Westerbeke 10.0KW-60Hz User manual

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are caused
by failure to follow fundamenfLll ruks and precautions.
Know when dangerous conditions exist and fLliaJ the
necessary precautions
to protectyourself, yourpersonnel,
andyour machinery.
The following safety instructions are in complimlce with the
American Boat and
Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine Is running, Dr when connected to shore
power. Lethal voltage is present at these connections!
• 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-ta-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 capacitor.
Discharge capacitor
by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Dr
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 Dr 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 Dr 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 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 ~ 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/gener-
ator clean and free ofdebris to minintize 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 can cause
Injury Dr death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumeslvapor before running
the blower. Run the blower for four ntinutes before start-
ing your engine.
• All fuel vapors are highly explosive. Use extreme care when
handling and storing fuels. Store fuel in a well-ventilated
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 ntight
spill.
DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servicing.
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 of leaks.
• 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.
...v- WESTERBEKE
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
01 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 EXPLOSION
A WARNING: Battery explosion can cause injury
«death!
• Donot 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 elec~cal
arcing or by lit tobacco products. Shut off all electncal
equipment in the
vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection ternrinal
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 conlllcting the ternrinals with tools, etc., to prevent
burns or sparks that could cause
an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the
battery.
• Always tum the battery charger offbefore disconnecting
the battery connections.
Remove the negative lead first
and reconnect it last whenservicing the battery.
BAMRYACID
A WARNING: Sulfuric acid in batteries can cause
SIWBI8 injury 01 death!
• When servicing the battery orchecking the electrolyte
level, wear rubber
gloves, a rubber apron, and eye protec-
tion. Batteries conlllin sulfuric
acid which is destructive.
If itcomes in conlllCt 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 manifold!
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.
• Don't run the generalor sel 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 waterlme, 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 of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing in temples
Muscular twitching
Weakness and sleepiness
A WARNING: Rotating 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 operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleev~.
rings, necklaces or bracelets that could be caught in
moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts' tension while
the engine/generator is operating.
• 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 a generator without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines or generators for long periods with
their enclosures
open.
A WARNING: Do not work on machInery when you
am 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 safety
procedures.
GASOLINE ENGINE AND GENERATOR
INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination ofsources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P-I Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING GASOLINE AND DIESEL ENGINES AND
GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your WESTERBEKE engine/generator.
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 Craft"
Order
From:
NFPA
1Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order
From:
U.S. Government Printing Office
Washington, D.C. 20404
.... WESTERBEKE
Engines & Generators
iii

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TABLE OF CONTENTS
Engine Specifications ............................................ 2
Testing for Overhaul ............................................... 3
Troubleshooting Guide ....................................... .4
Safety Shutdown Switches .................................. 6
High RPM Shutdown Switch ................................ 7
Disassembly and Assembly Procedures ............. 8
Bolt Tightening Methods ..................................... 9
Engine Disassembly, Inspection & Assembly ... 10
Timing Belt Inspection & Replacement......... 10
Removing Exterior Assemblies...................... 13
Engine Disassembly, Inspection & Assembly ... 15
Distributor .......................................................... 29
Testing the Igniter ............................................. 30
DC Electrical System .......................................... .31
AlternatorTroubleshooting ............................ 31
Generator Schematic ...................................... 33
Wiring Diagram............................................:.34
Remote Start Diagram....................................
35
Remote Instrument Panel Diagram.......... .36-37
Engine AdJustments .......................................... .38
Oil Pressure ................................................... .38
Ignition Timing.............................................. .39
Valve Clearance............................................. .39
Compression Test .......................................... .39
Drive Belt .......................................................40
Spark Plugs.....................................................40
High Tension Cords........................................40
Carburetor...................................................... .41
Governor.........................................................42
Mando Alternator ........................................ .43-49
Starter Motor ........................................................ 50
Generator ...................................................... 52-60
Service Specifications ...................................... 61
Torque Speciflcations ..................................... 63-66
Sealants and Lubricants ................................... 64
Metric Conversions ...................................... 65~67
Special Tools .................................................... 68
Index .................................................................. 69
~ WESTERBEKE
Engines & Generators
1

