Westerbeke 8.0 KW-60Hz SBEG Operator's Manual
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Westerbeke 8.0 KW-60Hz SBEG Operator's Manual

Westerbeke 8.0 KW-60Hz SBEG Operator's Manual

Marine gasoline generators
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OPERATORS MANUAL
8.0KW . 60Hz SBEG /6.4KW • 50 Hz SBEG
10.0KW • 60Hz SBEG / 8.0KW· 50 Hz SBEG
12.5KW· 60Hz SBEG /10.0KW • 50 Hz SBEG
14.0KW· 60Hz SBEG /11.6KW • 50 Hz SBEG
MARINE G
E GENERATORS
PUBLICATION NO. 49735
FOURTH EDITION
FEBRUARY 2009
, u) ra-Low Carbon Monoxide Emissio
s

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Summary of Contents for Westerbeke 8.0 KW-60Hz SBEG

  • Page 1 ~£ " It /I .."':. } . .--.;;" i '" '" ~I.D"'" OPERATORS MANUAL 8.0KW . 60Hz SBEG /6.4KW • 50 Hz SBEG 10.0KW • 60Hz SBEG / 8.0KW· 50 Hz SBEG 12.5KW· 60Hz SBEG /10.0KW • 50 Hz SBEG 14.0KW·...
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. 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 a bulkhead near your engine or generator.
  • Page 4 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefuay. Most accidents are caused by failure to follow funtlamental rules and WARNING: Fire can cause injury death! precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your •...
  • Page 5 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is a deadly gasl ordeathl • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine/ discharged from the engine.
  • Page 6 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-1 Exhaust Systems P-4lnboard Engines E-9 DC Electrical Systems All installations must comply with the Federal Code of Regulations (FCR). """ WESTERBEKE Engines & Generators...
  • Page 7 Westerbeke Safe-CO generators achieve an approximate 99% Westerbeke Safe-CO generators are designed to reduce reduction of typical CO by precise control control of the normal levels of CO in the engine exhaust by approximately engine's air/fuel ration coupled with after treatment in a 99%.
  • Page 8 Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI, contains entrained cooling water (except stack exhaust Teledyne and others. Westerbeke recommends analyzers with systems). Only analyzers with probes should be used at this a probe connected to the analyzer by a length of transparent tubing.
  • Page 9 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 10 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

  • Page 11: Table Of Contents

    Starter Motor ............ .31 Generator Information ........BE Generator ............. Generator AC Voltage Connections ....Lay-up and Recommissioning ......Generator Specifications ......... Shorepower Transfer Switch ......Metric Conversion ..........Standard Hardware and Sealants ....Suggested Spare Parts ........WESTERBEKE -.,y: Engines & Generators...

  • Page 12: Parts Identification

    RIGHT SIDE FUEL PRESSURE REGULATOR OIL FILL SIPHON BREAK SENSOR ,--",:::::o,"<~ DISTRIBUTOR FRDNT HIGH EXHAUST. TEMPERATURE:SENSOR DC ALTERNAlroR----- GENERATOR START SOLENOID :--t-I'XHIIUST ELBOW STARTER Mn,rnD . - - REAR '-.E:(HAI~ST CHECK POINT HEAT CONNECTION LEFT SIDE MOUNT WESTERBEKE Engines & Generators...

  • Page 13: Introduction

    NOTE: A carbon nwnoxide warning decal has been provided are verticle in-line, and the engine's cylinder head has an by WESTERBEKE. Affix this decal in a visable location in overhead camshaft which is chain-driven. The engine utilizes the engine room.

  • Page 14: Fuel, Engine Oil, And Engine Coolanl

    FUEL, ENGINE OIL AND ENGINE COOLANT ENGINE COOLANT GASOLINE WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals CAUTION: Only use unleaded fuel with an octane that can corrode internal engine surfaces.

  • Page 15: Preparations For Initial Start-Up

    PREPARATIONS FOR INITIAL START-UP PRESTARTINSPECTION • Visually examine the unit. Look for loose or missing parts, disconnected wires, unattached hoses, and check Before starting your generator for the first time or after a pro- threaded connections. Search for any gasoline leaks. longed layoff, the following items: check...

