Westerbeke 12.5KW-60Hz User manual

, ,
-(lRIJ
" ~
.., .,.
l II'
-t 'fer
o q
~LD"'"
SERVICE MANUAL
44A-44B-44C"FOUR '
35C-35D-35E- THREE
MARINE DIESEL ENGINES
8.0KW • 60Hz " 6. OKW • 50Hz BTOA
10.0KW • 60Hz' , 7.5KW • 50Hz BTOA
11.SKW • 60Hz 9.2KW· 50Hz BTO,:(elec)
12.SKW • 60Hz' 9.4KW· 50HzBTOB
12.6KW • "6llHz 10.4KW· 50Hz BTO'(elec)
'15.0J(W. 60Hz 12.0KW • 50Hz BTOC
--.~ -" - --- "-- .. -.- ... _----- -
,' Single and Three Phase
MARINE DIESEL GENERATORS
, '.'of". . _. __ ,
, PUBLICATION NO.45100
REVISION 2
APRIL 2010

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.
A WARNING:
Exhaust gasses contain carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide Is poisonous and can cause
unconscltiusness and death. Symptoms of Carbon Monoxide
exposure can Include:
-Dizziness
-Nausea
-Headache
- Throbbing In Temples
- Muscular Jlltltchlng
- Vomiting
- Weakness and Sleepiness
-InabIlIty to ThInk Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THt FRESH AIR IMMEDIATELY. If symptoms persist,
seek medIcal attention. Shut down the. unit and do not restart
until It has blfen Inspected and repaired.
This WARNING DECAL Is provided by
WESTERBEKE and should be flxed to a
bulkhead near your engIne or genemtor.
. WE$TERsEKEa!so recommends installing
CARBON MONOXIDE DETECTORS In the
IlvInll/Sleeplng quartem tif your vessel.
T1Ieyare Inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions existand tak£ the
necessary precautions to protect yourself, yourpersonnel,
andyour
machinery.
The following safety instructions are in complinnce with the
Ameriean Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not toullh AC electrillal Ilonnelltions
while engine is running, or when Ilonnellted to shore
power. Lethal voltage Is present at these connelltions!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not toullh hot engine parts or
exhaust system Ilomponents. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire Ilan cause Injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump,
or other potential sources of spilled fuel or fuel
vapors. Use a suitable container
to catch all fuel when
removing the
fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors Ilan Ilau;e
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open
and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out
of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for
all applications encountered in this environment.
~ WESTERBEKE
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
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 re-
installed before starting the engine.
BAnERY EXPLOSIDN
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases Or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive
gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid in batteries can cause
severe Injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention
to the martifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration of copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. lithe engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting Muscular twitching
Dizziness Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touching
moving parts and hot exhaust system components.
-...v: WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and 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 dtive belt's tension while
the engine is operating.
• Stay clear of the dtive shaft and the transruission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open,
A WARNING: Do not wOlk on machinery when you ale
mentally 01 physically Incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABVC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft" .
Order from:
ABYC
3069 Solomon'S Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Oaft"
Order
from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast
Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines arid 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.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to '
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
ntinimum of20"
above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injectionport is at or below the load waterline will resuf1 in
raw water damage to the engine andpossibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, instaU a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation.
Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified fur marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed Marine Installation Manual covering gasoline and diesel
engines and generators is supplied with every unit sold. This manual
is also available in pdllormat on our website to download
Website: www.westerbeke.com
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification/Engines ............................................... 2
Wiring Schematic - Engines .............................................. 59
Parts Identification/Generators .......................................... 3 Specifications - 44-Four Models ...................................... 60
Introduction ........................................................................ .4
Specifications - 35- Three Models .................................... 61
Engine Troubleshooting ....................................................... 5
DC Electrical System (Alternator) .................................... 62
Testing for Overhaul... ......................................................... 9
Mando Alternator Service ................................................. 64
Engine Disassembly ...... .................................................... 10 Wiring Diagram - Generators ............................................ 71
Inspection .......................................................................... 16
Wiring Schematic - Generators ....................................... 71a
Assembly ............................................................................ 27 Remote Panel Schematic .................................................. 72
Exhaust ManifoldlHeat Exchanger ................................... .35
Specifications - Generators ............................................... 73
Fuel Injection Pump .......................................................... 36 BT Generator Single/fhree Phase .................................... 76
Governor ........................................................................... 38
12 Stod Internal Wiring Schernatic................................ 77
Fuel Injection Timing ....................................................... .39
Glow Plug Testing ............................................................. .41
Starter Motor ..................................................................... 42
Raw Water Pumps
#33636 ........................................................................... .46
#48080........................................................................... .47
Component Resistance Values ....................................... 77
Internal Wiring Schematic 6 Stod.................................. 78
BT Generator Troubleshooting (Chart) ...................•.......... 79
BT Generator Troubleshooting .......................................... 80
, BT Generator Troubleshooting (Single Phase) ................. 81
AC Terminal Board (12 Stud) ...•••....................••...•.•........... 85
#48080 Parts List.......................................................... .48
BT Internal Wiring (Three Phase) ...................................... 86
Engine Adjustments .......................................................... 49
BT Troubleshooting (Three Phase) ..............................•..... 87
Valve Clearance Adjustment......................................... .49
BT Voltage Regulator Adjustments (Three Phase) ........... 88
(
Testing Engine Compression ......................................... 50
Generator Frequency Adjustment.................................. 51
Fuel Run Solenoid ......................................................... 51
Oil Pressure........................ ~ ........................................... 52
Drive Belt Adjustment................................................... 53
Adjusting Idle Speed...................................................... 53
Service Data-Standards and Limits ................................. .54
Wiring Diagram - Generator (Electronic Governor) ........... 89
Wiring Schematic- Generator (Electronic Governor) ....... 90
Electronic Governor (Optional) .......................................... 91
Electronic Governor (Adjustments) ..............................•.... 92
Linear Actuator Troubleshooting ...................................... 93
Special Tools - Generator ................................................. 94
Special Tools - Engines ..................................................... 56
Standard Hardware ............................................................ 95
Torque Specifications ....................................................... 57
MetriC Conversion Data .................................................... 96
Wiring Diagram - Engines ................................................. 58
Index .................................................................................. 98
".yo WEBTERBEKE
Engines & Generators
1

PARTS IDENTIFICATION/PROPULSION
WATER INJECTED
EXHAUST
20ACIRCUIT
REAR
FRONT
DC ALTERNATOR
RAW WATER
UNIHD,
OIL
,coo LAN I PRESSURE CAP
RIGHT SIDE
DRAIN HOSE
COOLER
I INTAKE/AIR FILTER
THERMOSTAT
FRONT
. OIL FILL
l@L ___ PRE'HEAT SOLENOIO
'll.~~~a&"~r---FUEl FILTER
REAR
HEAT EXCliANGiER
LEFT SIDE
... WESTERBEKE
Engines & Generators
2
\
J

(
(
(
PARTS IDENTIFICATION/GENERATORS
LEFT SIDE
OIL
RAW WATER ru .. r--:- __ ~~~
HEAT
PANEL
BACK-ENO.
20
CIRCUIT
BREAKER
FRONT
PREHEAT
BREAKER OIL
REAR MOUNT
OIL
RIGHT SIDE
OIL PRESSURE
GENERATOR EMERGENCY
STOP SWITCH
CONNECTION TO
~'"'"UN BREAK
'0t<>ct-t---E'XHAUSTELBOW
~~~ __ --'I-IL_-!iTART SOLENOID
REAR
'!'O(iLANTJ PRESSURE CAP
C .FILL
FRONT
FILL
THERMOSTAT
ASSEMBLY
AIR INTAKE
SILENCER & FILTER
PUMP
OIL FILL
FILTER
Engines & Generators
3"

INTRODUCTION
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than .
WESTERBEKE are not within WESTERBEKE'S control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOF1WARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BEliABLE
FOR ANY TYPE OFDAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF
THE FURNISHING OR USE OF SUCH SOF1WARE.
