Westerbeke 12.5KW-60Hz User manual

SERVICE MANUAL
44A FOUR and 3SC THREE
MARINE DIESEL ENGINES
8. 0KW-60Hz 6. 0KW-SOHz BTDA
10 . 0KW-60Hz 7.SKW - SOHz BTDA
12 . 5KW - 60Hz 9. 4KW-SOHz BTDB
1S . 0KW - 60Hz 12 . 0KW-SOHz BTDC
Single and Three Phase
MARINE DIESEL GENERATORS
PUBLICATION NO.45100
FIRST EDITION
March 2001
~ WESTERBEKE
WESTERBEKE CORPORATION ' MYlES STANDISH INDUSTR I AL PARK
150 JOHN HANCOCK ROAD . TAUM'ON , MA 02780-7319 · TEL ' ~ 508-&3-76n
FAX '·508 884·9688 ' WEBS ITE : www.W ESTERBEKE . COM
---
Al ANA Member National Ma.rine Mall1~faclurus AsJ'ocUJl io l'l
--

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused byfailure to follow fundJJ.mental rules
and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself,
your personnel,
and your trUlcltinery .
Tire following safety instructions are in compliance with Ihe
American Roal
and Yacht Council (A RYC ) s/aJuklrds.
PREVENT ELECTRIC SHOCK
A WARNING : Do no t touch AC electr i cal connections
while engine is runn i ng , or when connected to shore
power . Lethal voltage is present at these connections!
• Do not opera te this machinery without elecuical
enclosures and covers in place.
• Shut off electrical power before accessing electrical
equipment
• Use insulated mats whenever working on elecuical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling elecuical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment
• Do not co nnect 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 tenninals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot eng i ne parts or
exhaust system components . A runn i ng 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 can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburet or , 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
ca n 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 ncar
the fuel system. Keep the compartment and the
engine/generator clean and free
of debris to minimize the
chances
of fire. Wipe up all spilled fuel a nd engine o il.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: ExplOSions from fuel vapors can cause
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
staning 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 of children.
• Do not fill the fueltank(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 supp li es 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.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• D isco nn ec t th e ban ery cab l es be fore se rv ic in g th e en g in e/
gene rat or. Rem ove th e n egat i ve l ea d fir st a nd reco nn ec t
it last.
• Make ce rt ain all pe r so nn el are clear of th e en gi ne befo re
start in g.
• Make ce l1ain a ll covers, guards, and hatches are re-
ins tall ed b efo re s tartin g th e en gi n e.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do n ot smoke or all ow an open flam e ne ar the battery
be in g serv ic ed . L ead ac id batt e ri es emil hy dr ogen, a
highl y ex pl osive gas, w hi ch can be ign i ted by el e ctri cal
arcing or by lit tobacco products. Shut off all electrical
equi p ment in th e vic ini ty to pr ev ent el e ctri c al ar c in g dur -
in g se rvi c in g.
• Nev er co nn ect the negative (-) ban cry ca bl e to th e p os i-
tive (+) co nn ec ti on te rm inal of th e s tarter so len oi d. Do
not test th e batte ry condition by shorting th e te rminals
t ogethe r. Spar ks co ul d ig nit e ba tte ry ga ses or fu el va po r s.
Ve ntil ate any co mpartm e nt co ntainin g ba tteri es to pre v ent
acc umulati on of ex pl os i ve gases. To av o id s parks , do not
disturb th e batte ry char ge r connec ti ons while the bane ry
is bei ng c har ged.
• Avoid co n tacti ng the te nnin aIs w ith too l s, etc., to pr eve nt
b urn s or sp arks th at co uld ca use an ex pl osion. Rem ove
w ri st wa tch, rings , and any o th erjewe lry be fore handlin g
th e battery.
• A lw ays turn th e ba tt ery c har geroff be fo re di sco nn ecting
th e ban ery co nn ec ti on s. Remove the n egati ve le ad firs t
and reco nn ect it l ast when di sco nn ec tin g th e batte ry.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• Whe n se rv ic in g th e ba tt ery orchec kin g th e el ec tr olyte
l
eve l, wear ru bbergl ov e s, a ru bbe ra pr on, an d eye pr ot ec-
ti on. Ba tteri es co ntai n s ulfuri c acid w hi ch is d es tru c ti ve.
If itcomes in co nta ct with yo ur s kin , was h it off at on ce
wi th wate r. Acid ma y splash on th e skin or into the eyes
in ad ve rt e ntl y when rem ov in g elec tr olyte ca p s.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure th at the exhaust system is adequate to expel gases
di sc har g ed fr om th e eng in e. Ch eck th e ex hau st system
regularly for le aks and make sure th e exhaust manifolds
are s ecur ely att ac hed and no w arpin g exi sts. Pay close
a
tt e nti on to th e ma ni fo ld . wa ter in jec ti on el bow, and
exhaust pipe nippl e.
• Be su re th e unit a nd its su rro und ings ar e we ll ve n tilated .
