Related Manuals for Westerbeke 20.0KW SBEG
Summary of Contents for Westerbeke 20.0KW SBEG
- Page 1 OPERATORS MANUAL 20.0KW SBEG and SBEGA • 60HZ 22.5KW SBEG and SBEGA • 60HZ MARINE GASOLINE GENERATORS Single and Three Phase PUBLICATION NO.049800 THIRD EDITION MARCH 2008 Ultra-Low Carbon Monoxide Emissions...
- Page 2 Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel.
- Page 3 SAFETY INSTRUCTIONS • Do not operate with the air cleaner/silencer removed. INTRODUCTION Backfire can cause severe injury or death. Read this safety manual carefully. Most accidents are • Do not smoke or permit flames or sparks to occur near caused by failure to follow fundamental rules and precau- the fuel system.
- Page 4 SAFETY INSTRUCTIONS BATTERY EXPLOSION WARNING: Carbon monoxide (CO) is an invisible WARNING: Battery explosion can cause injury odorless gas. Inhalation produces flu-like symptoms! ordeathl nausea death! • Do not smoke or allow an open flame near the battery • Do not use copper tubing in diesel exhaust systems. Diesel being serviced.
- Page 5 SAFETY INSTRUCTIONS OPERATORS MANUAL ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and Read the following ABYC, NFPA and USCG publications notes to highlight critical information.
- Page 6 EPA andCARB. Even though Westerbeke Safe-CO generators are designed to Maintenance of any components affecting the flow of air or reduce nonnallevels of CO in the engine exhaust by...
- Page 7 Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI, The other location is the boat's exhaust outlet, which 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 8 California 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 air intake, or speed control system components that affect dealer.
- Page 9 The Westerbeke generator that you purchased is certified for constant-speed operation only. The of any Westerbeke product in any manner inconsistent with its intended use could be a viol,ation of Federal Law. "If you 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".
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Page 10: Table Of Contents
Engine Troubleshootlng ........36,37,38,39 Lay-Up and Recommissioning ......... 40,41 20KW SBEG and 22.5KW SBEG Generator Specifications ......... 42,43 Torque Specifications ............ Standard and Metric Conversion Data ..... ..45 Metric Conversions ............Suggested Spare Parts ..........WESTERBEKE ...,y' Engines Generators &... -
Page 11: 20Kw Sbeg/22.5Kw Sbeg Parts Identification
20KW SBEG/22.5KW SBEG PARTS IDENTIFICATION SCHRAIIER VAlVE FUEL PRESSURE REGULATOR SENSOR (liB) HEATER CIRCUIT BREAKER REAR OXYGEN tIVBli7~?~~;+_-\L SENSOR ~'" _T--_ EXHAUST TEMPERATURE fRONT SWITCH BELT GUARD EXHAUST CONNECTION ISOLATOR MOUNT HEAT EXCHANGER RAll RAW WATER lEFT SIDE OIL SUMP DISCHARGE COOLANT FILL COIIJBALLAST... -
Page 12: Introduction
USE OF SUCH SOFTWARE. manual carefully and observe all the safety precautions throughout. Should your generator require servicing, contact WESTERBEKE customers should also kcep in mind the your nearest WESTERBEKE dealer for assistance. time span between printings of WESTERBEKE product software and the unavoidable existence of earlier This is your operators manual. - Page 13 Also insist upon WESTERBEKE packaged parts the way. WESTERBEKE will provide you with a suggested because or generic parts are frequently not made to the...
