Westerbeke 10.0KW-60Hz User manual

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SERVICE MANUAL
8.0KW-60Hz . 6.0KW-50Hz EDT
10.0KW-60Hz· ·7.5KW-50Hz·EDT
.. 11.5KW-SOHz 9~2KW·50Hz EDT
12.5KW-60Hz9.4KW-50Hz EDT
12.6KW-60Hz 10.4KW-50Hz EDT
15.0KW-60Hz 12.0KW-50Hz EDT
. -
.- Single and Three Phase
:\D~NEt-D1ESEL-GENERATORS
PUBLICATION NO.54600
REVISIONl
JANUARY 2010
~ WESTERBEKE
WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: www.WESTERBEKE.COM
.... ..,.~~
NMMA Member National Marine Manufacturers Association
--
I]

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:
-Dizziness - Throbbing in Temples
-Nausea
- Muscular1lvitching
-Headache
- Vomiting
- Weakness IIIId Sleepiness
-Inability to Think Coherently
IF YDU DR 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.
WARNING
Generators Produce CARBON MONOXIDE
Regular Maintenance Required
rry~~~;.~
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety lfUmual carefully. Most accidents are
caused by failure to follow fundamental rules andprecau-
tions. Know when dangerous conditions existand take the
necessary precautions
to protectyourself, your personne~
andyour machinery.
The following safety instructions are in compliance with the
American Boatand
Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running, Of when connected to shore
power. Lethal voltage Is pfesent at these connections!
• Do not operate this machinery without electrical
enclosures and. covers in place.
• Shut off electrical 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 aship-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 capad-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts Of
exhaust system components. A running engIne gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury Of 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 Of death!
.• Prevent flash fires. Do not smoke or pennit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled 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 pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator
clean and free of debris to ruiniruize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions ;fom fuel vapors can cause
injury Of 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 .t the engine when servicing
the fuel system. Take care in catching any fuel that ruight
spill. DO NOT allow any smoking, open fiames, 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.
Engines & Generators
i

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 fust 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.
BATTERY EXPLOSION
A WARNING: Batteryexplosion 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
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) 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 contaiuing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is
being charged.
• Avoid contacting the terminals with Iools, etc., 10 prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
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
protection. 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/water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functiOning marine carbon monoxide
detector that
complies with ABYCA-24. Consult your
boat builder or
dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational 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
systems. 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. If the 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
symptoms or signs ofcarbon monoxide inhalation or
poisoning
are:
Vomiting Inability to thinkcoherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rot~ting parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation
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 INSTRUCTI'ONS
• 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 drive belts tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission 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 work on machinery 'when you are
mentally or 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 sarety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination of the American Boat andYacht'
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust Systems
P-4 Inboard Engines
E-9 DC Electtical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Staudards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
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
~ WESTERBEKE
Engines & Generators
iii

TABLE OF CONTENTS
Installation ........... ~ .................................................. 2 Oil Pressure ....................................................... 50
Parts Ide rr rD'
nI Ica Ion rawlngs .............................. .3
Actuator .................... : ............................................ 51
Introduction· ............................................................. 4
Service Limits Chart.. ........................................ 52
Serial Number Location ....................................... ..4
Alternator Testing ............................................. 54
Engine Troubleshooting ......................................... 5
Wiring Diagrams
Testing for Overhaul.. ............................................. 9
Engine.Disassembly ............................................. 10
Engine Inspection ................................................. 16
#54193 1O-15Kw
EDT 3 Phase ..................... 57
#54655 1O-15Kw EDT 3 Phase 24V ............. 58
#53477 5.5Kw EDCI7.6-15 EDT 24V ........... 59
#54628 5.5Kw EDCI7.6-15 EDT .................. 60
Assembly ............................................................... 28 #54680 5.5Kw EDCI7.6-15 EDT
24V .. ,...:... 61
Thermostat ............................................................ 34
#52793 5.5Kw EDCI7.6-15 EDT .................. 62
Actuator ........... : .................................................... .34
Specification Charts .......................................... 63 .
