTMENTS Stability Description This potentiometer pennits variation of the regulator's The voltage regulator is an advanced design which ensures response to generator load changes so as to limit optimum AC alternator performance. is equipped with overcompensation and obtain a minimum recovery time to complete protection circuitry to guard against operating the normal voltage output.
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Page 45: Shore Power Transfer Switch
SHORE POWER TRANSFER SWITCH CONNECTIONS CONNECTIO~S SHORE POWER (60 HERTZ) 120 VOLT/60 HZ THREE WIRE CONFIGURATION Notice the repositioning of the white wire ground load on the NOTE: Diagram stlows .:onnec:toonl lor .. IWO_ tenninal block to the generator case. "If"... -
Page 46: Wiring Diagram #49209
20KW and 22.5KW SBEG GENERATOR WIRING DIAGRAM #49232 ""." ".""." -=-- ..I c=ll! I.q; tp:~!if; c.;..::J ".-" 11- •• . \WJI ± ~" ·:·:::~l@· " . . """ . . : .IJl l . 0 0 0 0 0 0 0 . - Page 47 20KW AND 22.5KW SBEGA GENERATOR WIRING DIAGRAM #53467 i i l ii:HH~dHili hdd~~d~hd • • • i ~ ~ • • ! ! ! ! ! ! • • • • "'"'''''' ,.' "" ,-(j WESTERBEKE ",,,,,,,,.,,,,,,3 Engines & Generators...
- Page 48 #20 WHT/BLK/GRN VIEWED FROM WIRE SIDE TO T3) riopi #18 WHT/BLK/RED I/'" AVAILABLE FROM YOUR WESTERBEKE DEALER WIRING HARNESS EXTENSIONS: 15 FT. PART NO. 49201 30 FT. PART NO. 49211 50 FT. PART NO. 49667 75 FT. PART NO. 49666 100 FT.
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Page 49: Engine Li'oubleshooting
ENGINE TROUBLESHOOTING The following troubleshooting tables are based upon certain NOTE: The engines control system (electrical system) is engine problem indicators and the most likely causes of the protected by a Ampere manual fuse located on the control problems. panel. The generator has an AC circuit breaker at the control panel which should be in the off position when performing When troubleshooting indicates an electrical problem, see the troubleshooting. - Page 50 (4) running minutes. lfyour product is equipped with OBO (on board diagnostics) go to www.WESTERBEKE.COMand follow the free mterface software download instructions specific to your engine to obtain and install the appropriate diagnostic software.
- Page 51 The following lesl procedures will require lhe use of a mullimeler and Ihe engine~ wiring diagram (in Ihis manual). Also refer 10 Ihe relay lesling page. WESTERBEKE recommends lhat these lesls be performed by a qualified technician. CAUTION: When servicing or replacing DC components, tum off the circuit breaker.
- Page 52 ELECTRICAL TROUBLESHOOTING CHART The following test procedures will require the use of a multimeter and the engine~ wiring diagram (in this manual). Also refer to the relay testing page. WESTERBEKE recommends that these tests be peiformed by a qualified technician. PROBLEM TESTING...
- Page 53 LAY-UP & RECOMMISSIONING GENERAL Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane including engines and generators, for lay-up during the or higher. A fuel conditioner such as Sta-Bil gasoline off-season or for long periods of inactivity.
- Page 54 Lay-up time provides a good opportunity to inspect your if access to the starter permits its easy removal. Make sure the Westerbeke engine to see if external items such as drive belts battery connections are shut off before attempting to remove or coolant hoses need replacement.
- Page 55 WESTERBEKE 20KW AND 22.5KW SBEG GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS IGNITION SYSTEM Engine Type General Gasoline, four-cycle, four-cylinder, Battery ignition 12V negati\.' Jround. fresh water-cooled, Vertical, in-line Distributor with ignition module and ignitor. overhead mechanism Ignition coil and spark plugs. Governor 1.0% speed regulation.
- Page 56 WESTERBEKE 20KW AND 22.5KW SBEG GENERATOR SPECIFICATIONS LUBRICATION SYSTEM AC GENERATOR (SINGLE PHASE) General Pressure fed system General·Single Phase Brushless six pole, revolving field. Sealed lubricated s'lngle bearing design. Oil Filler Full flow, paper element, spin-on type Reconnectable single phase lor 1201240 volts...
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Page 57: Torque Specifications
Water Pump ..........12.7 " 17.4 91.9 " 2.6) Front Housing Assembly ......12.7" 17.4 (1.9" 2.6) Intake Manifold ........12" 17 (1.6" 2.4) NOTE: Formula to convert /I"lbs to Nm (Newton Meters) multiply /I"lb x 1.356 WESTERBEKE Engines & Generators... -
Page 58: Standard And Metric Conversion Oata
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet Miles x 1.609 = Kilometers (km) x .0621 = Miles DISTANCE EQUIVALENTS 1 Degree ofLatitude = 60 Nm = 111.120 km 1 Minute of latitude = 1 Nm = 1.862 km VOLUME... -
Page 59: Metric Conversions
LITERS TO PINTS Liters Liters Liters Pints Liters Pints Pints Pints 0.47 2.84 2.11 12.68 0.95 3.31 4.23 14.79 16.91 1.42 3.79 6.34 1.89 4.26 8.45 19.02 2.37 4.73 10.57 21.13 TEMPERATURE 175 212 °C -.v: WESTERBEKE Engines & Generators... -
Page 60: Suggested Spare Parts
SUGGESTED SPARE PARTS WESTERBEKE MARINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION fUEL/WATER SEPARATOR fiLTER ELEMENT HEAT EXCHANGER END GASKET THERMOSTAT fUEL fiLTER AND GASKET OIL fiLTER CAP~iP' DISTRIBUTER AND WIRES SPARE FUSES CONTROL PANEL AND BE REGULATOR... - Page 61 SAFE 1-.y'IWESTERBEKE (OENERATORS BERIES WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 US.A. TEL: (508) 823-7677 • FAX: (508) 884-9688 • Website: WWW.westerbeke.com lD1111GO...