WESTERBEKE 8.0KW TO 15KW BEG ENGINE SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Aring Onter
Direcllon of Rolation
Compression Ratio
Weight
GENERAL
Gasoline, four-cycle,four-cyJinder,
fresh water-cooled, vertical in-line
overhead mechanism,
Hoof, flybaJ type,<i% speed reduction,
Semi-spherical type,
2,97 x 3,23 cu,in, (75,5 x 82,Omm)
89,6 cubic Inches (1468 cubic centimeters),
1-3-4-2
Clockwise, when viewed from the front.
9:0:1
8.OKw
10.OKw
12.5Kw
15.0 Kw
440 lbs (199 Kg)
466 Lbs (211 Kg)
497 Lbs (497 Kg)
525 Lbs (238 Kg)
TUNE-UP SPECIFICATIONS
Compression Pressure
(11mK of difference
between cylinders)
Valve Seal Angle
vaJvo Clealance
(engine hot)
Engine Timing
General
Oil FIller
SUmp Gapacity
(not Including fiKer)
Operating Oil Pressure
(engine hot)
Oil Glade
165psi at 300 rpm
14psi
Inlake45°
Exhaust 45
0
Iniake 0.08 inchas (0.20 mm)
Exhaust 0.09 inches (025 mm)
20" BlDC at 1800 rpm ± .5
0
Forced lubrication by geared pump.
Full flow, spin-on replaceable type.
3.5 U.S. qts (3.3IKers)
plus llKer
50-60 psi
API Specification of SJ class.
ELECTRICAL SYSTEMQ
StaJlMotor
Starting BatleIY
CCA
BaileIY Gapacity
General
Distributor
Spark Plug Thread Size
12 Volt, reduction gear/solenoid,
12 Volt, (-) negative ground
3O(Hj()() Amps
150 Cold Cranking Amps (CCA).
IGNITION SYSTEM
BatleIY Ignitionl2V negative ground,
Distributor with Ignhion module and ignher.
Ignition coli and spark plugs,
Equipped with auto timing controller, ignition coil
buih-in breake~ess type.
14mm X 1.25 pitch
IGNITION SYSTEM (CONT.)
Carburetor (STD Typ!)
Spark Plug Gap
General
Fuel
Fuel Lift Pump
Fuel Consumption
(approximate)
Fuel Rher
(on engine)
I'jr cleaner
(ilame arrester)
I'jr Row
(engine combustion)
General
Operating Temperature
Fresh Water Pump
Raw Water Pump
Raw Water Row
at 1800 rpm,
System Capacity
(coolant)
Down draft type. single barrel.
U,S,C.G. approved flame arrester,
,030 inches (0.8 mm)
FUEL SYSTEM
Conventional carburetor type with electric
fuel ~ump,
Regular or unleaded gasoline with an octane
rating of 89 or better,
Electric-lift capability of 6 ft, (18mm)
8.0Kw 1,1 gph
10.0Kw 1.25 gph
12.5Kw 1,45 gph
15.0 Kw 1.7 gph
Replaceable cartridge-screw on,
Metal screen type • cleanable,
46,6 elm (1.3 cmm),
COOLING SYSTEM
Fresh water-cooled block, thermostatically-
controlled whh heat exchanger,
140 -1600 F(61-710 C)
Centrifugal type, metal impeller, beh-driven,
Positive displacement, rubber impeller,
beh-driven,
5,5 gpm (5.20 Ipm),
5,5 US qts (5,20 liters)
AC GENERATOR (SINGLE PHASE)
Single Phase
Vohage
Vohage
regulation:
Frequency regulation:
Rating (Voks AC)
8.0Kw
10.0Kw
12.5Kw
15.0 Kw
Generator Cooling
I'jr Requirements
(60 Hertz at 1800 rpm)
Engine Combustion Air
Requirements
(60 Hertzat 1800 rpm)
Brushless Six-pole, revoMng field,
Sealed lubricated Single-bearing design,
Reconnactable, single·phase transformer whh
solid-state vohage regulation,
120 or 1201240 Voks - 60 Hertz
230 Volts - 50 Hertz.
.5% no load to full load,
3 Hertz (5%) no load to full load,
1201240 voks - 66133
'1201240 voks) - 83/41
1201240 voks -104152
1201240 voks -125162
200- 225 elm (5,6' B.4 cmm)
NOTE: Increase air supply 15% for 50 Hertz
operaUon (1500 tpm),
46,6 elm (1.3 cmm)
Generator Compartment 100-200 elm (2,83-5,66 cmm),
Cooling Requirements
....v' WESTERBEKE
Engines & Generators
2