• In additi on to ro utin e in spection of th e ex hau st syst em ,
instaii a c arb on mon ox id e detect or . Cons ult yo ur boa t
builder or de al er for in stallation of approved detectors.
• For additional in fo nnation refer to ABYC T-22 (educa-
li onal infonnation on Carbon Mon ox ide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas . Inhalation produces "u-like symptoms ,
nausea or death!
• Do not use cop pe r tubing in di esel exhaust system s. Diesel
fumes c an rapidl y d estro y co pper tubin g in ex hau st sys-
tems. Exhaust sulfur causes rapid dete ri oration of cop pe r
tu b in g r es ultin g in ex hau st/ waterle ak age.
• Do n ot in s tall ex haust o utl et where ex haust ca n be draw n
thr ough porth oles. ve nts , or ai rco nditi oner s. If th e en gine
ex haust di sc har ge o utl et is ne ar th e wa te rl ine, wa t er cou ld
e nt er th e e xhau st di sc har ge o utl et and close or res tri ct the
fl ow of exh au st. Avo id o~e rl oad in g th e cr aft.
• Alth ough diesel e ngin e ex hau st gases are not as toxic as
ex haust fum es fro m gaso l ine eng in es, carbon mo noxide
gas is pr ese nt in diesel ex haust f um es. So me of th e symp-
toms orsigns of c arb on mon ox i de i nh al at ion or po i so nin g
are:
Vomiting
Di zz in ess
Thr o bbin g in te mpl es
AVOID MOVING PARTS
Mu sc ular tw it c hin g
Int ense h ea da che
Weakness
and sl eep in ess
A WARNING: Rotating parts can cause i njury
or death!
• Do n ot se rvi ce th e eng in e w hil e it is runn in g. If a situa -
tio n ari ses in w hich it is abso lut ely necessary to m ake
o per a ting a dju s tm en ts , use ex trem e care to avoid t ouc h ing
moving pans a nd hot exhaust system componen ts .
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose c10lhing or jewelry when servicing
equipment: tie back long hair and avoid wearing loose
jackets, shins. sleeves, rings, necklaces or bracelets that
could
be ca ught in moving parts.
• Make sure aJl attaching hardware is properly tightened.
Keep protective
shie lds and guards in their respective
places al all times.
• Do nOl check fluid levels or the drive bell's lension while
th eeng in e is ope ratin g.
• Stay clear of the drive shaft and the transmission cou pling
when the eng in e is running; hair and clothing can easily
be ca ught in these rotating pans .
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do n01 run an engine with the air intake (silenc er )
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Man y of the preceding safelY lips and warnings are repeated
in yo ur Operators Manual along wilh olher ca utions and
notes to highlight critical information.
Re ad yo ur manual
caref ull y. mainlain your equipment. and follow all safely
pr oce dures.
ENGINE INSTALLATIONS
Preparations to instaJl an engine should begin wilh a thor-
ough exam ination of the Am erican Boat and Yacht Council's
(ABYC) slandards. These slandards are a combination of
sources in cluding th e USCG and the NFPA.
Se c ti ons of the ABYC slandards of particular inleresl are:
H-2 Venlilalion
P-I Exhausl syslems
P-4 In board engines
E-9 DC Electrical syslems
All insla
ll alions mU Sl co mply with the Federal Code of
Regulalions (FCR ).
ABYC , NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publicalions
for safely codes and slandards. Follow their recommenda-
tions when installing yo ur engine.
AB YC (American B aal and Yachl Council)
"Safely Slandards for Small Crafl"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewaler,
MD 21037
NFPA (National Fire Prol ecl ion Associalion)
"Fire Prolection Slandard for M alar Craft"
Order
fr om:
NFPA
II Tracy Drive
Avon Industrial Park
Avon. MA 02322
USCG (Uniled SlaleSCoasl Guard)
"U SCG 33CFR183"
Order from:
U.S. Government Printing Office
Washinglon, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following info rmation :
CODES AND REGULATIONS
Strict federal regulations. ABYC guidelines. and safety codes must be complied with
wh en instal lin g en gines a nd ge nera tors in a marine environment.
SIPHON· BREAK
For in stallatio ns where the exha u st manifold/water injected exhaust elbow is close to
or will be be l ow the vessel's wa te rlin e. provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This ho se must be looped a
minimum of 20 " above the vessel's waterline . Failure to use a siphon-break when
th e ex haust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possibleflooding 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 operati ng conditions , install a
siphon-break.
NOTE: A siphon-break. requires periodic inspection and cleaning to ensure proper
operation. Failure 10 properly maimain a siphon-break can result in catastrophic
eng
in e dama ge. Consult the siphon-break m.anufa cturerfor proper m.a i ntenan c e.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea condilio ns and al any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel , engines and generators , is available from your WESTERBEKE
dealer.
Engines & Generators
iv

