INSTALLATION MANUAL MARINE ENGINES/GENERATORS DIESEL AND GASOLINE PUBLICATION #43268 2nd Edition May 2004
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. n WARNING: Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.
SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS — FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES ▲ WARNING: Accidental starting can cause injury ▲ WARNING: Carbon monoxide (CO) is a deadly gas! or 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 reinstalled before starting the engine.
SAFETY INSTRUCTIONS ■ ■ ■ ■ Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. Do not check fluid levels or the drive belts’ tension while the engine/generator is operating.
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.
TABLE OF CONTENTS Introduction .......................................................................2 Fuel System .....................................................................24 Installation Codes and Safety Standards......................2 Recommended Reading ...............................................2 Product Software ..........................................................3 Notes, Cautions and Warnings .....................................3 Inspection of Shipment ......................
INTRODUCTION This marine Installation Manual covers all WESTERBEKE Engine and Generator models, both diesel and gasoline. The purpose of this manual is to provide boatyards and installers who are already familiar with installation procedures, additional detailed installation instructions to ensure the safest and most efficient operating conditions. These instructions may vary due to the many WESTERBEKE Engines and Generators available and the diversity of boat designs.
INTRODUCTION PRODUCT SOFTWARE INSPECTION OF SHIPMENT Product software, (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within WESTERBEKE’s control. The engine/generator is shipped from the factory securely mounted and properly crated. Accessory equipment is shipped in a separate small box, usually packed within the engine’s crate.
ENGINE LOCATION AND MOUNTING Many boat manufacturers are now providing preformed fiberglass mounting beds for their engine installations. These beds, when used, should be of sufficient thickness for proper support and should be well-glassed to the hull when installed. ENGINE LOCATION The overall layout of the engine room should be planned for easy inspection, servicing, and handling of the engine. Thoroughly study all the equipment to be installed and make a paper plan to provide optimum engine room space.
ENGINE LOCATION AND MOUNTING The engine’s mounting angle cannot exceed 15L from the horizontal plane. Refer to the specification section in your operating manual for the angle limit of your engine. NOTE: There are various transmissions that provide down angle output flanges to help in positioning the engine on a more level plane. ENGINE MOUNTING Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the engine’s flexible mounts.
GENERATOR LOCATION AND MOUNTING GENERATOR LOCATION GENERATOR MOUNTING A solid, level mounting platform is very important for the proper operation of your generator. Select a location that will allow adequate space on all sides for ventilation and servicing, preferably on, and parallel with, the keel or vessel center line. Keep the generator away from living quarters, and away from bilge splash and vapors.
SOUND ENCLOSURE There are custom designed sound enclosures for each model of WESTERBEKE generators. The Sound Guard is a rigid, attractive, easy to clean enclosure that reduces the generator noise to a pleasant hum. The enclosure can be assembled easily in close quarters. Quick action fittings allow for easy access for inspection or routine maintenance of the generator. If major repairs are needed, all the panels can be disassembled in a few minutes. No tools required.
RIGGING AND LIFTING The engine/generator is fitted with lifting eyes. Attach wire rope or chain slings capable of supporting the engine/ generator's weight to the eyes and lift the engine/generator by means of tackle attached to these slings. The lifting eyes have been designed to carry the full weight; auxiliary slings are not necessary.
PROPELLER SHAFT ALIGNMENT PROPELLER SHAFT COUPLING (Engines) A propeller shaft half-coupling is available for all engine models. It is bored to shaft size for the specific order, and has either a keyway with set screws and two locking bolts, or is of the clamping type with a keyway. This coupling is carefully machined to allow a slight forced-fit onto the shaft and to make an accurate mating surface between the coupling and the output flange of the transmission.
PROPELLER SHAFT ALIGNMENT ALIGNMENT The engine must be exactly aligned with the propeller shaft. No matter what material is used to build a boat, the material will be flexible to some extent. The boat’s hull will change its shape to a greater extent than is usually realized when the boat is launched and operated in the water. Therefore, it becomes extremely important to check the engine’s alignment at frequent intervals and to correct any errors when they appear.
PROPELLER SELECTION The type and size of propeller varies with the gear ratio and must be selected to fit the application, based upon boat tests. To utilize the full power of the engine and to achieve ideal loading conditions, use a propeller which will permit the engine to reach its full rated rpm at full throttle while under a normal load and while the boat is moving forward through the water. The following information is needed to calculate and match a marine propeller to a boat. a.
EXHAUST SYSTEM INSTALLATION RECOMMENDED GUIDELINES Sea Water Intrusion Through The Exhaust Outlet These guidelines dated February 2004 supercede all previous guidelines published by Westerbeke Corporation for all types of exhaust systems. Water intrusion is not covered by warranty because it is not caused by a product defect. Please study these guidelines carefully before planning your exhaust system installation. The diagram above illustrates a below waterline installation of an engine or genset.