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 wom plugs or fueVcarburetor
problems .. The decrease in compression pressure is caused
by many factors. It is, therefore, necessary to detennine a
cause or causes on the basis ofdata 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 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 carburetor performance or worn plugs.
They are caused also by defective electrical devices such as
the battery, alternator or starter. 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 ifother parts ofthe engine are
operating properly. To detennine the period of engine
overhaul, 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.
When the decrease ofcompression pressure reaches the
repair limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blow-by evident, and compression valves are at minimum or
below.
NOTE: Make cenain the engines valve clearances are
properly adjusted. An incorrect valve clearance can cause
symptoms that might, incorrectly, suggest an engine
overhaul (cylinder misfire, white smoke, noise, etc).
Before preparing
for an engine overhaul, adjust the valve
clearances to the correct specification. install a new cover
gasket and test the engine.
DISASSEMBLY
NOTE: Before disassembly and cleaning, carefully check
for defects which cannot befound after disassembly and
cleaning.
• All disassembled parts should be carefully arranged in
the order ofreassembly. Mark or label the parts as
needed to insure proper mating and reassembly in the
proper directions and positions.
• If the disassembly procedure is complex requiring many
parts to be disassembled, the parts should be disassembled
in a way that will allow them to be efficiently reassembled
without any change in the engine's extemal appearance or
its performance.
• Do not remove or disassemble parts that require no
disassembly.
• Carefully inspect each parts after removal for damage,
deformation, and other problems.
• Carefully check gaskets, packings and oil seals, even if
checking is not specified. Replace with new ones if defective.
• Be careful not to damage the disassembled parts. Keep the
parts clean.
• Use the proper tools. Apply oil when necessary. Take
special care to keep the fuel system parts free from the
intrusion ofdust and dirt.
-..v: WESTERBEKE
Engines & Generators
3

TROUBLESHOOTING GUIDE
The following engine troubleshooting guide may be helpful in
detennining if acomplete or partial overhaul is necessary.
Insomclen! Power
InsuHlclen! Compression
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Burned cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston
ring
Cracked or worn piston
Malfunction of Fuel System
Malfunction ollgnllion System
Excessive 011 Consumption
011 Worklng Up
Worn or sUcking piston ring or piston
ring groove
Worn plslon or cylinder
011 Worklng Down
Bad valve seal
Worn valve stem or guide
011 Leakage
Dlfllcull starting
Malfunction 01 Englne-relaled
Components
Burned valve
Worn pislon, plslon ring, or cylinder
Burned cylinder head gasket
Mallunctlon 01 Fuel System
Mallunction of Electrical System
Abnonnal Combusllon
Mallunction of Engine-mlaled
Components
SUcking or burned valve
Weak or broken valve spring
Carbon accumulated in
combusllon chamber
Malfuncllon 01 Fuel Syslem
Mallunctlon ollgnillon Syslem
Poor Idling
Mallunctlon of Englne-mlaled
Components
Poor valve-to-valve seal contact
Failure of cylinder head gasket
Malfunction of Fuel Syslem
Malfunction of Ignition
System
Engine Noise
Crankshaft or bearing mlaled
parts .
Excessive main bearing oil clearance
Main bearing seized or heat damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil
clearance
Connecting rod bearing seized or hea
damaged
Piston mlaled parts
Worn Cylinder
Worn piston or piston pin
Seized plstpn
Damaged piston ring
Bent Connecting Rod
Malfuncllon ollgnilion Syslem
Valve or timing relaled parts
Malfunction of HLA *
Broken valve spring
Excessive clearance between valve
stem and guide
InsuHlcient lubrication of rocker arm
Others
Malfunction of water pump bearing
Malfunction of attemator bearing
Malfunction of timing belt tensioner
Engine Misfires Poor quality fuel.
Incorrect timing.
Dirty flame arrester.
Cracked distributor cap.
Faulty Ignnlon wires.
Spark plugs are worn.
High exhaust back-pressure.
Valve clearances are incorrect.
Engine Backfires Spark plug wires are connected
wrong.
Incorrect timing.
Engine is flootiad.
Dirty flame arrester.
Cracked distributor cap.
High exhaust back-pressure.
Choke Is stuck closed.
* Tapet noise mayoccur if the engine is not operated for a
period
of time. Tapet noise should stop within J0 minutes
after operating the engine.
Engln"s.& Generators
4