SERVICE MANUAL
44A FOUR and 35C THREE
MARINE DIESEL ENGINES
8.0KW-60Hz 6.0KW-50Hz BTDA
10.0KW-60Hz 7.5KW-50Hz BTDA
12.5KW-60Hz 9.4KW-50Hz BTDB
15.0KW-60Hz 12.0KW-50Hz BTDC
Single and Three Phase
MARINE DIESEL GENERATORS
PUBLICATION NO.45100
FIRST EDITION
March 2001
,~ WESTERBEKE
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319. TEL [phone]
FAX 1·508 884·9688· WEBSITE: WVtW.WESTERBEKE.COM
..,""~,.".
NMMA Member National Marine Manu/acturers Association
~..,,,..,

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
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can Include:
o Dizziness
o Nausea
o Headache
o Throbbing In Temples
o Muscular TWitching
o Vomiting
o Weakness and Sleepiness o Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
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.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
~S1FRBEKEalso recommends installing
CARBON MONOXIOE DE1FCTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

TABLE OF CONTENTS
Parts Identification/Engines ... .............................. 2 Service Data-Standards And Iimits ................... 52
Parts Identification/Generators ............................ 3 Special Tools - Engine ....................................... 54
Introduction ............................................................. 4 Wiring Diagram - Engines ................................. 56
Engine Troubleshooting ....................................... 5 Wiring Schematic - Engines .............................. 57
Testing For Overhaul ........................................... 9 Specifications - 44A FOUR ................................ 58
Engine Disassembly ........................................... l0
Specifications - 35C THREE ............................ .59
Inspection .......................................................... 16
DC Electrical System (Alternator) ..................... 60
Assembly ............................................................ 27
Mando Alternator Service ................................. 62
Exhaust Manifold/Heat Exchanger .................... 35
Generator Wiring Diagram ................................. 69
Fuel Injection Pump .......................................... 36
Governor .............................................................38
Fuel Injection Timing ........................................ 39
Fuel Injectors ................................................... .40
Glow Plug Testing ............................................. .41
Starter Motor .................................................... .42
Generator Wiring Schematic ............................. 70
Remote Panel Schematic .................................. 71
Specifications - Generator ................................ 72
BT Generator Single/Three Phase ..................... 76
12 Stud Internal Wiring Schematic ................77
Component Resistance Values........................77
Internal Wiring Schematic 6 Stud ..................78
Raw Water Pump .............................................. .46
BT Generator Voltage Regulator ....................... 79
Engine Adjustments ............................................ .47
BT Generator Troubleshooting .......................... 80
Valve Clearance Adjustment ......................... .47
Testing Engine Compression......................... .48
Generator Frequency Adjustment.................. .49
Fuel Run Solenoid ........................................ .49
Special Tools - Generator .................................. 89
Standard Hardware ........................................... 90
Metric Conversions .......................................... 91
Oil Pressure ....................................................50
Metric Conversions [Chartj ............................... 92
Adjusting Idle Speed ...................................... 51
Drive Belt Adjustment....................................50
Engines & Generators
1

PARTS IDENTIFICATION 44A/35C THREE
WATER INJECTED
EXHAUST
20A CIRCUIT
REAR
ZINC ANODE
OPTIONAL V-ORIVE
TRANSMISSION
ILLUSTRATED
RIGHT SIDE
OIL
FRONT
DC ALTERNATOR
RAW WATER
UNIT 1.0_
START
PRESSURE CAP
THERMOSTAT
WATER HEATER
FRONT
OIL FILL
COOLER
AIR INTAKE/AIR FILTER
_F'REfIEAT SOLENOIO
LIFT PUMP
~ffB~~i;~(;?-""""'~---FUEL FILTER
REAR
HEAT EXCHIANGER
LEFT SIDE
'ATF DRAIN
Engines & Generators
2