WESTERBEKE customers should keep in mind the time
span between printings ofWESTERBEKE product software
and the
unavoidable existence ofearlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE
or other suppliers, must not and cannot be relied upon
exclusively as the definitive authority on the respective
product. Itnot
ouly makes good sense bnt is imperative that
appropriate
representatives ofWESTERBEKE or the
supplier in question be consulted to determine the accuracy
and currentness of the product software being consulted by
the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical infonnation will behighlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures which, if not properly
followed, can result in pelSonal injury or loss of life.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine
model number and serial number as they appear on
the silver and black nameplate located on the manifold. You
must provide us with this infonnation so we may properly
identify your
engine. Inaddition, include a complete part
description
and part number for each part needed (see the
separately furnished Parts List). Insist upon
WESTERBEKE
packaged parts because will fit or generic parts are frequently
not made to the same specifications as original equipment.
Customer Identification Card
·/"Mf'IWESTERBEKE
I
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Modelll.5 EDT Ser. #UOOOO-ESll
Expires: 8/5/2013
The WESTERBEKE engine serial number was an
alphanumeric
number that can assist one in detennining the
date of manufacture. Amanufactoring date code is placed
at the end of the engine serial number. It consisted of a
character followed
by three numbers. Today it consists of
two characters. Previous date code. The character indicated
the decade
E=2000s. The first number represented the year in
the decade, and the second and third, the month ofthat year.
Beginning in May 200S, the two characters HE. H
represented
2008 and the E the month ofMay and so on HF
2008 July, HG 200S July.
SERIAL NUMBER LOCATION
The engine's serial number can be found stamped into the
engine blockjust above the injection pump. An identification
plate on the engine manifold also displays the engine model
and serial number.
The gene.rator serial number is stamped on the left side of the
generator housing
and on the flat surface above the rotary
. ENDI.NE
SERIAL
NUMBER
ENGINE OVERHAUL
The following sections contain information
GENERATOR
10 DECAL
relating to the proper operation characteristics of the major
components and systems of the engine. Included are
disassembly, inspection and reassembly instructions
for the
guidance of suitable equipped and staffed marine engine
service and rebuilding facilities. The necessary procedures
should be taken ouly by such facilities.
Additional detailed iufonnation
and specifications are pro-
vided in other sections of this manual, covering the
generator, alternator, starter motor, engine adjustruents,
cooling pumps, etc.
~ WESTERBEKE
Engines & Generators
4

(
ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain
problems
relating to engine service, the probable causes of
these
problems, and the recommendations to overcome
these problems.This chart may be ofassistance indetermin-
ing
the need for an engine overhaul.
PROBLEM PROBABLE CAUSE
HARD STARTING LOW CRANKING SPEED
1. Engine oil viscosity too high.
2. Run-down battery.
3. Worn battery.
4. Battery terminals loosely connected.
5. Defective starter.
6. Defective main drive section.
DEfECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
2. Clogged fuel filter.
3. Low injection pressure.
4. Inadequate spray.
5. Injection pump delivering insufficient fuel.
6. Injection too early.
MAIN ENGINE TROUBLES
1. Low compression.
a. Incorrect valve clearance.
b. Inadequate contact of valve seat.
c. Valve stem seized.
d. Broken valve spring.
NOTE: The engine's electrical system is protected by a 20-
ampere manual reset circuit breaker. The preheat solenoid is
mounted on the same bracket.
VERIFICATION/REMEDY
1. Replace engine oil with less viscous oil.
2. Recharge battery.
3. Replace battery.
4. Clean terminals and correct cables.
5. Repair or replace starter.
6. Check clutch for disengagement.
1. Bleed air from fuel system.
2. Clean or replace filter.
3. Adjust injection pressure.
4. Clean or replace nozzle.
5. Repair or replace Injection pump.
6. Adjust injection timing.
a. Adjust valve clearance.
b. Lap valve.
c. Replace valve and valve guide.
d. Replace valve spring.
o. Compression leaks through cylinder head gasket. e. Replace gasket.
f. Piston ring seized. f. Replace piston and piston ring.
g. Worn piston ring and cylinder. g. Overhaul engine ..
2. Burnt glow plug. 2. Replace glow plug.
3. Faulty glow plug operation. 3. Correct lead wire connection.
4. Incorrect governor lever position.
4. Set lever to starting position.
5. Governor spring out of POSITION 5. Correct spring
LOW OUTPUT
LOW COMPRESSION See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1. Incorrect injection timing. 1. AdjustinjoClion timing.
