Westerbeke 7.6kw-60Hz EDT User manual

SERVICE MANUAL
-----. . .
D·"NET DIESEL GENERATORS
. ----- - . --,---< ---
-
; I 7.6KW • 60Hz 15.7KW • 50Hz EDT
,. 5.5KW • 60Hz 15.0KW • 50Hz ED'C ..
REVISIONi~
.. MARCH2010
V6 WESTERBEKE
I -"AT...... WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
I ~:1!"'ft' ". 150 JOHN HANCOCK ROAD. TAUNTON MA 02780-7319· TEL. 1-508·823·7677 ,
___ _ ___ .. . FAX 1-508·884·9688· WEBSITE: Www.WESTERBEKE.COM

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 - Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMP.TDMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
untilIt has been inspected and repaired.
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.
WAR NING Theyare inexpensive and easily
",,,""o~ Produco CARBON MONOXIDE. . obtainable at your local marine store.
Regular Maintenance Required
f'iiV'lW9TERBEKE
~_"'~'''''''Ioro
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 manual carefuUy. Most accidents are.
caused
by failure to foUow fundamental rules andprecau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, yourpersonnel,
andyour
machinery.
The foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running. 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.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts or
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 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 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 n~t 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 minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -Diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• 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 ofthe reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies bave 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 faruiliar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for
all applications encountered in this environment.
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
• 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.
f-v.rl WESTERBEKE
r Engines & ,Generators
~
;"-

SAFETY INSTRUCTIONS
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen. a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection tenninal of the starter solenoid. Do
not test the battery condition by shorting the tenninals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the tenninals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewehy before handling
the battery.
• Always tum the battery charger offbefore 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.
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection ofthe exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of approved detectors.
A WARNING: Carbon monoxide (CO) is an invisible
odorlefS gas. Inhalation produces fln·like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destruy 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.
• 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
Dizziness Muscular
twitching
Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. Ifa
situation
arises in which it is absolutely necessary to
make operating adjustruents, use extreme care to avoid
touching moving parts and hot exhaust system
components.
• Do not wear loose clothing or jewehy 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 belt's tension while
the engine is operating.
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!
1"'MT1 WESTERBEKE
I Engines & Generators
If

SAFETY INSTRUCTIONS
OPERATORS MANUAL
Many of the preceding safety tips and wamings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical infonnation. Read your manual
carefully, maintaIn your equipmeut, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination ofthe American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
H-24 Gasoline Fuel Systems
P-l Exhaust Systems
P-4 Inboard Engines
E-9
DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
iii
ABVC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast
Guard)
"USCG 33CFRJ83"
Order
from:
U.S. Govemment Printing Office
Washington, D.C. 20404

