diagram on a Westerbeke 6kw generator

[paulga]

I have read the manual and tried to follow the wiring diagram to connect with the description language, but I'm missing some background
here is the instrument panel part. The volts and hours meters each has two connectors, + and -. Oil pressure and water temp meters each has 3 connectors. Comparing to the volts and hours meters, there is one extra connector "s" in these two meters, wired to their respective sender unit. These connectors are represented by a small circle.

1. oil pressure and water temp meters also each has a small rectangle, wired to the + connector
2. there are also 4 small rectangles of the same shape in the preheat switch as well as the start switch, and 2 in the stop switch

what do these small rectangles refer to?

the model of the genny is BCD6.0KW, the technical documents are available from their website
the above picture is from page 44 of the operator's manual

 

[High Wire]

They are 1/4” quick connect terminals or screw in ring terminals.

 

[paulga]

They are 1/4” quick connect terminals or screw in ring terminals.

only 2 terminals in the start switch is connected, so are the other 2 not in use?
this is the full schematic. but some component is not included. eg, the start switch activates the fuel injection pump, but injection pump is not included for some reason

 

[High Wire]

The diagram is correct. The injection pump is mechanical. The Stop switch closes when “not in the Stop position”to power the Fuel or Run solenoid. Lose power to that solenoid and the fuel gets shut off to the injection pump. The Westerbeke generator circuitry is the only engine that I’ve run across in 40 years that use black wire color code for positive DC use.

 

[paulga]

The diagram is correct. The injection pump is mechanical. The Stop switch closes when “not in the Stop position”to power the Fuel or Run solenoid. Lose power to that solenoid and the fuel gets shut off to the injection pump. The Westerbeke generator circuitry is the only engine that I’ve run across in 40 years that use black wire color code for positive DC use.

if I want to "dry crank" the engine ie without providing fuel, so as to build up the oil pressure before actually cranking, is this doable by pressing the start and stop switch at the same time?

Edit: i realized this way does not work, as per the manual, the start switch will not operate electrically unless the PREHEAT switch is pressed and held at the same time

 

[High Wire]

On my old WB the electric fuel pump had a quick connect in the wire lead. If you disconnect that the generator will not start.
Better yet, the Emergency Stop Switch does the same.

 

[paulga]

The diagram is correct. The injection pump is mechanical. The Stop switch closes when “not in the Stop position”to power the Fuel or Run solenoid. Lose power to that solenoid and the fuel gets shut off to the injection pump. The Westerbeke generator circuitry is the only engine that I’ve run across in 40 years that use black wire color code for positive DC use.

are the timing and speed both mechanical adjustment within the injection pump?
does this pump start to inject fuel as soon as the fuel run solenoid is activated?

 

[High Wire]

It’s gear driven off the crankshaft. Never mess with the injection pump or you will regret it. It’s factory set. The fuel solenoid is just an electrical operated valve. Full open or full closed. Never partial. Open ports fuel to the injection pump.

 

[paulga]

The diagram is correct. The injection pump is mechanical. The Stop switch closes when “not in the Stop position”to power the Fuel or Run solenoid. Lose power to that solenoid and the fuel gets shut off to the injection pump. The Westerbeke generator circuitry is the only engine that I’ve run across in 40 years that use black wire color code for positive DC use.

The oil pump and water pumps should also be activated by the start switch. If the engine didn't start, they would stop. So they should be wired to a device like the oil pressure sensor. Should these pumps be included in the wiring diagram?

 

[High Wire]

No. The cooling water pumps and oil pump are mechanical driven by the engine. If the engine crankshaft moves, they move. They are not independently driven by electric motors.

 

[Delta Riverat]

Both the water pump and the oil pump are mechanical. The sensors are for high temp and low pressure.

 

[paulga]

No. The cooling water pumps and oil pump are mechanical driven by the engine. If the engine crankshaft moves, they move. They are not independently driven by electric motors.

Per the manual, the start switch will be released as soon as engine starts, the pre heat switch will be released about 3 seconds after that.
After that, is the start battery disconnected from the circuit and the alternator continues to power the circuit? Does the alternator also charge the battery? Or is the battery solely charged by the genny's ac output?

 

[High Wire]

When you release the start switch, the start solenoid drops out disconnecting the starter MOTOR from the generator starting battery. The battery remains connected to the generator set at all times exactly like a typical modern car. The alternator charges the battery when running.