2. Insufficient injection. 2. Repair or replace Injection pump.
3. Low injection pressure. 3. Check Injection nozzle and adjust pressure.
INSUFFICIENT FUEL
1. Air trapped in fuel system. 1. Check and retighten connector.
2. Clogged filter. 2. Clean or replaee filter.
3. Contaminated fuel tank. 3. Clean tank.
INSUFFICIENT INTAKE AIR
1. Clogged air cleaner.
1. Clean or replace air cleaner.
(continued)
""" WESTERBEKE
Engines & Generators
5

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATIONJREMEOY
LOW OUTPUT (cont.) OVERHEATING
1. Low coolant level. 1. Add coolant.
2. Loose V-belt. 2. Adjust or replace V-belt.
3. Incorrect injection timing.
3. Adjust injection timing.
4. Low engine oil level. 6. Add engine oil.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION 1. Defective oil seals. 1. Replace oil seals.
2. Broken gear case gasket.
2. Replace gasket.
3. Loose gear case attaching bolts.
3. Retighten bolts.
4. Loose drain plug.
4. Retighten plug.
5. Loose oil pipe connector.
5. Retighten all connections.
6. Broken rocker cover gasket.
6. Replace gasket.
7. Loose rocker cover attaching bolts.
7 •. Retighten attaching bolts.
OIL LEVEL RtSING
1. Worn piston ring ..
1. Replace ring.
2. Worn piston or cylinder.
2. Replace piston and rebore;cylinder.
3. Incorrectly positioned piston ring gaps.
3. Correct ring gap positions.
4. Displaced or twisted connecting rod.
: ~. Replace connecting rod.
OIL LEVEL FALLING
1. Defective stem seal.
1. Replace stem seal.
2. Worn valve and valve guide.
4. Replace a valve and valve guide.
EXCESSIVE FUEL ENGINE BODY TROUBLES
CONSUMPTION 1. Noisy knocking.
1. See KNOCKING.
2. Smoky exhaust 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn.
3. Repair orreplace.
4. Poor compression.
4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing.
5. Adjust.
6. Improper valve clearance.
6. Adjust.
INSUFFICIENT INTAKE AIR
1. Air Intake obstructed.
1. Remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle.
1. Replace ..
2. Worn nozzle.
2. Replace.
IMPROPER FUEL
Replace with proper fuel.
FUEL LEAKS
Find fuel leaks.
SMOKY EXHAUST WHITISH OR PURPLISH
1. Excessive engine oil.
1. Correct oil level.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact.
a. Check.
b. Seized piston ring.
b. Replace or clean.
c. Excessive plston-to-cylinder clearance. c. Replace or correct.
(continued)
... WESTERBEKE
Engines & Generators
. 6

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERIFICATIONJREMEDY
SMOKY EXHAUST (cont.) WHITISH OR PURPLISH (cont.)
d. Worn valve stem and valve guide. d. Replace.
e. Low engine 011 viscosity.
e. Replace.
I. Excessive 011 pressure.
I. Correct.
3. Injection timing is too late.
3. Adjust.
4. Insufficient compression.
4. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAYISH
1. Engine body troubles.
a. Poor compreSSion. a. See LOW COMPRESSION; HARD STARTING.
b. Improper valve clearance.
b. Adjust.
2. Insufficient intake air (air cleaner clogged). 2. Clean air cleaner.
3. Improper fuel.
3. Replace with proper fuel.
ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE 1. Badly worn bearing.
1. Replace bearing and grind crankshaft.
2. Badly worn crankshaft.
2. Grind crankshaft.
3. Melted bearing.
3. Replace bearing and check lubrication system.
CONNECTING ROD AND CONNECTING ROD BEARING
1. Worn connecting rod big end bearing. 1. Replace bearing.
2. Worn crankpin. 2. Grind crankshaft.
3. Bent connecting rod. 3. Correct bend or replace.
PISTON, PISTON PIN, AND PISTON RING
1. Worn cylinder.
1. Rebore cylinder to oversize and replace piston.
( 2. Worn piston pin.
2. Replace piston.
3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or damaged.
4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft. 1. Replace.
2. Excessive valve clearance.
2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing.