INSTALLATION
When installing WES1ERBEKE 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 must be complied with
when installing
engines and generators in a marine environment.
SIPHON·BREAK
For installations where the exhaust mauifoldlwater injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install asiphon-
break
in the raw water supply hose to the exhaust elbow. This hose must be looped a
ruiuimum of
20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifold
injectWn 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 ofthe 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
ofthe vessels
hull.
A detailed Marine Installation Manual covering gasoline and diesel
engines and generators is supplied with every unit sold. This manual
is also available in pdf format on our website to download
Website: www.westerbeke.com
--"- -- ---._-.-
I~J WESTERBEKE
rEngines & Generators
. iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Introduction ................................................................ 2
Digital Control Box .................................................. .41
Engine Troubleshooting ... .......................................... .3
7.6/5.7KW Wiring Diagram ....................................... 42
Testing for Overhaul ................................................... 7
Specifications· 7.6/5. 7KW ...................................... 43
Engine Disassembly .................................................... 8
Specifications· 5.5/5.0KW ...................................... 44 .
Cylinder Head ............................................................ 10
Generator Information .............................................. 45
Valve and Valve Spring Inspection .......................... 11
7.6/5.7 EDT Generator Single Phase ....................... .46
Valve InstaliationNalve Clearance ......................... 12
Troubleshooting ................................................. .47
Gear Case/Governor .................................................. 13
No-Load Voltage Adjustment ............................. .48
Timing Gear ............................................................... 14
Camshaft ............................................................... '" .14
Piston and Connecting Rod ...................................... 15
Crankshaft .......................... '" ................................... 17
Residual Voltage Check ...................................... .49
Bridge Rectifier ...•....••...............•........................ .50
Exciter/Rotor Field .............................................. .51
Measuring Resistance ......................................... 52
Shore Power Transfer Switch .............................. 53
Cylinder Block .................... '" ................................... 19
5.5/5.0 EDC Generator Single Phase ...................... .54
Governor System ....................................................... 20
Troubleshooting .................................................. 55
Engine Assembly ....................................................... 22
Dual Exciter No-Load Voltage Adjustment ......... .56
Exhaust Manifold ...................................................... 24
Single Exciter No-Load Voltage Adjustment... .... .57
Heat Exchanger .......................................................... 24
Fuel Injection Pump ................................................. 25
Fuel Lift Pump/lnjection Timing ............................... 26
Fuel Injectors ............................................................ 27
Integral Controller ............................................... 58
Testing the Battery Charging Circuit... ................. 58
Testing the Exciter Windings ............................... 59
Field-Testing Capacitors ..................................... .59
Shore Power Transfer Switch .............................. 60
Glow Plugs ................................................................ 29
Testing Component Resistance Values ................ 61
Coolant Circulating Pump ........................................ 30
Special Tools ............................................................ 62
Raw Water Pump ...................................................... .31
Service Data/Tolerances & Limits ............................ 63
Starter Motor ........................................................... .32
Torque Specifications ............................................... 65
011 Pressure ............................................................. .36
Standard Hardware Torques ..................................... 66
Engine Adjustments ................................................. .37
Metric Conversions .................................................. 67
Alternator TestingJTroubleshootlng ........................ .38
Index .......................................................................... 68
(
tfIIt'fj WES,JiRBEKE
EngInes a C;.mcratol's
1

INTRODUCTION
PRODUCT SOFTWARE
Product software (tech data, parts lists, maouals,
brochures aod catalogs) provided from sources other than
WESTERBEKE are not within WES1ERBEKE'S control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WIU IN NO EVENT
BE UABLE 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 also keep in rrrlnd the
time spao between printings of WES1ERBEKE product
software aod the unavoidable existence of earlier
WES1ERBEKE manuals. Product software provided with
WESTERBEKE products, whether from WESTERBEKE
or other suppliers, must not and cannot be relied upon
exclusively as the definitive authority on the respective
product. It not only makes good sense but is imperative
that appropriate representatives ofWES1ERBEKE or the
supplier in question be consulted to detennine the accuracy
aod currentness of the product software being consulted by
the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the disassembly, inspection
aod assembly procedure of your engine/generator, critical
information will be highlighted by NOms, CAUTIONS,
aod WARNINGS. An explaoation follows:
NOTE: An operating procedure essentinl to note.
A CAUTION: Procedures, which if not strictly
obserVBd, can result in the damage or destruction of
-
your engine/generator.
A WARNING: Procedures, which If not properly
followed, can result In personal injury or loss of life.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver aod black
name-plate located on the generator end. You must provide
us with this infomation so we may properly identify
your engine/generator. In addition, include a complete part
description and part number for each part needed (see
the separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not made to the same specifications
as original equipment.
CUSTOMER IDENTIFICATION CARD
t"""'WESTERBEKE
I
Customer Identification
WES1ERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Mode17.6KW Ser. #
Expires
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing.
The engine serial number can also be found stamped into the
engine blockjust above the injection pump. The generator
serial
number is stamped into the generator housing on the
flat surface on the left side of the generator.
An identification plate on the engine manifold also displays
the engine model aod serial number.
ENGINE
SERIAL
NUMBER
ENGINE OVERHAUL
GENERATOR
ID DECAL
The following sections contain detailed information
relating to the proper operation charactelistics of the major
components aod systems ofthe engine. Included are
disassembly, inspection aod reassembly instructions for the
guidance of snilable equipped and staffed marine engine
service and rebuilding facilities. The necessary procedures
should be undertaken only by such facilities.
Additional detailed information and speCifications are
provided in other sections of this manual, coveling the
generator, alternator, starter motor, engine adjustments,
cooling pumps, etc.
I"VtTI WESTERBEKE
I Engines & Generatol's
2