TROUBLESHOOTING GUIDE
Engine Overheats Coolant loss. Pressure test cooling
system.
Faulty raw water pump impeller.
Belts are loose or broken.
Raw water pump worn.
Faulty thermostat.
Heat exchanger is clogged.
Collapsed hose.
Low 011 Pressure
Low oil level.
Faulty oil pressure sender
Wrong SAE type oil in the engine.
Faulty gauge
Wrong type oil filter.
Relief valve is stuck.
Faulty oil pump.
Faulty engine bearings.
Starting Battery Loose alternator drive belt
Faulty battery voltage regulator.
Connections to the alternator are loose
or faulty.
Faulty alternator.
No excitation to the regulator
High 011 Pressure Faulty sender or gauge
Di';% oil or wrong SAE type oil in the
eng ne.
Relief valve is stuck.
Blue Exhaust Smoke Lube oil is diluted.
Discharge from the Engine
High lube oil level.
Crankcase breather hose is clogged.
Valves are worn or adjusted
incorrectly.
Piston rings are worn or unseated.
Black exhaust smoke
Dirty flame arrester.
Discharge from the Engine
Faulty carburetor.
Idle mixture jet too rich.
Accelerator diaphragm leaking.
Valves are worn or incorrectly
adjusted.
Lube oil is diluted.
Piston rings are worn or unseated.
NOTE: The engines control system (electrical system) is
protected by a 20 Ampere manual reset circuit breaker
locatedjust outboard
of the starter motor.
-..v- WESTERBEKE
Englnes'& Generators
5

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
The engine is protected by five automatic shutdown
switches. Should a shutdown occur, do not attemptto restart
witlwutjinding and co"ectingthe cause. Refer to the
heading
Engine stans, runs and then shuts down in the
ENGINE TROUBLESHOOTING section of this manual.
The following is a description ofthese automatic shutdown
switches:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the
DC voltage (shutting offthe engine) should the switch's
sensor indicate
an excessive exhaust temperature (an inade-
quate supply of raw water causes high exhaust temperatures).
This
switch opens at 26O-27O"F (l27-132°C). This switch
resets at approximately
225"F. (\o7°C).
EXHAUST
low Oil Pressure SwItch
Alow oil pressure shutdown switch is located offthe
engine's
oil gallery . Nonnally open in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's.oil
pressure fall to 5-10 psi, this switch will open
interrupting the DC voltage thereby shutting offthe engine.
ENGINE BLOCK
High Water Temperature Switch
A high water temperature switch is located at the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 2\o'F
(99°C), will open and interrupt the DC voltage thereby
shutting offthe engine. This switch resets at 195'F (107°C).
20 AMP .'."IIIT·"
BREAKER
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring will cause the breaker to trip. In this
event the generator will shut down because the opened
breaker interrupts the DC circuit. If this should occur, check
and repair the source ofthe problem. After repairing the
faul~ reset the breaker and restart the generator.
~ WESTERBEKE
Engines & Generators
6

HIGH RPM SHUTDOWN SWITCH
DESCRIPTION
An overspeed switch in the DC circuit shuts off the
generators engine by grounding out the ignition system if
the engine's s~ reaches 2175 rpm (approximately).
After correcting the problem, this switch can be reset by
momentariJy depressing the stop switch. Refer to the
WIRING DIAGRAMS in this manual.
Ifthe overspeed switch is faulty, (resetting with the stop
switch fails to reset the circuit), lift the white/yellow wire
off the T5 terminal and connect it with the redlpurple wire
on the T4 terminal. Now restart the generator.
Ifthis bypass is successful, replace the faulty overspeed
switch.
NOTE: Overs peedswitches draw a small amaunt of amperage
(25 milliamps) at all
times once the generator is connected
to its starting battery. This amounts to approximately 18
amp-hnurs in a month. It is not necessary to be concerned
with
this slight amperage draw during normal seasonal
operation.
However, if the generator set is to be unusedfor
many
months, it is best to either remove the 8 amp ignition
fuse from
the control panel on the generator ortum off the
generator~ starting battery switch.
OVERSPEEO
CIRCUIT
BOARD
A CAUTION: It is very important that the overspeed
shutdown always be instal/ed and functioning. Any
tampering with the overspeed shutdown module, which
would cause it to malfunction. could be a cause of
injury should·the generator's belt·driven governor fail
and cause the generator to run away.
~ WESJERBEKE
Engines & Generators
7