4. Replace.
ROUGH OPERATION
INJECTION PUMP SYSTEM
1. Uneven Injection.
1. Adjust injection or replace parts.
2. Control rack maltunctionlng.
2. Disassemble .• check and correct injection pump.
3. Worn delivery valve. 3. Replace.
4. Inadequate Injection nozzle spray.
4. Replace injection nozzle.
GOVERNING SYSTEM
1. Governor lever maltunctionlng. 1. Check governor shaft and correct operation.
2. Fatigued governor spring. 2. Replace.
(continued)
..-v' WES'ERBEKE
Engines & Generators
7

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATIONjREMEDY
KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a. Overheated cylinder. a. See OVERHEATING; LOW OUTPUT.
b. Carbon deposits In cylinder. b. Clean.
2. Too early injection timing. 2. Correct.
3. Too high injection pressure. 3. Correct.
4. I mproper fuel. 4. Replace wtth proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
1. See LOW COMPRESSION; HARO STARTING.
2. Injection pump malfunctioning. 2. Adjust/Repair
3. Improper nozzle.
a. Poor spray. a. Clean or replace nozzle.
b. Poor chattering. b. Repair or replace nozzle.
c. After-injection drip. c. Repair or replace nozzle.
d. Nozzle needle valve seized. d. Replace.
INTERMITTENT 1. Fuelfilter clogged. 1. Clean or replace.
EXHAUST SOUND 2. Fuel pipe sucks air. 2. Retighten pipe Joints or replace pipe.
3. Water mixed in fuel 3. Replace fuel.
OVERHEATING 1. V-belt slackening or slippery with 011. 1. Adjust, replace or clean.
2. Damaged water pump. 2. Replace.
3. Lack of coolant 3. Add.
4. Low oil level or poor 011 qualtty. 4. Add or change.
5. Knocking. 5. See KNOCKING.
6. Moving parts seized or damaged. 6. Replace.
7. Defective thermostat. 7. Replace.
LOW OIL PRESSURE 1. Worn Bearings. 1. Engine overhaul replace bearings.
2. Relief valve malfunction. 2. Dverhaul oil pump.
3. Clogged 011 cooler. 3. Repair.
4. Diesel dilution of the oil. 4. Injection pump repair.
~ WESTERBEKE
Engines .& Generators
8

(
L
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine itself, but is
sometimes caused by injector nozzle wear or injection pump
wear. The decrease in compression pressure is caused by
many factors. It is, therefore, necessary to determine a cause
or
causes on the basis of data produced by periodic
inspection and
maintenance. Oil analysis on a seasonal basis
is a good means of monitoring engine internal wear. When
caused by worn cylinders or piston rings, the following
symptoms will occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased
oil consumption
4
Hard engine startiog
5 Noisy engine operation
These symptoms
often appear together. Symptoms 2 and 4
can result also from excessive fuel injection, improper injec-
tion
timing, and wear of the injectors. They are caused also
by defective electrical devices such as the battery, altemator,
starter and glow plugs. Therefore it is desirable to judge the
optimum engine overhaul time by the lowered compression
pressure caused by worn cylinders and pistons plus increased
oil
consumption. Satisfactory combustion is obtained only
under sufficient compression pressure. If an engine lacks
compression pressure, incomplete combustion of fuel will
take place even if other parts of the engine are operating
properly. To determine the period ofengine overhaul, it is
important to measure the engine compression pressure regu-
larly. At the same time, the engine speed at which the mea-
surement ofcompression pressure is made should be checked
because the compression pressure varies with engine rpm.
The engine rpm can be measured at the front end ofthe
crankshaft.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
ASSEMBLY
1. Wash all parts, except for oil seals, O-rings, rubber sheets,
etc., with. cleaning solvent and dry them with pressure alr.
2. Always use tools that are in good condition and be sure
you understand how to use them before performing any
job.
3. Use only good quality lubricants. Be sure to apply a coat
of
oil, grease or sealant to parts as specified ..
4. Be sure to use a torque wrench to tighten parts for which
torques are specified.
5. Ant time the engine is assembled, new gaskets and
O-rings must be installed.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear
of these parts.
When decrease of compression pressure reaches the repalr
limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blowby evident, and compression values are at minimum or
below. Engine compnession should be 30 kg/cm', 427psi at
290 rpm. The maximum difference between cylinders must
not exceed
IO%.
DISASSEMBLY
1. Before disassembly and cleaning, carefully check for
defects which carmot be found after disassembly and
cleaning.