  • Page 16: Remote Panel

    LED will remain illuminated. To reset the LED, the stop instructions in this manual. SYSTEM switch must be momentarily depressed. This remote panel is a plug-in accessory and is available with a to 100' wiring harness . • START----'STOP REMOTE CONTROL PANEL WESTERBEKE Engines Generators &...

  • Page 17: Break-In Procedure/Daily Operation

    BREAK-IN PROCEDURE/DAILY OPERATION BREAK-IN PROCEDURE NOTE: Some unstable running may occur in a cold engine. This condition slwuld abate as nonnal 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% to 60% of full load for the first 10 hours.

  • Page 18: Safety Shutdown Switches

    SAFETY SHUTDOWN SWITCHES DESCRIPTION The engine/generator is protected by switches and sensors that send signals to the ECU that it interprets as a fault and automatically shuts down the generator drive engine. When an automatic shutdown occurs, one of the control panel fault LED lights will illuminate indicating what fault caused the engme to shutdown.

  • Page 19: Maintenance Schedule

    MAINTENANCE SCHEDULE WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the co"ect tools for each job. Disconnect the battery terminals when serviCing any of the engine's DC electrical equipment. SAFE Maintenance items that are very imponant to the proper operation of "Safe CO"...
  • Page 20 2000 hours. Replace as needed. 1"t1f1 Inspect every 1 000 hours. Replace every 2000 hours. Oxygen Sensor Sample with CO analyzer. CO In Exhaust ·WESTERBEKE recommends this service be performed by an authorized mechanic. ADJUSTABLE CLAMP .0~~" EXHAUST MANIFOLD Engines & Generators...

  • Page 21: Fuel System

    1. Shut off the fuel supply to the generator. Disconnect the valves to use when checking for water and fuel supply line to the inlet filter and unscrew the filter impurities. WESTERBEKE PART from the pump inlet. Take care to catch any fuel that may NUMBER (49602) be present.

  • Page 22: Bleeding The Fuel System

    FUEL SYSTEM BLEEDING THE FUEL SYSTEM 1. Insure that the fuel cell connected to the wiring harness, and that the lift pump connected. 2. Attach Snap On MT337B, OTC or equivalent fuel pressure gauge set to the Schrader valve on fuel cell. CAUTION: Follow manufacturer's instructions for "SNAP-ON-TOOL"...
  • Page 23 Dipswitch #1 is used to charge the generators frequency. ON is for 50 hertz and OFF is for 60 hertz operation. The remaining switches #2, 3#. and #4 service no functions. -..v- WESTERBEKE ADJUSTMENT POT Engines & Generators...

  • Page 24: Cooling System

    Carry a spare cap. spilled coolant. MANIFOLO KEEP THESE PASSAGES CLEAR TO ENSURE PRESSURE A FULL FLOW OF COOLANT TO ANO FROM COOLANT EXPANSION SEAL THE COOLANT RECOVERY TANK ( A PIPE CLEANER WORKS WELL) WESTERBEKE -.y- Engines & Generators...

  • Page 25: Thermostat

    COOLING SYSTEM If the zinc anodes need replacement, hold the hex boss HEAT EXCHANGER into which the zinc anode is threaded with a wrench while Cool raw water flows through the inner tubes of the heat loosening the anode with another wrench. This prevents the exchanger.

  • Page 26: Raw Water Pump

    COOLING SYSTEM RAW WATER PUMP RAW WATER INTAKE STRAINER The raw water pump is a self-priming, rotary pump with a NOTE: Always install the strainer at or below the waterline so non-ferrous housing and a neoprene impeller. The impeller has the strainer will always be self-priming.

  • Page 27: Engine Lubricating Oil

    ,auT engine. NOTE: Use genuine WESTERBEKE oil filters. Generic filters are not recommended. CHANGING THE ENGINE OIL REFILLING THE OIL SUMP The engine oil should be warm.