EXHAUST SYSTEM INSTALLATION This leads to B, the amount by which the spill over point of the exhaust outlet is above the worst case water level. B should be maximized (and certainly always positive). Then the exhaust loop height, C, from the high point spill over point to the through hull fitting spillover point, becomes a back up to B for preventing water intrusion, rather than being the primary defense – as becomes the case whenever the exhaust outlet spillover point dips beneath the water level.
EXHAUST SYSTEM INSTALLATION Sea water Intrusion Through The Intake Seacock Generator-Not in Operation Water Intrusion Another means of water intrusion is though the sea water intake seacock. This can occur when any part of the sea water system or exhaust system are below the worst case water level (other than the seacock itself which is already below the water level, of course).
EXHAUST SYSTEM INSTALLATION Check Valves Dry Stack Exhaust Systems Various types of check valves are available and suitable for exhaust runs. Examples are in-line check valves offered by some exhaust component manufacturers and flapper valves on exhaust outlets. None of these may be considered as an alternative to a good installation. They can leak, they can foul, and they can open intermittently. Think of them as an emergency means to keep out that rogue wave or extreme following sea.
EXHAUST SYSTEM INSTALLATION Exhaust Back Pressure (cont.) Exhaust Hose Back pressure should not exceed 1.5 psi or 41” WC. Excessive back pressure can be reduced by increasing E, increasing the size of the water lift muffler, reducing J, and reducing G. However A, C, and B should not be compromised to relieve back pressure.
EXHAUST SYSTEM EXHAUST ELBOW INSTALLATION Exhaust elbows are standard on generators, optional on engines. For installation on your engine/generator, we offer , 450 700 and 900 exhaust elbows. NOTE: Fabricated exhaust elbows or risers attached to the exhaust manifold shall not exceed 8 lbs. when unsupported. 1. Coat only one side of the exhaust gasket with High Tack (manufactured by Permatex Company, Brooklyn, N.Y.) adhesive sealant.
EXHAUST SYSTEM EXHAUST SYSTEM PRECAUTIONS Raw Water Erosion When the engine’s raw water is fed into an exhaust system so that the full stream of this water strikes a surface, erosion takes place. This erosion may cause premature failures. The proper design of either a water-jacketed or water-injected “wet” exhaust system to prevent this problem requires that the raw water inlet be positioned so that the entering stream of raw water does not directly strike a surface.
ELECTRICAL SYSTEM The panel can also be remote mounted by using optional plug-in extension harnesses which are available in 15 ft. (4.6 m) increments. A maximum of two harnesses, 30 ft (9.2 m) can be connected. For longer distances, hard wiring can be used as shown in the Operators Manual. An optional cover plate is available to cover the face of the panel box when the instrument panel is remote mounted.
ELECTRICAL SYSTEM Starter batteries must be of a type which permits a high rate of discharge. See your Operators Manual specifications for cold cranking ampere hours requirements. Most marine batteries on the market today have large cranking capacities. The battery compartment must be well ventilated to prevent accumulation of explosive battery gases. Mount the battery in an acid-resistant tray on a platform above the floor. It must be secured to prevent shifting.
ELECTRICAL SYSTEM ▲ WARNING: An improper ground can cause severe personal injury or death from fire or explosion. Be sure to install a common ground conductor between all onboard cranking circuits. A common ground for (–) negative DC is located at the bellhousing of the engine/generator next to the starter in the form of a threaded grounding stud. This location is tagged. It is recommended that the battery ground be connected here. Failure to do so can cause arcing or resistance in the cranking circuit.
ADMIRAL CONTROL PANEL When the engine is shut down with the key switch turned off, the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical power was turned off. The oil pressure gauge will fall to zero when the key switch is turned off. The temperature gauge will once again register the engine’s true temperature when electrical power is restored to the gauge. A separate alarm buzzer with harness is supplied with every Admiral Panel.
CAPTAIN CONTROL PANEL DESCRIPTION The panel also includes an alarm buzzer for low OIL PRESSURE or high COOLANT TEMPERATURE. The RPM gauge is illuminated when the KEY switch is turned on and remains illuminated while the engine is in operation. This manually-operated control panel is equipped with a KEY switch, an RPM gauge, PREHEAT and START buttons, an INSTRUMENT TEST button and three indicator lamps, one for ALTERNATOR DISCHARGE, one for low OIL PRESSURE, and one for high ENGINE COOLANT TEMPERATURE.
FUEL SYSTEM Mount the fuel tank and secure it into position. The NFPA recommends that the bottom tanks be installed on slatted wooden platforms to help prevent moisture condensation. Cylindrical tanks should be set in chocks or cradles and securely fastened.Insulate all wood or metal surfaces from the tank surface with a non-abrasive and non-absorbent material.