(
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
detannining the need for an engine overhaul.
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
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
HARD STARTING
LOW CRANKING SPEED
1. Engine oil viscosity too.high.
1. Replace engine 011 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.
DEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
1. Bleed air from fuel system.
2. Clogged f~el 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 dillivering 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.
I. Piston ring seized.
/. 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.
S. Correct lead wire connection.
LOW OUTPUT POWER 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. Air intake obstructed.
1. Cleanlntake.
(continued)
1""ffIVi WESTERBEKE
I Engines & Generators
3

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEOY
\
lOW OUTPUT POWER OVERHEATING
j
1. low coolant level. 1. Add coolant
2. loose V-belt
2. Adjust or replace V-belt
3. Incorrect Injection timing.
3. Adjust injection timing.
4. Low engine oil level. 6. Add engine oil.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION
1. Defective oil seals. 1. Replace oil seals.
2. Broken gear case gasket 2. Replace gasket
3. Loose gear case attaching bolts. 3. Retighten bolts.
4. loose oil drain hose. 4. Retighten connections.
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.
DlllEVEl RISING
1. Incorrectly positioned piston ring gaps. 1. Correct ring gap positions.
2. Displaced or twisted connecting rod. 2. Replace connecting rod.
3. Worn piston ring.
3. Replace ring.
4. Worn piston or cylinder.
4. Replace piston and rebore cylinder.
Oil lEVEL FALLING
1. Defective stem seal.
1. Replace stem se.al.
2. Worn valve and valve guide.
4. Replace a valve and valve guide.
EXCESSIVE FUEL ENGINE BODY TROUBLES
CONSUMPTION 1. Noisy knocking.
1. See KNOCKING.
2. Smoky exhaust 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn. 3. Repair orreplace.
4. Poor compression. 4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing. 5. Adjust
6. Improper valve clearance. 6. Adjust
INSUFFICIENT INTAKE AIR
1. Air intake obstructed.
1. Remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle. 1. Replace.
2. Worn nozzle.
2. Replace.
IMPROPER FUEL Replace with proper fuel.
FUEL LEAKS Find fuel leaks.
SMOKY EXHAUST WHITISH OR PURPLISH
1. Excessive engine all.
1. Correct all level.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact.
H. Check.
~. Seized piston ring.
b. Replace or clean.
c. Excessive piston-to-cylinder clearance.
c. Replace or correct
(continued)
rvvlWESII!RBEKE
I Engines & Generators
4

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
SMOKY EXHAUST (cont.) WHITISH OR PURPLISH (cont •• )
d. Worn valve stem and valve guide. d. Replace.
e. Low engine oil viscosity. e. Replace.
r. Excessive oil pressure. r. 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. 2. Clean air inlet.
3. Improper fuel.
3. Replace with proper fuel.
ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE 1. Badly worn baa ring.
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 AND CONNECTING ROD BEARING
1. Worn connecting rod big end bearing. 1. Replace bearing.
2. Worn crankpin.
2. Grind crankshaft.
3. Bent connecting rod.
3. Correct bend or replace.
PISTON, PISTON PIN, AND PISTON RING
\
1. Worn cylinder. 1. Rebore cylinder to oversize and replace piston.
2. Worn piston pin. 2. Replace piston.
3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or damaged. 4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft. 1. Replace.
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear.
3. Replace.
4. Worn fan pulley bearing. 4. Replace.
ROUGH OPERATION INJECTION PUMP SYSTEM
1. Uneven injection.
1. Adjust injection or replace parts.
2. Control rack 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)
1"VV1 WES,E#!!KE
I Engines s::erators
5