Heat Exchanger ..................................................... 35
hijection Pump .................................................. 36
Injection Pump Timing ...................................... 37A
Governor ............................................................. 38
Fuel Injectors .~~ ................................................ .40 .
Glow Plug Testlng ............................................. .41
Starter Motor .................................................... .42
Raw Water Pump .............................................. .46
Valve Clearance ............................................... .48
Air Intake ......... , ................................................ .49
Testing Engine CompreSSion ............................ .49
Drive Belt Adjustment ...................................... .49
Generator . Information ....................................... 68
BT Generator Single Phase ............................... 70
Generator FrequencyNoltage Changes ............ 75
I t mal W" D'
n e iring lagram .................................... 78
BT Troubleshooting 3 Phase ............................. 79
Voltage Regulator AdJustments ........................ 81
Torque Specifications ....................................... 82
Special Tools .................................................... 83
Remote Oil Filter ..................... : ......................... 84
Remote Stop/Start PaneL ................................ 84
Hardware Chart ................................................. 85
Metric Conversion Data ................................... 86
~ WESTERBEKE
Engines & Generators
1

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes mnst 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 iI siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding 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, install 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 manufacturer for proper maintenance.
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 conditions and at any angle
of the vessels hull. .
A detailed Marine Installation Manual covering gasoline and diesel
engine and generators is suppied with each unit. Additional copies
can be obtained from our website in pdf form. www.westerbeke.com.
~ WESTERBEKE
Eng/ntis & Generators
2
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
\
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•
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PARTS IDENTIFICATIO'N/GENERATORS
OIL
FRONT
RAW WATER
PANEL, '
BACK-ENQ,
,BHEAKEH ' ' PREHEAT SOLIENOID'----'"
REAR
LEFT SIDE
CONTROL PANEL
CONNECTION TO
-"or'nu .. BREAK
COOLING AIR TO AIR INTAKE
EXHAUST.
TEMPERATURE
r~t-t-:'--''-EXH,AUST ELBOW
EXHAUST
MANIFOLD
~~~-:-7"----STA,RTSOLENOID
-STAIITER MOTOR
REAR
MANIFOLD PRESSURE CAP
~:-:--=--=--=- _-_-_-_-_-_-_- ..:.-~II':.F_IL_L ~~BLEED
"" PETCDCK
'K\1Jk-'--~----", THERMOSTAT
ASSEMBLY
AIR INTAKE
SILENCER & FILTER
INJECTION
PUMP
Ol~ FILL
SUMP DRAIN HOSE
"'---- IN-LINE FUEL FILTER
DIPSTICK
PRESSURE
SENDDR
FRONT
Engines & Generators
3

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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.
NOTE: The engine's electrical system is protected by a 20-
PROBLEM
HARD STARTING
LOW OUTPUT
. ampere manual reset circuit breaker. The preheat solenoid is
mounted on the same bracket.
PROBABLE CAUSE
VERIFICATION/REMEDY
LOW CRANKING SPEED
1. Engine 011 viscosity too high.
1. Replace engine oil with less viscous 011.
2. Run-down battery.
2. Recharge battery.
3. Worn battery.
3. Replace battery.
4. Battery terminals loosely connected.
4. Clean terminals and correct cables.
5. Defective starter.
5. Repair or replace starter.
6. Defective main drive section.
6. Check clutch for disengagement.
DEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
1. Bleed air from fuel system.
2. Clogged fuel filter.
2. Clean or replace filter.
3. Low injection pressure.
3. Adjust Injection pressure.
4. Inadequate spray. 4. Clean or replace nozzle,
5. Injection pump delivering insufficient fuel.
5. Repair or replace injection pump.
6. Injection too early. 6. Adjust injection timing.
MAIN ENGINE TROUBLES
1. Low compression.
a. Incorrect valve clearance.
a. Adjust valve clearance.
b. Inadequate contact of valve seat. b. Lap valve.
c. Valve stem seized.
c. Replace valve and valve guide.
d. Broken valve spring.
d. Replace valve spring.
e. Compression leaks through cylinder head gasket. e. Replace gasket.
t . Piston ring seized.
t 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 posnion.