FUEL TANKS/ FUEL SYSTEM This shutoff valve is necessary to guard against the possibility of gasoline siphoning through the supply line to the carburetor and into the engine in case the carburetor float valve doesn’t close, the carburetor needle valve doesn’t operate properly, or the fuel line ruptures between the engine and the fuel tank at a point below the fuel level.
FUEL SYSTEM Run fuel lines at the top level of the fuel tank to a point as close to the engine or generator as possible to reduce the danger of fuel siphoning out of the tank if the line should break. Fuel piping should always be routed and securely anchored to prevent leaks from vibration and chafing. Fuel piping is usually secured by copper straps every 12-14 in (30-36 cm). Use as few connections as possible, and install the lines so they are accessible and protected. Avoid locked-in torsional stresses.
FUEL SYSTEM SHUT-OFF VALVES FUEL Make sure your fuel system has positive shut-off valves; know their locations and how they operate. NOTE: See the U.S. Coast Guard publication “Fuel System Compliance Guideline” for basic fuel system layouts and shut-off valve locations. To insure satisfactory operation, an engine or generator must have a dependable supply of clean fuel. Diesel Fuel – use No. 2 oil with a cetane rating of 45 or higher. Gasoline – use unleaded 89 octane or higher.
COOLING SYSTEM A through-hull fitting that is completely flush with the surface of the boat’s hull and without an external strainer may be necessary for the generator raw water intake on very high-speed boats. The protrusion of a standard type throughhull fitting and a strainer can cause a venturi effect on the intake of a high speed boat, creating a suction which works against the raw water pump causing an inadequate supply of cooling water to the engine.
COOLING SYSTEM COOLANT RECOVERY TANK A coolant recovery tank kit is supplied with each WESTERBEKE engine/generator. The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation, without the loss of coolant and without introducing air into the cooling system. This coolant recovery tank should be installed at or above engine manifold level, in a location where it can be easily monitored.
ENGINE OIL When additional sensing devices such as switches or sensors need to be installed that function on engine oil pressure, these devices must be bulkhead-mounted and connected to the oil sump using an appropriate grade of lubricating oil hose. Any fittings used to connect the hose to the gallery must be of steel or malleable iron composition. Brass must not be used for this application.
REMOTE OIL FILTER Always install this kit with the oil filter facing down, as illustrated. Contact your WESTERBEKE dealer for more information. NOTE: WESTERBEKE is not responsible for engine failure due to incorrect installation of the Remote Oil Filter. INSTALLATION This popular accessory is used to relocate the engine’s oil filter from the engine to a more convenient location such as an engine room bulkhead.
VENTILATION The ventilation requirements of the engine or generator include the following: combustion air is required for the engine’s cylinders, and cooling air is required for the engine and generator electrical end and also for removing the heat produced during operation. ▲ WARNING: Ventilating air is required to clear the bilges, as well as the compartment in which the engine or generator is located, of potentially toxic and flammable vapors.
WATER HEATER CONNECTIONS INSTALLATION REMOTE EXPANSION TANK Water heater hose connections vary from one engine to another. Refer to your WESTERBEKE Operators Manual for your engine’s water heater connections. NOTE: Water heater connections are not standard on marine generator products. WESTERBEKE marine engines are equipped with connections for the plumbing of engine coolant to heat an on-board water heater.
TRANSMISSIONS SHIPMENT CONTROL CABLES For safety reasons, the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft. Before leaving the WESTERBEKE plant, each transmission undergoes a test run, with Dextron III ATF transmission fluid. The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year if properly stored.
TRANSMISSIONS BORG WARNER VELVET DRIVE Shifting Into Gear Check the transmission fluid level on the dipstick. If the transmission has not been filled, fill with Dextron III and continue to use this fluid. During the first 50 hours of operation, keep a lookout for any leakage at the bell housing, output shaft, and transmission cooler. This fluid should be changed after the first 50 hours and approximately every 1000 operating hours or at winter lay-up.
FINAL INSTALLATION CHECKS NOTE: Also refer to PREPARATIONS FOR INITIAL START-UP in your Operator’s Manual. Before starting the engine or generator complete the following checklist: With the engine or generator running, check the following: ■ Make certain that water is flowing from the exhaust. ■ Check the instrument gauges for proper readings. ■ Inspect the engine for fuel, water, coolant, and oil leaks. Has the proper coolant mix been added? ■ Listen for unusual sounds and vibrations.
ENGLISH TO METRIC CONVERSION CHART 37
WIRE SIZING 38
DECIMAL TO METRIC EQUIVALENT CHART 39
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