PROBLEM
KNOCKING
INTERMITTENT
EXHAUST SOUND
OVERHEATING
LOW OIL PRESSURE
ENGINE TROUBLESHOOTING
PROBABLE CAUSE
VERIFICATION/REMEOY
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; HARO STARTING.
2. Injection pump malfunctioning.
a. Worn plunger. a. Replace.
b. Pinion Is not in mesh with control rack. b. Correct.
c. Broken dellvelY valve spring. c. Replace.
d. Worn delivery valve Seat.
d. Replace.
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.
1. Fuelfilter clogged. 1. Clean or replace.
2. Fuel pipe sucks air. 2. Retighten pipe joints or replace pipe.
3. Water mixed In fuel 3. Replace fuel.
1. V-belt slackening or slippelY 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.
1. Worn Bearings. 1. Engine overhaul replace bearings.
2. Relief valve malfunction.
2. Overhaul all pump.
3. Clogged all cooler.
3. Repair.
4. Diesel dilution of the 011. 4. Injection pump repair.
(continued)
1"JMf WESTERBEKE
? Engines & Generators
6
\)
.,
i

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY
LCD DISPLAY FAULTS 1. Check battery. 1. Battery on.
2. 20 amp breaker off. 2. Turn breaker off.
3. Loose display connection. 3. Check all cable connections.
.
4. 1 amp fuse blown (faulty). 4. Check/replace. Determine cause.
LOW OIL PRESSURE
1. 011 level low/oil leak. 1. Check 011 level, add 011 and repair leaks.
2. Lack of oil pressure. 2. Test oil pressure. If OK, test oil pressure sendor,
inspect oil filter, inspect 011 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.
HIGH COOLANT 1. Check system coolant level. 1. Add coolant. Check for leaks.
TEMPERATURE
2. Sea water pump.
2. Inspect impeller/pump/replace.
3. Check water pump drive bell 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.
HIGH EXHAUST 1. Check sea water flow. 1. Inspectthru hull fitting, hose and strainer. Correct
TEMPERATURE
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.
BATTERY VOLTAGE 1. Check alternator drive bell
1. Adjusttension/replace if worn.
2. Check charge voltage. 2. Check excitation. Replace/repair alternator.
3. Check battery connections.
3. Check + and - cables from battery to engine.
4. Faulty control module (ECU). 4. Check plug connections/replace.
GENERATOR FREQUENCY
1. Check engine speed. 1. Check speed setting.
Overspeed (steady LED) 2. Check fuel supply.
2. Inspect filters/replace filters. Test fuel pump
Underspeed (flashing LED)
operation.
3. Amperage load.
3. Check + and - cables from battery to engine.
4. Crank cycle with no start. 4. Check cause for no start.
(underspeed fault)
LED DISPLAY EDGES 1. Compartment ambient temperature
1. Ventilate compartment.
TURN PINK
too high. NOTE: Heat will often change the color of an LCD
display. This will not effect the operation of the
engine.
I"TAT} WESTEBBEKE
( Engines ~ Generators
6A