4. Set lever to starting position.
5. Governor spring out of POSITION
5. Correct spring
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. Airtrapped in fuel system.
1. Check and retighten connector.
2. Clogged filter. 2. Clean or repiace filter.
3. Contaminated fuel tank. 3. Clean tank.
INSUFFICIENT INTAKE AIR
1. Clogged air cleaner. 1. Clean or repiace air ~ieaner.
(continued)
Engines & Generators
5

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 all level. 6. Add engine oil.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION
1. Defective oil seals. 1. Replace all seals.
2. Broken gear case gasket. 2. Replace gasket.
3. Loose gear case attaching bolts. 3. Retighren bolts.
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 posit.ioned piston ring gaps.
3. Correct ring gap positions.
4. Displaced or twisted connecting rod.
I 4: Replace connecting rod.
OIL LEVEL FALLING
1. D~fective 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 or replace.
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 TRDUBLES
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 011. 1. Correct oil level.
2. Excessive rtse of oil Into combustion chamber.
a. Poor piston contact. .
a. Check.
b. Seized piston ring. b. Replace or clean.
c. Excessive piston-to-cylinder clearance. c. Replace or correct.
(continued)
E,?glnes & 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 oil viscosity.
e. Replace.
I. Excessive oil 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 wfth 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 orreplace 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.
(continued)
..,... WESTERBEKE
EngInes & Generators
7

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

PROBLEM
LCD DISPLAY DOES
NOT ILLUMINATE
LOW OIL PRESSURE
HIGH COOLANTTEMPERATURE
HIGH EXHAUSTTEMPERATURE
BATTERY VOLTAGE
GENERATOR FREQUENCY
overspeed (steady LED)
Underspeed (flashing LED)
LED DISPLAY EDGES
TURN PINK
WAITING FOR ECU
ENGINE TROUBLESHOOTING
LCD DISPLAY FAULTS,
PROBABLE CAUSE
VERIFICATION/REMEOY
1. Check ballery. 1. Ballery on.
2. 20 amp breaker off. 2. Turn breaker on.
3. Loose display connection.
3. Check all cable connections.
4; 1 amp fuse blown (faulty) •. 4. Check/replace. Determine cause
1. Oil level low/oil leak.
1. Check oil level. add oil and repair leaks.
2. Lack of oil pressure
2. Test oil pressure. If OK. test oil pressure sendor. inspect
oil filter. inspect oil pump.
3. Ground connection.
3. Check ground connection.
4. Faulty control module (ECU).
4;' Inspect all the plug connections/replace.
5. Faulty oil pressure sensor. 5. Check sensor/replace.
1. Check system coolant level.
1. Add coolant. Check for leaks.
2. Sea water pump. 2. Inspect Impeller/pump/replace.,
3. Check water pump drive belt. 3. Adjust belt tension. replace belt.
4. Faulty temperature sensor.
4. Check sensor/replace.
5. Ground connection. 5. Check ground circuit.
6. Faulty control module (ECU). 6. Check plug connections/replace.
1. Check sea water flow. 1. Inspect thru hull filling. hose and strainer. Correct
as needed.
2. FaultY exhaust temperature switch. 2. Test/replace.
3. Ground Connection. 3. Check ground circuit.
4. Faulty control module (ECU). 4. ,Check plug connections.
5. Sea water pump. 5. Inspect impeller/replace.
6. Faulty fire suppression system. 6. BY'pass system/check.
1. Check alternator drive belt. 1; Adjusttensionireplace if worn.
2. Check charge voltage. 2. Check excitation. Replace/repair alternator
3. Che,ck battery connections. 3. Check + and· cables from ballery to engine.
4: Faulty control module (ECU). 4. Check plug connections/replace.