DISASSEMBLY AND ASSEMBLY PROCEDURES
DISASSEMBLY
• Before disassembly and cleaning, carefully check for
defects which cannot be found after disassembly and
cleaning.
• Drain water, fuel and oil before disassembly.
• Clean or wash the engine exterior.
• Donot remove or disassemble parts.
• 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 intrusion of dust and dirt.
• Parts must be restored to their respective components from
which they were removed at disassembly. This means that all
parts mustbe set aside separately in groups, each IIllIIked for
its component, so that the same combination or set can be
reproduced at assembly.
• Pay attention to marks on assemblies, components and
parts for their positions or directions. Put on marks, if
necessary, to aid assembly ..
• Carefully check each part orcomponent for any sign of
faulty condition during removal orcleaning. The part will
tell you how it acted or what was abnormal about it more
accurately dm!ng removal or cleaning.
ASSEMBLY
• Wash aU parts, except for oil seals, O-rings,and rubber
gaskets with cleaning solvent and dry them with air
pressure .
• Always use tools that are in good condition and be sure
you understand how to use them before performing any
job.
• Use only good quality lubricants. Be sure to apply a coat
of oil, grease or sealant to parts as specified ..
• Be sure to use a torque wrench to tighten parts for which
torques are specified.
• When the engine is assembled,install new gaskets and
O-rings.
TORQUING DATA
Parts of the engine use plastic region tightening bolts. The
tightening procedure for these is different from that of
conventional bolts and is described in this manual, Note that
plastic region tightening bolts have fixed service limitS.
These limits are indicated in this manual and must be strictly
observed.
• Plastic region tightening bolts are used for the following
applications:
1. Cylinder head bolts
2. Connecting rod cap bolts
• The tightening procedure is basically as follows: After
tightening a bolt to the specified torque, tighten it by a
further 90" + 90" or by a further 90-100". The exact
tightening procedure differs depending on the bolt and is
described where it applies in this manual.
GASKET INFORMATION
The engine has several areas where form-in-place RTV
silicone gaskets are used such as LOCTITE 598 orGE
RTV 100. To ensure that the gasket fully serves its pmpose,
it is necessary to observe some precaution when applying the
gasket. Bead size, continuity and location are very important.
Too thin a bead could cause leaks and too thick a bead could
be squeezed out of location causing blocking or narrowing of
the fluid feed lines. To eliminate the possibility of leaks from
ajoint, it is necessary to apply the gasket evenly without a
break while observing the correct bead size.
The gasket material used in the engine is a room temperature
vulcanization (RTV) type and is supplied in a l40z (400
gram) applicator/tube. The RTV hardens as it reacts with the
moisture in the atmospheric air and can be used for sealing
both engine oil and coolant assemblies.
Disassembly
The parts assembled with the silicone can be easily
disassembled without use of a special method. In some cases,
however, the sealant between the joined surfaces may have
to be broken by lightly striking with a mallet or similar tool.
A flat and thin gasket scraper may be lightly hammered
in between the joined surfaces. In this case, care must be
taken to prevent damage to the joined surfaces. For removal
of the oil pan, use a special "oil pan remover".
Surface Preparation
Thoroughly remove all substances deposited on the gasket
application surfaces using a gasket scraper or wire brush.
Check to ensure that the surfaces to which the silicone gasket
is to be applied is flat. make sure that there are no oils,
greases and foreign substances deposited on the application
surfaces. Do not forget to remove the old sealant that
remains in the bolt holes.
Form-in-place Gasket Application
When assembling parts with the silicone gasket, you must
observe some precautions but the procedures are very simple
as in the case of a conventional precut gasket.
The applied gasket bead should be the specified size and
without breaks. Be sure to encircle the bolt hole circumfer-
ence with a completely continuous bead. The gasket material
can be wiped away unless it has hardened. While the gasket
is still moist, mount the parts in position. When the parts are
mounted, make sure that the gasket is applied to the required
area only. Do not apply oil or water to the sealing locations
or start the engine until a sufficient amount of time has
passed after installation is completed.
The gasket application procedure may vary on different
areas. Observe the procedure described in the text when
applying the gasket silicone and follow the directions on the
applicator/tube.
".. WESTERBEKE
Engines & Generators
8