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output,
in the case of diesel engines, is not necessarily due to trouble
with the engine itself, but is sometimes caused by injector
nozzle wear or injection pump wear. It is most reasonable to
judge by a decrease in compression pressure. The decrease
in
compression pressure is caused by many factors. It is,
therefore, necessary to determine a cause or causes on the
basis of data produced by periodic inspection and
maintenance. Oil analysis on aseasonal 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 enginepower 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
injection timing, and wear of glow plugs and nozzles. They
are caused also by defective electrical devices such as the
battery, alternator, starter and glow plugs. Therefore itis
desirable to judge the optimum engine overhaul time by the
lowered compression pressure caused by worn cylinders and
pistons plus increased oil consumption. Satisfactory combus-
tion is obtained only under sufficient compression pressure.
If an engine lacks compression pressure, incomplete combus-
tion of fuel will take place even if other parts of the engine
are operating properly. Th determine the period ofengine
overhaul, it is important to measure the engine compression
pressure regularly. At the same time, the engine speed at
which the measurement 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 tke
ENGINE ADJUS1MENT section of this manual.
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 prograss ofwear
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 valves are at minimum or
below. Engine compression should be 398 psi, 28 kg/Cnf at
280 rpm.
Precautions for Disassembly and Reassembly
When servicing an engine, keep in mind the following
precautions.
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 parts that do not require
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.
Reassembly
1. Carefully check gaskets, packings and oil seals even
if checking is not specified. Replace with new ones
if defective.
2. Be sure to install components in proper directions and
positions. (pay attention to dowel pins, mating mijfks and
specified directions.) Where tightening torque is not
specified, tighten evenly to an ordinary torque. Apply
sealant where specified.
3. After completion of reassembly, recheck for any
abnormalities. Prepare for starting the engine, and idle
the engine sufficiently for a test run.
PRECAUTIONS
• Be careful not to mix bolts and nuts. Metric and S.A.E.
bolts are used on various engine assemblies.
• During assembly, recheck clearances and insure that parts
are being assembled in their proper order and facing in
the correct direction in relation to the engine block, such
as, pistons, piston rings, bearings and bearing caps.
• Apply lubricating oil to moving parts during assembly.
Insure that moving parts, when assembled on the engine,
rotate or slide and are not subject to binding or excessive
tension.
• If there are mating marks scribed during disassembly, ref-
erence them correctly for assembly ..
• Use new gaskets, lockwashers, a-rings, etc.
• TIghten the bolts and nuts on important parts of engine to
specified torques using areliable torque wrench.
• Use liquid sealants when required on nuts, bolts and gas-
kets. Refrain from using tape sealants.
rVV"1 WESTERBEKE
I Engines & Generators
7

ASSEMBLY INFORMATION
Be aware of these common problems that can occur during
reassembly.
Insufficient Lubrication. Heavily oil sliding and reciprocat-
ing parts, lightly oil head bolts and other fasteners, except
those that penetrate into the waterjacket. These fasteners
should be sealed with Pennatex No.2 or the high-tech equiv-
alent
Reversed Orientation. Most gaskets, many bolt washers,
and all thennostats are symmetrical.
Mechanical Damage. Run fasteners down in approved
torque sequences and in three steps - 1/2, 2/3, and 111 torque.
Exceptions are torque-to-yield bolts and rocker ann shaft fas-
teners. The former are torqued as indicated. The latter-rocker
shaft fasteners- should be brought down in very small incre-
ments, working from the center bolts out. Gaskets, especially
head gaskets, might also be damaged during assembly, and
should be positioned with great care
Service Manual
The engine that powers the 7.6Kw/5.7Kw BID Generator
also is used to power the 5.0Kw/4.0Kw BCD generator.
TIlls 3 cylinder diesel engine has gone through several model
deSignations but it is essentially the same engine internally.
The engine overhaul data, including the tolerance standards
and limits are the same for both generators thrDughout this
manual (the exceptiDns being the cylinder bore and piston
diameter). The GENERKl'OR SECTION COvers both the
BID and BCD back ends.
ENGINE DISASSEMBLY
GENERATOR
DiscDnnect ground wires, battery cable cDnnections and
incoming and r.eturn fuel lines.
Disconnect the AC wiring and unplug the DC wiring hamess.
Separate the the exhaust hose at the water injected elbow.
Carefully suppor! and then unbolt the generatDr back end
from the engine.
See SPECIAL TOOLS - GENERATOR.
MOTOR
BACK
With the generator separated from the engine begin the
fDllowing step by step procedure of engine disassembly.
Drain the engine Dil and coolant from the engine and beat
exchanger.
Remove the generator/engine wiring harness in its entirety.
Label the terminal connections tD ensure proper reattach-
ment.
LABEL THE WIRES
Lock the ring gear
with a ring gear brake
I before disassembly.
\,
1"VV'1 WESTERBEKE
I Engines & Generators
8
The engine should be securely mounted on a
sUltabte engine stand.