PARTS IDENTIFICATION/GENERATORS
DC AITI'RN,ATOIL
HEAT
BACK·END
20
CIRCUIT
BREAKER
I
OIL
PREHEAT
BREAKER OIL
REAR
LEFT SIDE
OIL PAN
RIGHT SIDE
OIL PRESSURE
GENERATOR EMERGENCY
STOP SWITCH
CONNECTION TO
_o"nu" BREAK
,-,qt---+---EXHA.UST ELBOW
"""'r----++---S"rART SOLENOID
MANIFOLD PRESSURE CAP
"UULA~I FILL
~:STAF!TER MOTOR
REAR
OIL FILL
ASSEMBLY
AIR INTAKE
SILENCER & FILTER
PUMP
OIL FILL
ENGINE BLOCK DRAIN PLUG
OIL DRAIN HOSE
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 SOFTWARE, MAKES NO WAR,
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING
OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should keep in mind the time
span between printings of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product.
It
not only makes good sense but is imperative that appropriate
representatives of WESTERBEKE 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 information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
it. CAUTION: Procedures which, if not strictly
observed, can result in the damage or destruction of
your engine.
it. WARNING: Procedures which, if not properly
followed, can result in personal injury or loss oflife.
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 information so we may properly
identify your engine. In addition, 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.
CustDmer IdentificatiDn Card
L ",.,,/WESTERBEKE
I Engines & Generators
Customer Identification
MR. GENERATOR
OWNER
MAIN STREET
HOMETOWN, USA
Model44A
Expires 2/5/200I
Ser. #UOOOO,EI02
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date of manufac-
ture of your WESTERBEKE engine or generator. The manu-
facturer's date code is placed at the end of the engine serial
number and consists of a character followed by three num-
bers. The character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s E=2000s), the first number represents the
year
in the decade, and the second and third numbers repre-
sent the month of manufacture.
SERIAL NUMBER LOCATION
The engine's serial number can be found stamped into the
engine block just out board of the injection pump. An
identification plate on the engine manifold also displays the
engine model and serial number.
The generator serial number is stamped on the left side of the
generator housing and on the flat surface above the rotary
carrier bearings.
ENGINE
SERIAL
NUMBER
ENGINE OVERHAUL
The following sections contain detailed information
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 only by such facilities.
Additional detailed information and specifications are
provided
in other sections of this manual, covering the
generator, alternator, starter motor, engine adjustments,
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 of assistance in
determin~
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.
e. 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. Adjust injection 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 replace filter.
3. Contaminated fuel tank. 3. Clean tank.
INSUFFICIENT INTAKE AIR
1. Clogged air cleaner.
1. Clean or replace air cleaner.
(continued)
Engines & Generators
5
I

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERIFICATION/REMEDY
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.
I
3. Loose gear case attaching bolts. 3. Retighten bolts.
I
4. Loose drain plug. 4. Retighten plug.
!
5. Loose oil pipe connector. 5. Retighten oil connections.
6. Broken rocker cover gasket. 6. Replace gasket.
7. Loose rocker cover attaching bolts. 7. Retighten attaching bolts.
OIL LEVEL RISING
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.
4. 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
I
CONSUMPTION 1. Noisy knocking. 1. See KNOCKING.
2. Srnoky exhaust. 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn.
3. Repair or replace.
4. Poor compression. 4. See LOW COMPRESSION: HARD STARTING.
5. Improper valve timing. 5. Adjust.
I
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.
I
a. Poor piston contact. a. Check.
b. Seized piston ring. b. Replace or clean.
c. Excessive piston-to-cylinder clearance. c. Replace or correct.
(contmued)
WESTERBEKE
Engines & Generators
6

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERIFICATION/REMEOY
SMOKY EXHAUST (coni.) WHITISH OR PURPLISH (cont.)
d. Worn valve stern and valve guide. d. Replace.
e. Low engine oil viscosity. e. Replace.
f. Excessive oil pressure. f. Correct.
I
3. Injection timing is too late. 3. Adjust.
4. Insufficient cornpression. 4. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAYISH
1. Engine body troubles.
a. Poor cornpression. a. See LOW COMPRESSION; HARD STARTING.
b. Irnproper valve clearance. b. Adjust.
2. Insufficient intake air (air cleaner clogged). 2. Clean air cleaner.
3. Irnproper fuel. 3. Replace with proper fuel.
ABNORMAL SOUNO
CRANKSHAFT ANO 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 ROO ANO CONNECTING ROO BEARING
I
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 reb ore cylinder.
4. Piston seized and ring worn or damaged. 4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft. 1. Replace.
I
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing. 4. Replace.
I
ROUGH OPERATION INJECTION PUMP SYSTEM
1. Uneven injection. 1. Adjust injection or replace parts.
2. Control rack malfunctioning. 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 malfunctioning.
1. Check governor shaft and correct operation.
2. Fatigued governor spring. 2. Replace.
(contmued)
Engines & Generators
7