ANGULAR NUT AND BOLT TIGHTENING METHOD
1. Carefully wash the nuts and bolts to remove all oil and
grease.
2. Apply a coat ofmolybdenum disulfide grease to the
threads and setting faces ofthe nuts and bolts.
3. Tighten the nuts and bolts to the specified torque (snug
torque) with a torque wrench.
CENTER LINE
LINE
-"--:).l
C D
4. Draw a line (A-B) across the center of each bolt.
5. Draw another line (C-D) on the face of each of the parts
to be clamped. This line should be an extension of the
line (A-B).
COINCIDING LINE
G
6. Draw another line (F-G) on the face of each of the parts
to be clamped. This line will be in the direction of the
specified angle (Q) across the center (E) of the nut or
bolt.
7. Use a socket wrench to tighten each nut or bolt to the
point where the line (A-B) is aligned with the line (F-G).
Example: Specified Angle and Tightening Rotation
A
3D·
1/12 of a tum
B
60·
1I6 of a tum
C
90· 1I4 of a tum
D 180·
1I2 of a tum
E 360·
One full tum
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS
Parts ofthe engine use plastic region tightening bolts. The
tightening procedure for these is different from that of con-
ventional bolts and is described in this manual.
NOTE: The plastic region tightening bolts havefixed service
limits. These limits are indicated where they occur in this
manual
and must be strictly observed.
Plastic region tightening bolts are used for the following
applications:
1. Cylinder Head Bolts
2. Connecting Rod Cap Bolts
The tightening procedure
is as follows:
After tightening a bolt to the specified torque, tighten it by a
further 90· +90· or
by a further 90" to 100·. The exact
tightening procedure differs depending on the bolt
and is
described as it occurs in this manual.
Engines & Generators
9

ENGINE-DISASSEMBLY, INSPECTION AND ASSEMBLY
NOTE: In TlU)st cases the inspection 'and replacement of the timing belt can be
peiformed with the engine/generator in the boat. '
TIMING BELT INSPECTION AftID REPLACEMENT
A CAUTION: water or oil on the timing belt severly
reduces the service lifeof the belt. Keep the timing
belt sprocket ami fensloner free of 011 and greese. '
These paris should never be cleaned. Replace if serio
ousIy contaminated with dirt or oil. If ollis evident on
these paris, check the front case, oil pump oil seals,
ami ctankshaft 011 seals fora possible leak.
7 SPROCKET BOLT
5 BELT TENSIONER
1 UPPER COVER
--~..\.
8
CAMSHAFT
TIMING BELT ASSEMBLY
9 BELT REAR COVER
2 LOWER COVER_---l~
CRANKSHAFT
'PULLEY
TIMING BELT
NUMBERS INDICATE THE
ORDER OF DISASSEMBLY
4 TENSIONER
SPRING
TIMING BELT REMOVAL
Using pIiets, grip the tensionet spring projection and remove
it from
the oil pump case stopper. Then, remove the tensioner
spring and the timing belt tensionet.
NOTE: Ifthe timing belt is to be reused, chalk an arrow on the
beltto indicaJe the direction of roll1tWn before reTlU)ving it.
This will eIISIU'E the timing belt isfitted correctly when
reused. • u)
MARKA
DIRECTION
ARROW
SPROCKET BOLT REMOVAL (CAMSHAFT)
Using the special tools shown in the illustration, lock the
camshaft sprocket in position and then loosen the camshaft
sprocket bolt.
CAMSHAFT
SPROCKET
Engines & Generators
10