  • Page 28: Oil Change

    INSTALLATION To install, simply remove the engine oil filter and thread on WESTERBEKE's remote oil filter kit as shown. Always This popular accessOIY is used to relocate the engine's oil install this kit with the oil filter facing down as illustrated.
  • Page 29 THROTTLE BODY ASSEMBLY FUEL INJECTOR FUEL PRESSURE SCHRADER VALVE AIR TEMPERATURE SENSOR PUSH ON SPAOE CONNECTION MAP SENSOR FROM THE THERMOSTAT ASSEMBLY i' .. MANIFOLD 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 30: Engine Adjustments

    ENGINE ADJUSTMENTS SPARK PLUGS DRIVE BELT ADJUSTMENT The spark plugs should be cleaned and regapped after the The drive belts must be properly tensioned. Excessive drive first 50 hour break-in period, then inspected every 250 hours belt tension can cause rapid wear of the belts and reduce the thereafter and replaced as needed.

  • Page 31: Engine Compression Test

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peifonned by a competent engine mechanic. The information below is provided to assist the mechanic. ENGINE COMPRESSION TEST IGNITION TIMING 1. To check the engine's compression pressure, wann up the engine then shut it down.

  • Page 32: Timing Belt Inspection And Replacement

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The infonnation below is provided to assist the mechanic. TIMING BELT INSPECTION AND REPLACEMENT CAUTION: TIMING BELT ASSEMBLY Water or oil on the timing belt severly reduces the service life of the belt.
  • Page 33 ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends tluit the following engine adjustments be pelformed a competent engine mechanic. The infonnation below is provided to assist the mechanic. Timing Belt Inspection Belt Tensioner Inspection Replace the belt if any of the following conditions exist: Replace the belt tensioner if it binds, rattles, or is noisy when turned.
  • Page 34 ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The infannalion below is provided to assist the mechanic. Timing Belt Installation I+_-CYLINDER --Ho-(,I CAMSHAFT HEAD SPROCKET ALIGN THE TIMING MARK 1. Align the camshaft timing mark with the timing mark on the cylinder head.

  • Page 35: Engine Troubleshooting Guide

    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 peiforming When troubleshooting indicates an electrical problem, see the troubleshooting.
  • Page 36 Fuel pump clogged. Remove and 7. Faulty oil filter. replace. Dirty oil or wrong SAE type oil in the High oil pressure. Throttle body filter screen dirty. Remove and clean. engine. Relief valve is stuck. """ WESTERBEKE Engines & Generators...
  • Page 37 (in this manual). Also refer to the relay testing page. WESTERBEKE recommends that these tests be peiformed by a qualified technician. PROBLEM TESTING INSPECTION/SOLUTION is battery + vo/mge measured...

  • Page 38: Electrical Troubleshooting Guide

    ELECTRICAL TROUBLESHOOTING GUIDE 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 39: Dc Electrical System

    DC and AC converters, and shut down the engine (IGNITION ON • ENGINE OFF before perfonning DC testing. No AC tests should be ~ggggees made without proper knowledge of AC circuits..STARTIN G BATTERY WESTERBEKE GROUND Engines Generators &...

  • Page 40: Battery Care

    DC ELECTRICAL SYSTEM Now check the voltage between the alternator output ter· Checking the Service Battery minal (B+) and ground, the circuit is good, the voltage at Check the voltage of the service battery, This battery should the alternator will be the same as the battery, or if an isola· have a voltage between 13 and 14 volts when the engine is tor is in the circuit the alternator voltage will be zero, running,...

  • Page 41: Wiring Schematic #49167

    WIRING SCHEMATC #49167 ..--=. --!, : . . n p - ""',' -=rr- r - - 'r=-. f---; ' - - ; ll)l '"l c-11 f~--;j J:~~,~ '--' '--'~ I"' , .,,,,,, ,._ ' ' ' ' ' ' ' ' ' i lb ' v ' "...