1. Check engine speed. 1. Check speed selling.
2. Check fuel supply.
2. Inspect filters/replace filters. Test fuel pump operation.
3. Amperage load. 3. Check + and· cables from ballery to engine.
4. Crank cycle with no start
(underspeed fault)
4. Check cause for no start.
1. Compartment ambient temperature 1. Ventilate compartment.
too high. Nola: Heat will often change the c%r of an LCD
display. This will not effect the operation of the engine.
1. ECU and LCD display not compatible 1. Check compatibility with Westerlink or NMEA.
2. Loose cable connection. 2. Check all cable connections.
3. Panel DC breaker OFF. 3. Turn ON. check DC vollage across breaker.
4. Blown 8 amp fuse.
4. Check/replace fuse. Check DC voltage across fuseholder
5. Terminating ReSistors.
5. Check alilerminating resislors ara In place. 120 ohm
per resister measured across pin #4 and #5.
6. Battery Voltage to ECU. 6. Check between pins P2-24 and P2-25. P2 ECU plug
unplugged from ECU. Power turned ON. If voltage Is
present. ECU is faulty .
... WESTERBEKE
Engines& ,Generators
SA

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUl. PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determlned by various conditions such as lowered engine
power outpu~ decreased compression pressure, and increased
fuel
and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine iiself, 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 determlne 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 wom cylinders or piston rings, the following
symptoms
will occur:
1 Low engine power ontput
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 mjection, improper injec-
tion
timing, and wear of plugs and nozzles. 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 warn cylinders and pistons
plus increased
oil consumption. Satisfactory combustion is
obtained ouly under sufficient compression pressure. If an
eugine lacks· compression pressure, incomplete combustion
of
fuel will take place even if other parts ofthe engine are
operating properly. To determlne the period ofengine over-
haul, it is important to measure the engine compression
pressure
regularly. At the same time, the engine speed at
which the measurement 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
ADJUSTMENTsection 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 air.
2. Always use tools that are in good condition and be sure
you nnderstand how to use them before perfonning any
job.
3. Use only good quality lubricants. Be sure to apply·a coat
ofoil, 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
a-rings must be installed.
OVERHAUL CONDITIONS
Compression pressure tends to increase alittle in a new
engine until piston
rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear
. ofthese 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 evideut, and compression values
are at minimum or
below. Engine compression should be 30 kglcm', 427psi at
290 rpm. Tlje maximum difference between cylinders must
not exceed IO%.
Minimum compression of 384 psi (27 kglcm') is an indication
for overhaul.
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
necessary. Take special care to keep the fuel system parts
from intrasion 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 abnonnal about it more
accurately during removal or cleaning.
OVERHAUL CONDITIONS
When rebuilding the engine, the alternator should be cleaned
and
inspected. The housing can be wiped off with a solvent
and
the altemator termlnal 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.
Foradditional information on alternators refer to the
ALTERNATOR TROUBLESHOOTING in this manual.
-.,.y: WESTERBEKE
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 an<j 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 offthe batteries and disconnect the battery cables
from the engine and tape over the terminals.
Drain or pump out
all the engine oil and drain the coolant
from t1Je engine and engine hoses.
Unplug the instrument panel wiring harness. Drain the
ttansmission fluid and the transmission oil cooler hoses,
Detach the ojl' cooler hoses and unbolt the transmission from
the engine.
NOTE: Label any lines, hoses or cables tis you separate them.
BLOCK
COOLANT
DRAIN PLUG
NOTE: A coolant
hose may be on this
boss in. lieu of the
plug. Remove the hosa·
If the transmission is not being rebuilt itshould be visually
inspected. Flush out
and pressure test the oil cooler and
replace the coolanthoses. Inspect and lubricate the gear sbift
linkage and the propeller shaft
coupling. Clean and repaint
the transmission and cbange the transmission fluid.