ENGINE-DISASSEMBLY, INSPECTION AND ASSEMBLY
NOTE: In most cases the inspection and replacement of the timing belt can be
performed with the engine/generator in the boat.
Timing Belt Inspection
Replace the belt if any ofthe following conditions exist:
1. Hardening of back rubber-back side is glossy, without
resilience, and leaves no indent when pressed with
fmgernail.
2. Cracks on rubber back.
3. Cracks or peeling ofcanvas.
4. Cracks on tooth bottom.
5. Cracks on belt.
6. Abnonnal wear ofbelt sides. The sides are normal if
they are sharp as if cut by a knife.
7: Abnormal wear on teeth.
8. Tooth missing and canvas fiber exposed.
~
CRACKS 08
PEEUNG
5.
RUBBER ___ : "'.
" ' ...
EXPOSED .: .~: .. :
;: .. ~ .. :~~.
: .: .... ~~~
7.
6.
••
Sprocket Bolt Installation (Camshaft)
Using the special tools shown in the illustration, lock the
camshaft sprocket in position and tighten the camshaft
sprocket bolt
to the specified torque.
LOCKING THE CAMSHAFT SPROCKET
Belt Tensioner Inspection
Replace the belt tensioner ifit binds, rattles, or is noisy when
turned.
TensionerSpring Installation
1. Lock the timing belt tensioner in the illustrated position.
TIMING BELT
TENSIDNER
2. Fit one of the tensioner spring projections over the hooked
portion of the belt tensioner and fit the tensioner onto the
oil pump case.
NSIDNER
SPRING
3. Grip the other tensioner spring projection and fit it onto
the oil pump case lug as shown in the illustration. Move
the timing belt tensioner in. the direction shown and
temporarily tighten the bolt.
OIL PUMP CASE
TENSIDNER
SPRING
88Nm (64.9 n·lb) ~ WESTERBEKE
.Engines & Generators
11

ENGINE-DISASSEMBLY, INSPECTION AND ASSEMBLY
NOTE: In most cases the inspection and replacement of the timing belt call be
peiformed with the engine/generator in the boat.
Timing Belt Installation
CAMSHAFT--f-1~\
K--- CYLINDER
HEAD
SPROCKET
ALIGN THE
TIMING MARK
1. Align the camshaft timing mark with the timing mark
on the cylinder head.
2. Align the crankshaft timing mark with the timing
made on the front case.
3. Keeping the tension side of the timing belt tight, fit the
timing belt onto the crankshaft sprocket, camshaft
sprocket, and tensioner pulley in that
order.
4. Loosen the tensioner pulley mounting bolts by 1/4 to
112 of a turn and allow the tensioner spring to apply
tension to the timing belt
5. Thrn the crankshaft twice in the normal rotating
direction (clockwise) and check that the tinting marks
are correctly aligned.
A CAUTION: This procedure utilizes the
camshaft's driving torque to apply tension evenly
to the timing belt. Be sure to tum the crankshaft
as described above. 00 not tum the crankshaft in
reverse.
6. Tighten the tensioner pulley mounting bolts.
IDLER PULLEY BOLTS TORQUE 23 Nm (17 H·lb)
7. Replace the timing belt covers.
TIMING BELT COVER BOLTS TORQUE 11 Nm (8 H·lb)
~ WESTERBEKE
Engines &. Generators
12

ENGINE/GENERATOR DISASSEMBLY
REMOVING EXTERIOR ASSEMBLIES
DISASSEMBLY PROCEDURE
Before mounting the engine on an engine stand, unbolt and
remove the generator backend, Make sure the back end is
properly supported, Refer to the generator section of this
manual for additional information and an exploded view of
the generator components. Also remove the engine flywheel
before mounting the engine.
NOTE: WHEN REMOVING THE
GENERATOR BACKENO, MAKE
CERTAIN ITiS PROPERLY
SUPPORTED UNDERNEATH
BELL HOUSING/FLYWHEEL
ASSEMBLY
GASOENSER
CONTROL PANEL
,,----
GENERATOR
BACKEND
Mounting the engine on a suitable engine stand and begin
removing the exterior engine components.
Note the following when disassemble these components.
• Drain any engine oil or coolant left in the engine.
• Clean the exterior ofthe 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 the parts clean.
DISTRIBUTOR
IGNITION WIRES
AND SPARK PLUGS
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.
Thrn the rotorpulley 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 "uu "Ul1~~//."="-~
SERVICE in this manual.
ALTERNATOR
,. WESTERBEKE
En!1lnes & Generators
13