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Page 14: Fuel, Engine Oil And Engine Coolant
FUEL, ENGINE OIL AND ENGINE COOLANT GASOLINE ENGINE COOLANT WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the CAUTION: Only use unleaded fuel with an octane chemicals that can corrode internal engine surfaces. -
Page 15: Preparations For Initial Start-Up
PREPARATIONS FOR INITIAL START-UP PLASTIC COOLANT RECOVERY TANK MANIFOLD PRESSURE CAP AIR BLEElJ PETCOCK THIS LINE RETURNS COOLANT THE ENGINE OIL DIPSTICK EXHAUST MANIFOLD PRESTART INSPECTION Before starting your generator for the first time or after a • Visually examine the unit. Look for loose or missing prolonged layoff, check the following items: parts, disconnected wires, unattached hoses, and check threaded connections. -
Page 16: Operating Instructlons
OPERATING INSTRUCTIONS CAUTION: When servicing or replacing DC components, tum offtbe 20 amp DC circuit breaker. fW'/WES1ERBEKE 0 '-r--r--r---r-'~ DC CIRCUIT BREAKER ON/OFF START STOP EMERGENCY STOP AND FIREBOY CONNECTIONS STOP SWITCH CHECK ENGINE LIGHT GENERATOR CONTROL PANEL The start/stop rocker switch is the only functional component The check engine light indicates a potential emission's control on the generator control panel used to start and stop the issue. -
Page 17: Break-In Procedure/Dally Operation
BREAK-IN PROCEDURE/THE DAILY OPERATION BREAK~IN NOTE: Some unstable running may occur in a cold engine. PROCEDURE This condition should lessen as normal operating temperature After the generator has been started, check for proper is reached and loads are applied. operation and then encourage a fast wann-up. Run the generator between 20% and 60% of full-load for the first 10 hours. -
Page 18: Safety Shutdown Sensors/Switches
SAFETY SHUTDOWN SENSORS AND SWITCHES Oil Pressure Sensor SAFETY SHUTDOWN SWITCH/SENSORS An oil pressure sensor is located off the engines oil gallery. The engine is protected by four automatic shutdown circuits. Oil pressure on the sensor affects the DC voltage through the Should a shutdown occur, do not attempt to restart without sensor to the ECU. -
Page 19: Maintenance Sehedule
MAINTENANCE SCHEDULE WARNING: Never attempt to pedorm any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. SAFE IMaintenance items that are very important to proper operation of "Safe... - Page 20 2000 hours. Replace as needed. Oxygen Sensor Inspect every 1000 hours. Replace every 2000 hours. CO in Exhaust Sample with CO analyzer. *WESTERBEKE recommends this service be performed by an authorized mechanic. ADJUSTABLE CLAMP EXHAUST MANIFOLD 41" MEASURING EXHAUST BACK-PRESSURE •...
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Page 21: 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 22: Thermostat
COOLING SYSTEM If the zinc anode needs replacement, hold the hex boss into THERMOSTAT which the zinc anode is threaded with a wrench while A thennostat controls the coolant temperature as the coolant loosening the anode with another wrench. This prevents the continuously flows through the closed cooling circuit. -
Page 23: 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 NOTE: Always install the strainer or below the waterline so non-ferrous housing and a Neoprene impeller. The impeller the 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 24: Fuel System
Periodically check the fuel connections and the filter bowl for leakage. Replace the filter element after the first 50 hours. See the MAINTENANCE SCHEDULE. SCHRADER TEST PORT FUEL CELL ELEMENT (FUEL PUMP/FILTER) O-RING OWNER INSTALLED FUEL WATER SEPERATOR ENGINE FUEL FILTER (WESTERBEKE PART #49602) Engines Generators &... - Page 25 FUEL SYSTEM BLEEDING THE FUEL SYSTEM If the engine cranks but fails to start or starts and then shuts S. 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.
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Page 26: Electronic Fuel Injection (Efi)
ELECTRONIC FUEL INJECTION (EFI) FUEL PRESSURE REGULATOR FUEL RETURN TO DISTRIBUTOR AIR HEATER STEPPER MOTOR PCVVALVE AIR SCREEN! FLAME ARRESTOR COOLANT RETURN DESCRIPTION The above illustration shows the throttle body assembly The injector is a solenoid operated pintle valve that meters attached to the intake manifold. -
Page 27: Changing The Engine Oil
Make sure the oil drain hose NOTE: is properly secured in its holder after all of the old oil has Use genuine WESTERBEKE oil filters. Generic jilters been drained. are not recommended. Always observe the old oil as it is removed. Ayellow/gray REFILLING THE OIL SUMP emulsion indicates the presence of water in the oil. -
Page 28: Testing Oil Pressure
OIL PRESSURE NOTE: WESTERBEKE recommends that the following engine adjustments be performed 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 4.3... -
Page 29: Remote Oil Filter (Optional)
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 Renwte Oil Filter. APPLY A THIN COAT OF CLEAN OIL TO THE O-RING WHEN INSTALLING THIS KIT. -
Page 30: Timing Belt Inspection/Lnstallation
TIMING BELT DISASSEMBLY IINSPECTION \~1:'~1"1 RUllBEl! 'EXl'OSBl TENSIONER PUllEY UPPER TIMING BELT TIMING BELT ' " PUllEY COVER 3. Replace the belt if any of the above conditions exist. TIMING BELT TENSIONER AND IDLER PULLEY Check the timing belt tensioner and idler pulley for smooth rotation and abnormal noise. - Page 31 TIMING BELT INSTALLATION DlRECTIO;n 1. Align the timing mark on the timing belt pulley and camshaft pulley with the marks. ARROW 2. Remove all the spark plugs. This is to prevent compression when rotating the timing belt. IF RE-USING THE TIMING MATING MARK MATING MARK BELT, INSTALL IT IN THE...