For transmission service and maintenance reter to your
ttansmission manual. To rebuild a transmission contact your
WES1ERBEKE dealer or an authorized transmission service
center:.
DAMPER
. PLATE
DAMPER PLATE
BOLTS .
ENGINE DISASSEMBLY
Take the following precautions:
• Oean the exterior ofthe engine of any deposits of
dirt and oil.
• Be careful notto damage the disassembled parts.
• Arrange partsin 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 lrljnsmission 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 uil hoses. Note oil
hose connections from the oil cooler to the engine.
3. Remove the engine heatexchanger. If possible, leave
one end of each hose connected to the part being removed.
4. Remove thebell housing and the circuit breaker!
preheatsolenoid monnting braeket.
5. Remove the engine backplate.
6. Remove thestartmotor, drive belt and the alternator.
Label the wires
and cables.
7. Remove the engine monnted raw water pnmp,
complete withits adapter mounting plate. See RAW
WAT.l?R PUMP for parts breakdown.
S. With thehoses disconnected, remove the thermostat
housing
and housing gasket, leaving the temperature
sender in
place.
9. Remove thecoolant circulatblg pump. Refer to
COOlANT CmCULATING PUMP ASSEMBLY.
lO.Remove the air intake silencer andthe intake manifold.
1l.Reinove the oil
61ter and themounting bracketfrom the
engine block.
l2.Unbolt the elbows and remove the exhaustmanifold in
its entirety.
l3.Remove thefuel injection pump. Disconnect the fuel
injection pipes and fuel leak-off pipe from the fuel injection
PU\IlP and nozzles,
NOTE: Putplugs or caps on the openings of the injection pump
and nozzle connectors. Golf tees work well as plugs.
l4.Remove thefuel 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 governor assembly.
a. Remove the tie rod cover.
b. Remove the spring from the tie rod with pliers to
disconnect the tie rod from t\1e fuel injection pomp.
c. Remove the governor assembly.
16. Remove governor weight.
a. Remove the sliding sleeve.
b. Remove the sliding sleeve shaft and governor weigbts.
17. Fuelinjection 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 fujection pomp.
18. Remove thefuel injection pump.
NOTE: Keep a record of the thickness of the shims for
in11tallation. .
19. Remov~ .. the pressure reliefvalve from
blOCk .• ii'····· .. ," . LOCATEiiJusr' ." . .
\ 'UNDER THE .
•. .
FUEL '
, : PUMP DN THE
, ' ENGINE BLGCK.'
. . '. .. -. ; .
20. Remo~e th~r;;~ker shaft assembly.' ',' .
a. Remove the bolts that hold the rocker stays in position
and remove the rocker shaft assembly. .
b. Remove the valve caps.
"'iIIISASSEMIBLlIIG THE
• ROCKER SHAFT ASSEMBLY
21. Disassemble the rocker shaft assembly. Put identifica-
tion on each rocker arm as to its location on the rocker
shaft.
22. Remov~ the.cylinder head bolt. Loosen the cylinder
head bolts in two orthree steps in the sequence shown.
. NiltE: it ~ny p~ris on the g,iinde~ head are faUlty, check
the cylinder headboltsfor tightness with a torque wrench "
before loosening them. .
07
G9
$3 .5 .10" 1118
.12 .14 .13
CYLINDER HEAD BOLT LOOSENING
SEQUENCE
".3'tYEINDER .
11
23. Remove the cyfuider head assembly. Lift the cylinder
head straight up with a hoist.
NOTE: if the gasket is seizedand the cylinder hedd cannot
be separated from the cylinder block, tap around the thick
Siile1WrtiOI:! of the cylinder head with a plastic hammer.
. ORDER OF DISASSEMBLY
)
)

(
ENGINE DISASSEMBLY
VALVE SPRING '
REMOVAL
• 24: Removethe valve 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 lock.! must '
be set aside separately in' groups, each taggedfor
cylinder
./lumber, for correct installation.