2. Drain water, fuel and oil before disassembly.
3. Clean or wash the engine exterior.
4. Do not remove or disassemble the parts that requite no
disassembly.
5. Perform disassembly in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when neces-
sary. Take special care to keep the fuel system parts from
intrusion of dust and dirt.
6. Parts must be restored to their respective components from
which they were removed at disassembly. This means that all
parts must be set aside separately in groups, each mmed for
its componen~ so that the same combination or set can be
reproduced at assembly.
7. Pay attention to marks on assemblies, components and
parts for their positions or directions. Put on marks, if
necessary, to aid assembly.. .
8. Carefully check each pint or component fore any sigu of
faulty condition during removal or cleaning. The part will
tell you how it acted or what was abnormal about it more
accurately during removal or cleaning.
ALTERNATOR INSPECTION
When rebuilding the engine, the alternator should be cleaned
and inspected. The housing can be wiped off with a solvent
and the alternator terminal studs should be cleaned with a
wire brush. Make certain the studs are tight and clean the
wiring counections that connect to the wiring harness.
Tum the rotor pulley by hand. It should tum smoothly.
Depending on when the alternator was last serviced, the
brushes may need replacing. If the alternator is at all suspect,
send it to a service shop for testing and overhaul.
For additional information on alternators refer to the
ALTERNATOR TROUBLESHOOTING and MANDO
SERVICE in this manual.
Engines & Generators
9

ENGINE DISASSEMBLY
GENERATOR
Disconnect the AC wiring and unplug the engine's DC
wiring harness at the generator control panel. Remove the
battery cables from the engine and tape over the terminals.
NOTE: Label any lines, hoses or cables as you separate them.
Separate the exhaust hose at the water injected elbow and
disconnect the fuel supply and return lines.
Drain the engine oil and the coolant from the engine.
Carefully support and then unbolt the generator backend
from the engine. See
SPECIAL TOOLS in this manual.
Additional generator information will be found
in the
GENERATOR section of this manual.
PROPULSION ENGINE
Switch off the batteries and disconnect the battery cables
from the engine
and tape over the tenninals.
Drain or pump out
all the engine oil and drain the coolant
from the engine and engine hoses.
Unplug the instrument panel wiring harness. Drain the
transmission fluid
and the transmission oil cooler hoses,
Detach the
oil cooler hoses and unbolt the transmission from
the engine.
NOTE: Label any lines, hoses or cables as you separate them.
BLOCK
COOLANT
DRAIN PLUG
NOTE: A Goolant
hose may be on this .
boss in lieu 01 the
plug. Remove the hose.
If the transmission is not being rebuilt it should be visually
inspected. Flush out and pressure test the oil cooler and
replace the coolant hoses. Inspect and lubricate the gear shift
linkage
and the propeller shaftcoupling. Clean and repaint
the transmission and change the transmission fluid.
For transmission service and maintenance refer to your
transmission manual. To rebuild a transmission contact your
WESTERBEKE dealer or an authorized transmission service
center.
c
C~ ~
lmIOlllJ
DAMPER P t~ ...
PLATE .... ...
DAMPER PLAT\:
BOLTS
ENGINE DISASSEMBLY
Take the following precautions:
• Oean the exterior of the engine of any deposits of
dirt and oil."
• Be careful not to damage the disassembled parts.
• Arrange parts in the order of disassembly. Mark or
label parts as needed to insure proper mating and
reassembly. Keep parts clean.
• Mount the engine on a suitable engine stand for
disassembly.
With the transmission separated from the engine, begin the
following step
by step procedure to disassemble the engine.
1.Remove
the transmission damper plate from the
engine flywheel.
2. Remove
the engine 011 cooler and 011 hoses. Note oil
hose connections from the oil cooler to the engine.
3.Remove
the engine heat exchanger. If possible, leave
one end of eachhose connected to the part being removed.
4.Remove
the bell housing and the circuit breaker!
preheat solenoid mounting bracket.
S. Remove the engine back plate.
6. Remove the start motor, drive belt and the alteraator.
Label the wires and cables.
7. Remove
the engine mounted raw water pump,
complete with its adapter mounting plate. See RAW
WATER PUMP for parts breakdown.
S. With the hoses disconnected, remove the thermostat
housing and housing gasket, leaving the temperature
sender in place.