  • Page 42: Starter Motor

    STARTER MOTOR DESCRIPTION No-Load Test The startu can be roughly divided into the following sections: L Connect the ammeter, voltmeter, and battery to the starter • A motor section which generates a drive power. as illustrated. • An overrunning clutch section which transmits an anna- 2_ When the switch is closed, the pinion must protrude and ture torque, preventing motor overrun after starting.
  • Page 43 STARTER MOTOR 4. Return test:. With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position ,.t;;~~-, ATTRACTION TEST when released from holding by hand. 3.

  • Page 44: Generator Information

    Run the generator first with no load applied, then at half the Carbon Monoxide Detector generator's capacity, and finally loaded to its full capacity as WESTERBEKE recommends mounting a carbon indicted on the generator's data plate. The output voltage monoxide detector in the vesssei's living quarters. Carbon...

  • Page 45: Be Generator

    The regulator produces a DC voltage to further excite the exciter stator A circuit breaker is installed on all WESTERBEKE windings, enabling the generator to produce a rated AC generators. This circuit breaker will automatically disconnect output The voltage regulator senses AC voltage output and generator power in case of an electrical overload.

  • Page 46: Generator Ac Voltage Connections

    3. Remove or install the jumper on the automatic regulator (depending on frequency). Refer to BE GENERATOR. NOTE: The green growui wire may be remnved in those /V\T!WESTERBEKE installations where the AC circuit IlLls a separate neutral 46455 This ground circuit.

  • Page 47: Lay-Up And Recommissioning

    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 or higher. A fuel conditioner such as Sta-Bil gasoline including engines and generators, for lay-up during the off-season or for long periods of inactivity.
  • Page 48 Lay-up time provides a good opportunity to inspect your 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 49 WESTERBEKE 8.0/6.4KW TO 14111.6KW SBEG ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS IGNITION SYSTEM General Engine Type Gasoline, four·cycle, four-cylinder, Battery ignition 12V negative ground. Distributor with ignition module and igniter. fresh water-cooled, Vertical, in-line overhead mechanism Ignition coil and spark plug. Electromagnetic...

  • Page 50: Shorepower Transfer Switch

    AC connections are correct. cause damage to the exciter circuit components in the generator. PN32133 GENERATOR/SHORE SWITCH SHIP'S LOAD ../ - - ~~. ~N L-____ !"EVTAAL)' • / SHIP'S - GROUND • SHORE POWEJI 230V 50HZ ""'" WESTERBEKE Engines & Generators...

  • Page 51: Metric Conversion

    ENGLISH TO METRIC CONVERSION CHART Mullinlu Temneralure To aet eauivalent number of: Denree Fahrenheit I'F) I"F-32) : 1.8 Demee Celsius 'C) MuJtinlv Acceleration To oet eouivalent number of: FooVsecond'lftlse~) 0.3048 Meterlsecond (m/s Inch/second (inlsec Im/s~ 0.0254 Meterlsecond' MultiDlv Toraue To cet eauivalent number of: Pound-inch Ilb·in.l 0.11298 Newton-meters IN·m)
  • Page 52 Specialized gasket sealers such as HYLOMAR work well in applicalions requir- Heavily oil all sliding and reciprocating components when assembling. Always ing non-hardening properties. HYLOMAR is particlarly effective on use clean engine oil! copper cylinder-head gaskets as il resists fuel, oil and water. ~...v-~WESTERBEKE Engines & t}enerators...

  • Page 53: Suggested Spare Parts

    SUGGESTED SPARE PARTS WESTERBEKE MARINE GASOLINE GENERATORS CONTACI' YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMAT THERMOSTAT AND GASKET RAW WATER IMPELLER/GASKET FUEL FILTERS AND WIRES MOlDED'· kIT . HOSE INA CANVAS'· CARRYING WESTERBEKE RECOMMENOS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRANO) FOR AN OIL CHANGE (5 DTS.) ANO A GALLON OF PREMIXED COOLANT.
  • Page 54 SAFE S E R I E S WMDWl13B-4/09 WESTERBEKE -member . WESTERBEKE CORPORATION· 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780 WEBSITE: WWWWESTERBEKE.COM...

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10.0 kw-5

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