25. Remove the valve stem se31s with pliers.
NOTE: Do not reuse the valve stem seals.
", 26. Remove the flywheei.
a.
Have someone hold the crankshaft pulley with a
wrench
to prevent the flywheel froin 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 back and forth to
facilitate removal.
, ORDER OF DISASSEMBLY
,
A WARNING: When removing the flywheel, wear '
heallY gloves to avoid hand injury. ,
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
ey linder blC)ck with a screwdriver.
A CAUTION: Do not caUSB damage to the oil
seal.
29. Remove the tappet. Remove the tappets from the
cylinder block with a valve push rod. '
NOTE: The tappets will fall into the 'oil pa~ if the camshaft
is removed before the tappets are removed.
REMOVING THE
CRANKSHAFT PULLEY
BAR
,30. Remove the crankshaft pulley.
12
B. Install two safety bars (MI2 x 1.25) into the threaded
,holes in the rear end of tile .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 rBmoving the crankshaff
,pulley, be pmpared to stop the Job in case the bar
slips oft the crankshaff to prevent injury.

NUMBERS INDICATE THE ,
. SUGGESTED ORDER OF
DISASSEMBLY. .
a IDLER GEAlf
ENGINE DISASSEMBLY
TIMING GEARS
ORDER OF DISASSEMBLY
.14 INJECTION
PUMP CAM~I:IAFT
. REMOVE 9 THRU 11
AS AN ASSEMBLY
·12 FUEL iNJECTION"
. 'PUMP CAMSHAFT
'REMOVE 12 THRU 14
AS AN ASSEMBLY .
Q t:RANKSHIIFT PULLEY
1.;J~r.'nINu.
7TIMING GEAR CASE'
'....v' WSTERBEKE
Englnes-& Generators
13
CAMSHAFT'
i
\
/

ENGINE DISASSEMBLY
31. Remove the timing gear 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 gearbacklash measurement. Measure the back·
lash of each gear and keep a record fOr correct measure.
ment. 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) ..
LIMIT
0.01.18 In
(0.30mm) .
0.0031 ·0.0075'10 .. 'o~dm In
(0.08·0.19mm) (0.30mm)
FUEL INJECTION PUMP CAMSHAFT 0.0028· 0.0079 In 0.0118 In
GEAR AND OIL PUMP GEAR (0.07' 0.20mm) (0.30mm)
37. Remove the oil pump. Remove the bolts that hold the oil
pump to the cylinder block and remove the pump.
38. Remove tIie 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.
Turn the engine upside down.
b. Tap the bottom comers of the oil P!'ll 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
oil pan can be the result.
40. Remove the oil screen. Loosen the nut that holds the oil
screen in position and remove the screen.
8~~
9---.~,u
10
6
.\ ORDER OF DISASSEMBLY
t-UlJ,----5
11----i~ .
33. Remove the idler gear. Th remove the idler gear, rotate 4 I
the gear in a direction of the helix of the teeth to pull it ~
out of mesh. 3~ _
34. Remove the camshaft. ~
... . ... ... Ji .•....
a. Remove the bolts that hold the thrust plate. NUMBERS INDICATE THE.
b. Pull the camshaft out of the cylinder block. SUGGESTED OROER OF
r------------------, . DISASSEMBLY
A CAUTION: Do not cause damage to the lobes
or bearing Joumals when removing the camshaft
35. Remove thefuel injection pump camshaft.
a.
Remove the stopper bolt.
b. Thp the rear end of the camshaft with a copper bar to
push it out ofthe front side of the cylinder block.
36. Remove the gear (when required). To remove the
gears from the camshafr and fuel injection pump
camshafr, use an arbor press.
. C'(LlNIIERiii.IICK
CRANKSHAFT
PISTONS AND
OIL PAN' .
Englnes-&'Gene;ators
14
""""'1"<'--1