 

[paulga]

When you release the start switch, the start solenoid drops out disconnecting the starter MOTOR from the generator starting battery. The battery remains connected to the generator set at all times exactly like a typical modern car. The alternator charges the battery when running.

Thanks. so these pumps are driven by the crankshaft.

one maintenance item is to "lubricate the ball joint linkage between the run solenoid and the throttle arm" (see P67 of the operator manual). P72 mentioned "move the throttle level to its full open position", it seems to mean the same as throttle arm. But I didn't find where the throttle arm or ball joint linkage is. Here is the fuel run solenoid:

 

[High Wire]

See the rubber boot? Where it meets the shaft. Follow the shaft to the right until it ends. There too.

 

[BruceK]

... The battery remains connected to the generator set at all times exactly like a typical modern car. The alternator charges the battery when running.

Paulga, it`s worth considering charging the genset battery when it doesn`t run, which can be for extended periods. On a previous boat I had a small 25w solar panel charging it via a simple regulator. On my current 2006 boat the genset battery gets charged via a "switch" from a main battery, which itself is charged by the battery charger at the dock, and of course alts when running. A DC to DC charger seems the preferred method these days.

 

[paulga]

See the rubber boot? Where it meets the shaft. Follow the shaft to the right until it ends. There too.

are these two joints the ball linkages?
what oil or grease should be applied to these joints?

 

[High Wire]

Yes they are the spots. 3 in 1 oil or even a drop of engine oil off the dipstick will do unless the manual specifies something else. It doesn’t take much.

 

[paulga]

Yes they are the spots. 3 in 1 oil or even a drop of engine oil off the dipstick will do unless the manual specifies something else. It doesn’t take much.

This does not need taking anything off, correct?
Is rod in between the two joints the throttle lever?
I didn't see how the lever or valve open or close the fuel supply.
This is the fuel line between the secondary fuel filter to the injection pump. It does not go through the solenoid.

 

[High Wire]

True. The fuel is shut off internally to the injection pump.

 

[paulga]

On top of the diagram in post #3 is a
20a manual reset circuit breaker. The manual says it is "near the starter and as close to the battery as possible, When there is excessive current draw in the instrument panel wiring or engine, the breaker will trip, this will disconnect fuel supply and shut the genny down"

How does the opened breaker disconnect the fuel supply in the diagram?

 

[paulga]

True. The fuel is shut off internally to the injection pump.

I have seen how the solenoid retracts when the preheat switch is pressed. The part circled in the first photo is the throttle arm.

which picture is when "solenoid's plunger is completely bottomed in the solenoid"? this word is from the manual on page 73.

 

[High Wire]

I believe (it’s been 7 years since I replaced my WB) “bottomed” would be fully retracted, or energized, the second photo.

 

[paulga]

I believe (it’s been 7 years since I replaced my WB) “bottomed” would be fully retracted, or energized, the second photo.

Thanks.
What is a good approach to understand the diagram in post #3?
I tried to follow the lines but could not get anywhere.

 

[High Wire]

Print it out as big as you can. Use a color highlighter to trace out one wire at a time. The color and wire gauge is marked on each.

 

[paulga]

Print it out as big as you can. Use a color highlighter to trace out one wire at a time. The color and wire gauge is marked on each.

The Ford Lehman FL135 owners manual has a wiring plot as below.
It says at the end of page A22:
... Locate battery as close as practical to the starter. Gauge of battery cables will be dependent upon length, but should be No. 0 minimum. Use No. 12 gauge or heavier wire for balance of system.

does the "balance of system" indicate the wires between a device and the battery negative?

 

[luna]

No, I don’t think so.

From my read of the manual what it is saying is should you chose to add a tachometer, oil pressure or temp. gauge, any other temp. gauge or the remote start button to turn the thing on while seated in the head, do yourself a favour, use 12 gauge or heavier wire.

 

[paulga]

No, I don’t think so.

From my read of the manual what it is saying is should you chose to add a tachometer, oil pressure or temp. gauge, any other temp. gauge or the remote start button to turn the thing on while seated in the head, do yourself a favour, use 12 gauge or heavier wire.

Thanks.
That makes sense.

 

[paulga]

They are 1/4” quick connect terminals or screw in ring terminals.

I checked the backside of the control panel. The number of quick connect terminals at the back of the switches align with the diagram, but I cannot see what happens when a switch is pressed. eg. which two terminals are connected when the pre heat switch is pressed?