9.Remove
the coolant circulating pump. Refer to
COOlANT CIRCULATING PUMP ASSEMBLY.
10.Remove the air intake sl1encer and the intake manifold.
n.Remove the 011 filter and the mounting bracket from the
engine block.
12.Unbolt
the elbows and remove the exhaust manifold in
its entirety.
13.Remove
the fuel injection pump. Disconnect thefuel
injection pipes and fuel leak-offpipefrom the fuel injection
PU\DP and nozzles.
NOTE: Put plugs or caps on the openings of the injection pump
and nozzle connectors. GOlf tees work well as plugs.
14.Remove the fuel injection nozzle.. Loosen the fuel
injection nozzles with a wrench. Remove the nozzles and
gaskets from the cylinder head.
NOTE: Remove the gaskets from the cylinder head with a
gasket scraper. Discard the gaskets.
... WESTERBEKE
Engines & Generators
10
\

,
\
ENGINE DISASSEMBLY
15. Remove governor assembly.
a. Remove the tie rod cover.
b. Remove the spring from the tie rod with pliers to
disconnect the tie rod from the fuel injection pump.
c. Remove the governor assembly.
16. Remove governor weight.
a. Remove the sliding sleeve.
b. Remove the sliding sleeve shaft and governor weights.
17. Fuel injection pump removal.
a.
Remove the tie rod cover.
b. Remove the spring from the tie rod with pliers to
disconnect the tie rod from the fuel injection pump.
18. Remove the fuel injection pump.
NOTE: Keep a record of the thickness of the shims for
installation.
19. Remove the pressure reliefvalve from the cylinder
bIOCk.@· -~". LOCATED JUST .
UNDER THE
~ FUEL INJECTION
~ PUMP ON THE
ENGINE BLOCK.
20. Remove the rocker shaftassembly.
a.
Remove the bolts that hold the rocker stays in position
and remove the rocker shaft assembly.
b. Remove the valve caps.
DISASSEMBLING THE
ROCKER SHAFT ASSEMBLY
21. Disassemble the rocker shaftassembly. Put identifica-
tion on each rocker arm as to its location on the rocker
shaft.
22. Remove the cylinder head bolt. Loosen the cylinder
head bolts in
two or three steps in the sequence shown.
NOtE: if any parts on the cylinderhead are faulty, check
the cylinder head boltsfor tightness with a torque wrench
before loosening them.
07
$9
23. Remove the cylinder head assembly. Lift the cylinder
head straight
up with a hoist.
NOTE: If the gasket is seized and the cylinder head cannot
be separatedJrom the cylinder block, tap around the thick
'. side portion of the cylinder head wiJh a plastic hammer.
. ORDER OF DISASSEMBLY
11=-- ........ 1
6
FRONT.
.3 05 .10 $S
.12 014 $·13
4 CYLINOER
12~
$5 07
CYLINDER HEAD BOLT LOOSENING
SEQUENCE
10~-
3 CYLINDER
!
Engines & Generators
11

ENGINE DISASSEMBLY
VALVE SPRING
REMOVAL
. 24. Rem()ye the yalve and valve spring.
a. Compress the valve spring with a valve lifter and
remove the valve lock.
b. Remove the retainer, spring and valve.
NOTE: The valves, retainers, springs and valve locks must
be set aside separately in groups, each taggedfor
cylinder
number, for correct installation.
25. Remove the valve stem seals with pliers.
NOTE: Do not reuse the valve stem seals.
26. Remove the flywheel.
a. Have someone hold the crankshaft pulley with a
wrench to prevent the flywheel from rotating.
b. Remove one ofthe bolts that hold the flywheel
in position.
c. Install a safety bar (MI2 x 1.25) into the threaded hole
in the flywheel from which the bolt was removed.
Remove the remaining bolts.
d. Hold the flywheel by hand and withdraw it from the
crankshaft. Joggling the flywheel hack and forth will
facilitate removal.
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
ORDER OF DISASSEMBLY
A WARNING: When removing the flywheel, wear
heavy gloves to avoid hand Injury.
\
27. Remove the rear plate.The rear plate is doweled in
position. pun the plate as straight as possible when
removing
it.
28. Remove theoil seal case. Remove the bolts that hold
the
oil seal case in position. Remove the case from the
cylinder
block with a screwdriver.