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
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. Improper fuel.
4. Replace with proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
1. See LOW COMPRESSION, HARD STARTING.
2. Injection pump malfunctioning. 2. AdjusVRepair
I
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.
INTERMITIENT
1. Fuel filter 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 oil.
1. Adjust, replace or clean.
2. Damaged water pump.
2. Replace.
3. Lack of coolant. 3. Add.
4. Low oil level or poor oil quality. 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. Overhaul oil pump.
3. Clogged oil cooler. 3. Repair.
4. Diesel dilution of the oil. 4. Injection pump repair.
Engines & Generators
8

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is detennined 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 detennine 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 starting
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, alternator,
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 deteITI1ine the period of engine overhaul, it is
important to measure the engine compression pressure regu-
larly. At the same time, the engine speed at which the mea-
surement
of compression pressure is made should be checked
because the compression pressure varies with engine rpm.
The engine rpm can be measured at the front end of the
crankshaft.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manuaL
ASSEMBLY
L Wash all parts, except for oil seals, O-rings, rubber sheets,
etc., with cleaning solvent and dry them with pressure air.
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 repair
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 compression should be 30 kg!cm', 427 psi at
290 rpm. The maximum difference betvveen cylinders must
not exceed 10%.
DISASSEMBLY
1. Before disassembly and cleaning, carefully check for
defects which cannot 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 require 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 marked for
its component, 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 part or component fore any sign 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 tenninal studs should be cleaned with a
wire brush. Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness.
Turn 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 tenninals.
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
wi11 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.
OIL DRAIN PLUG
TRANSMISSION
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 shaft coupling. 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
\VESTERBEKE dealer or an authorized transmission service
center.
DAMPER
PLATE
DAMPER PLATE
BOLTS
ENGINE DISASSEMBLY
Take the following precautions:
• Clean 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.
l.Remove the transmission damper plate from the
engine flywheel.
2. Remove the engine oil cooler and oil hoses. Note oil
hose connections from the oil cooler to the engine.
3.
Remove the engine heat exchanger. If possible. leave
one end
of each hose connected to the part being removed.
4.
Remove the bell housing and the circuit breaker/
preheat solenoid mounting bracket.
5. Remove the engine back plate.
6. Remove the start motor, drive belt and the alternator.
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 silencer and the intake manifold.
1l.Remove the oil filter and the mounting bracket from the
engine block.
12.UnboIt
the elbows and remove the exhaust manifold in
its entirety.
13.Remove
the fuel injection pump. Disconnect the fuel
injection pipes and
fuelleak·off pipe from the fuel injection
pump and nozzles.
NOTE: Put plugs or caps on the openings of the injection pump
and n012ie 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.
Engines & Generators
10

ENGINE DISASSEMBLY
15. Remove goven-lOr assembly.
a. Remove the tie rod cover.
h. Remove the spring from the tic 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.
h. 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 thichtess of the shim' for
installation.
19. Remove the pressure relief valve from the cylinder
block.
8' WCATEDJUST
UNDER THE
i ~ FUEL INJECTION
; m PUMP ON THE
'. ENGINE BLOCK.
20. Remove the rocker shaft assembly.
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 shaft assembly. Put idcntifica·
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 an)' parts on the cylinder head are faulty. check
the cylinder head bolts
for tightness with a torque wrench
be/ore loosening them.
01 1717
03 05
$12
001
.10 08
014 013
05 07
@10
08
011 06
CYLINDER HEAD BOLT LOOSENING
SEQUENCE
4 CYLINDER
3 CYLINDER
23. Remove tbe cylinder head assembly. Lift the cylinder
head straight
up with a hoist.
NOTE: If the gasket is seized and the cylinder head connor
be separated/rom the cylinder block, tap around the thick
side~partian a/the cylinder head with a plastic hammer
ORDER OF DISASSEMBLY
Engines & Generators
11

ENGINE DISASSEMBLY
VALVE SPRING
REMOVAL
24. Remove the valve and valve spring.
3. 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 tagged
for
cylinder number, for correct installation.
25. Remove the valve stern 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
of the bolts that hold the flywheel
in position.
c. Install a safety bar (M 12 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 back and forth with
facilitate removal.
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
ORDER OF DISASSEMBLY
27. Remove the rear plate.The rear plate is doweled in
position. Pull the plate as straight as possible when
removing
it.
28. Remove the oil 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 pulle)'.
BAR
a. Install two safety bars (M 12 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