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Page 32: Engine Adjustments
ENGINE ADJUSTMENTS SPARK PLUGS DRIVE BELT ADJUSTMENT The drive belts must be properly tensioned. Excessive drive The spark plugs should be cleaned and re-gapped after the belt tension can cause rapid wear of the belt and reduce the first 50 hour break-in period, then inspected every 250 hours service life of the fresh water pump's bearing. -
Page 33: Engine Compression Test
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed 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, wann up the cylinder is within the specified unit. -
Page 34: Ignition Tlmlng
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. VALVE CLEARANCE ADJUSTMENT IGNITION TIMING Attach a digital timing light to the #1 spark plug and mark NOTE: Retorque the cylinder head bolts before adjusting the... -
Page 35: Generator Information
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 motors is required for only an instant, the generator will not... -
Page 36: The Sbeg Generator (Single And Three Phase)
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. - Page 37 INTERNAL WIRING SCHEMATICS r - - - - - - SINGLE PHASE EXCITER STATOR ----1------ ----, ROTOR FIELD EXCITER r - - - - - ROTOR STATOR --/------- ----- ® _ _ J ----- REGULATOR ® ~~;===~ FUSE rell ..BLACK green yellow "-...
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Page 38: Generator Ac Voltage Connections
GENERATOR AC VOLTAGE CONNECTIONS Generator Frequency AC VOLTAGE CONNECTIONS NOTE: The frame ground wire (white/green) must be Frequency is a direct result of engine/generator speed: properly positioned when changing the AC output 1800 rpm 60 hertz; 1500 nnp 50 hertz. configuration of the AC terminal block. - Page 39 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/or 114" studs that accept multi-strand copper wire sized for the average rating from the hot lead connection. 1 +3 9+ 11 10 + 11...
- Page 40 GENERATOR AC VOLTAGE CONNECTIONS DESCRIPTION BLK AVR The regulator is equipped with seven numbered terminals (0 to 6) and their related brass jumpers. The illustrations show -N/GND connection points and jumpers for the 3 phase configuration of the generator. The sensing leads connect between pin #1 and pin #2 on the AC terminal block and connection #2 and CASE GND on the voltage regulator board.
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Page 41: Sbeg Troubleshootlng
SBEG TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ. FAULT PROBABLE CAUSE NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the 4. Open in exciter main stator winding. stator winding. 2. - Page 42 VOLTAGE REGULATOR ADJUSTMENTS Description Stability The voltage regulator is an advanced design which ensures This potentiometer permits variation of the regulator's optimum AC alternator performance. It is equipped with response to generator load changes so as to limit complete protection circuitry to guard against operating overcompensation and obtain a minimum recovery time to conditions that could be detrimental to the AC alternator.
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Page 43: Shore Power Transfer Switch
SHORE POWER TRANSFER SWITCH SHORE POWER CONNECTIONS (60 HERTZ) 120 VOLT/60 HZ THREE WIRE CONFIGURATION Notice the repositioning of the white wire ground load on the NOTE: Diagram ehows connections for a two- terminal block to the generator case. 120- wire. -
Page 44: Wiring Diagram #49209
20KW and 22.5KW SBEG GENERATOR WIRING DIAGRAM #49232... - Page 45 20KW AND 22.5KW SBEGA GENERATOR WIRING DIAGRAM #53467 - 1 - - - - ! ttlt ;a:~~~----*~!§ ~~ ~>-------"''"'-''''-------------1rn i ! ! • • .,,, ... , ... , .. , , ..,3 Engines Generators &...
- Page 46 ...J WHT/BLK/YEL #2'0 WHT/BLK/GRY WHT/BLK/GRN VIEWED FROM WIRE SIDE #18 WHT/BLK/RED AVAILABLE FROM YOUR WESTERBEKE DEALER. WIRING HARNESS EXTENSIONS: PART NO. 49201 30 FT. PART NO. 49211 50 fT. PART NO. 49667 PART NO. 49668 100 FT. PART NO. 49669...