A CAUTION: Do not cause damage to the oil
seal.
29. Remove the tappet. Remove the tappets from the
cylinder
block with a valve push rod.
NOTE: The tappets willfall into the oil pan ifthe camshaft
is removed before the tappets are removed.
REMOVING THE
CRANKSHAFT PULLEY
30. Remove the crankshaft pulley.
BAR
a. In.ian two safety bars (M12 x 1.25) into the threaded
holes in the rear end of the crankshaft. Put a bar
between the safety bars to hold the crankshaft to
prevent it from rotating.
b. Remove the crankshaft pulley.
A WARNiNG: When removing the crankshaft
pulley, be prepared to stop the job in case the bar
slips off the crankshaft to prevent injury.
Engines & Generators
12

(
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
8 IDLER GEAR
ENGINE DISASSEMBLY
TIMING GEARS
ORDER OF DISASSEMBLY
14 INJECTION
PUMP CAMSHAFT .
10 THRU 12 .
13BEARING
12 FUEL INJECTION
•
PUMP CAMSHA.FT GEAR
15 OIL PUMP
. PLATE
GEAR CASE
CRANKSHAFT PULLEY
Engines & Generators
13
. 4
6'FRONT PLATE
CAMSHAFT

ENGINE DISASSEMBLY
31. Remove the timinggear case. Remove the bolts that
hold the timing gear case in position and remove the case.
A WARNING: The front plate is bolted inside the
timing gear case. Do not attempt to remove this
plate along with the timing gear case by tapping.
32. Timing gear backlash measurement. Measure the back-
lash of each gear and keep a record for correct measure-
ment. . the .gears if the backlash exceeds the limit.
MEASURING
TIMING GEAR
BACKLASH
TIMING GEAR BACKlASH
CRANKSHAFT GEAR AND IDLER
GEAR - IDLER GEAR AND
CAMSHAFT GEAR - IDLER
GEAR AND FUEL INJECTION
PUMP CAMSHAFT GEAR
CAMSHAFT GEAR/P.T.O. GEAR
'-.../
STANDARD
0.0016 - 0.0047 in
(0.04 - 0.12mm)
0.0031 - 0.0075 In
(0.08 - 0.19mm)
LIMIT
0.0118 in
(O.30mm)
0.0118 in
(O.30mm)
FUEL INJECTION PUMP CAMSHAFT 0.0028 - 0.0079 In 0.0118 In
GEAR AND OIL PUMP GEAR (0.07 - 0.20mm) (O.30mm)
33. Remove the idler gear. Th remove the idler gear, rotate
the gear in a direction of the helix of the teeth to pull it
outofmesb.
34.
Remove the camsbaft.
a.
Remove the bolts that hold the thrust plate.
b. Pull the camshaft out ofthe cylinder block.
A CAUTION: Do not cause damage to the lobes
or bearing Journals when removing the camshaft
35. Remove the fuel injection pump camshaft.
a.
Remove the stopper bolt.
b. Tap the rear end of the camshaft with a copper bar to
push it out of the front side ofthe cylinder block.
36.
Remove the gear ( when required). To remove the
gears from the camshaft and fuel injection pump
camshaft, USe an arbor press.
37. Remove the oil pump. Remove the bolts that hold the oil
pump to the cylinder block and remove the pump.
38. Remove the front plate. Remove four bolts that hold the
front
plate in position. Tap the plate lightly with a plastic
hammer to separate the gasket.
39. Remove the oil pan.
a. Thrn
the engine upside down.
b. Tap the bottom comers of the oil pan with a plastic
hammer to remove the oil pan.
A CAUTION: Do not attempt to pry off the oil
pan by Inserting a screwdriver or a chisel between
the 011 pan and the cylinder block. Damage to the
011 pan can be the result.
40. Remove the oil screen. Loosen the nut that holds the oil
screen
in posItion and remove the screen.
ORDER OF DISASSEMBLY
8 16
10
1--""~-5
11-"""1
4
3~
I,!l
NUMBERS INDIGATE THE
SUGGESTED ORDER OF
DISASSEMBLY
CYLINDER BLOCK
CRANKSHAFT
PISTONS AND
OIL PAN
15
·~--'12
Engines & Generators
14
\