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Page 47: Engine Troubleshootlng
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 48 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE Low oil pressure. 1. Low oil level. Blue exhaust smoke 1. Lube oil is diluted. discharge from the 2. Wrong SAE type oil in the engine. 2. High lube oil level. engine. Crankcase breather hose is clogged.
- Page 49 The following test procedures will require the use of a multimeter and the engine's wiring diagram (in this manual). Also refer to the relay testing page. WESTERBEKE recommends that these tests be peiformed by a qualified technician. CAUTION: When servicing or replacing DC components, turn off the 20 amp DC circuit breaker.
- Page 50 ELECTRICAL TROUBLESHOOTING CHART following test procedures will require the use of a multimeter and the engine's wiring diagram (in this manual). Also refer to relay testing page. WESTERBEKE recommends these tests be performed that qualified technician. PROBLEM INSPECTION/SOLUTION TESTING + voltage measured to ground)
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Page 51: Lay-Up And Recommissioning
LAY-UP & RECOMMISSIONING Fuel System [Gasoline] GENERAL Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with wzleaded gasoline of 89 octane including engines and generators, for lay-up during the or higher. A fuel conditioner such as Sta-Bil ga'loline stabilizer should be added. - Page 52 Lubrication and cleaning the starter drive pinion is advisable, Westerbeke engine to see if external items such as drive belts if access to the starter permits its easy removal. Make sure the or coolant hoses need replacement. Check your basic spares...
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Page 53: Generator Specifications
WESTERBEKE 25KW AND 22.5KW SBEG GENERATOR SPECIFICATIONS IGNITION SYSTEM ENGINE SPECIFICATIONS Engine Type Gasoline, four-cycle, four-cylinder, General Battery ignition 12V negative ground. Distributor with ignition module and ignitor. fresh water-cooled, Vertical, in-line Ignition coil and spark plugs. overhead mechanism Governor 1.5% steady speed regulation. - Page 54 WESTERBEKE 25KW AND 22.SKW SBEG GENERATOR SPECIFICATIONS LUBRICATION SYSTEM AC GENERATOR (SINGLE PHASE) General Pressure fed system General-Single Phase Brushless six pole, revolving field. Sealed lubricated single bearing design. Oil Filter Full flow, paper element, spin-on type Reconnectable Single phase for 120/240 volts...
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Page 55: Torque Specifications
TORQUE SPECIFICATIONS • 20KW AND 22.5KW SBEG GENERATORS COMPONENT FT-LB (M-KG) COMPONENT FT-lB (M-KG) Main Bearing Cap ........56.4 - 60.4 (8.4 - 9.0) Air Cleaner Bracket ......... 12.7 -17.4 (1.9 - 2.6) Alternator bracket........25.5 - 35.6 (3.8 - 5.3) Oil Pan ............ -
Page 56: Standard And Metric Conversion Data
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 of Latitude::: 60 Nm ::: 111.120 km 1 Minute of Latitude::: 1 Nm ::: 1.862 km VOLUME Cubic Inches (in3) x 16.387::: Cubic Centimeters x .061 :::in... -
Page 57: Metric Conversions
METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches Inches 25.40 381.00 0.0394 0.5906 0.7874 50.80 508.00 0.0787 76.20 0.1181 0.9843 635.00 101.60 762.00 0.1575 1.1811 127.00 889.00 0.1969 1.3780 254.00 1016.00 03937 1.5748 ... 10 MILLIMETERS::: lCENTIMETER, 100 CENTIMETERS::: 1 METER = 39.37 INCHES (3.3 FEET) INCHES TO METERS METERS TO INCHES Inches... -
Page 58: Suggested Spare Parts
SUGGESTED SPARE PARTS WESTERBEKE MARINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION ZINC ANODES FUEl/WATER SEPARATOR FILTER ELEMENT HEAT EXCHANGER END GASKET THERMOSTAT FUEl FilTER AND GASKET OIL FilTER SPARE FUSES CONTROL PANEL AND BE REGULATOR WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE DRIVE BElTS ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE (5 DTS.) - Page 59 SAFE /w/WESTERBEKE /GENERATORS SERIES WESTERBEKE CORPORA TION • MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A. TEL: (508) 823-7677· FAX: (508) 884·9688 .,Website: www,westerbeke,com 1078DW/SC1204...