ENGINE DISASSEMBLY
1. Remove engine heat exchanger. If possible, leave one end
of each hose connection attached to the part being
removed. For maintenance, see HEAT EXCHANGER.
2. Remove the starter motor. For starter motor repair, see
STARTER MOTOR
3. Remove flywheel.
4. Remove engine backing plate.
S. Unbolt elbows at head and remove the exhaust manifold
in its entirety. See EXHAUST MANIFOLD.
6. Remove the engine alternator and raw water pump.
7. Remove the engine mounted fuel filter and fuel line to
injection pump. (Note the arrangement ofsesling washers
on banjo bolts at fuel filter and injection pump.)
8. Remove the thermostat housing and the thermostat.
Leave temperature sending unit in place.
9. Remove the coolant circulating pump.
10. Remove the air intake silencer.
AIR INTAKE SILENCER
GASKET--.......;~M..
Now the basic engine is ready for disassembly, cleaning, and
repair if necessary.
1. Remove the high pressure injector line assembly. When
disconnecting each injector line from the injection pump
side delivery valve holder, grasp the holder with a wrench
to preventit from loosening. After removing the pipe
assembly, plug the nozzle holders and delivery valve
holders to prevent intrusion of dust.
2. Disconnect the glow plug lead wire.
3. Loosen the fresh water pump drive belt and dismount the
belt, idler pulley and bracket.
4. Disconnect the air breather hose.
CYLINDER HEAD REMOVAL
S. Remove the rocker cover.
6. Remove the rocker shaft assembly.
7. Loosen the cylinder head mounting bolts equally and
gradually in the numerical order as illustrated and remove
the cylinder head assembly (including the exhanst mani-
fold).
9
SEQUENCE FOR LOOSENING CYLINDER HEAD BOLTS
8. Lift the cylinder head off the engine.
9. Remove the cylinder head gasket. Clean the cylinder
head and the cylinder block surface from which the gas·
ket bas been removed.
10. Remove the injector assemblies and glow plugs from the
cylinder head.
11. Remove the exhaust manifold from the cylinder head.
12. Remove the valve retainers, valve springs and valves
from the cylinder head. When removing each valve
retainer, depress the retainer against the valve spring and
remove the retainer lock. Identify each valve by putting a
mark indicating the number of the cylinder from which
the valve is removed.
13. Remove the valve stem seals.
ROCKER COVER
ROCKER COVER
GASKET
CYLINDER
VALVE SPRING RETAINER
HEAD
GASKET
\
i
\

CYLINDER HEAD
Cylinder Head Inspection
Clean the cylinder and the cylinder block surface from which
the gasket has been removed. Carefully check the cylinder
head for cracks or any other damage as shown below. Use a
straightedge and a thickness gauge to check the surface for
distortion and warpage.
Check the valve guides and valve contact surfaces.
Cylinder head distortion repair limit: 0.004 In (O.l mm)
Valve Seat Repair
If a valve seat is found defective. reface it or have a machine
shop install a new seat.
Sinkage of valve
Siandard 0.0191n (O,5mm)
Limn 0.0591n (l.5mm)
NOTE: When checking valve sinkage. the valve guide must be
in normal condition. Resuiface the valve seat so that it con-
tacls the mid-portion of the valve face.
Cheek guides for
wear and damage.
VALVE SINKAGE
.Ch,'ek •• lve contact, wear, "
Check valve contact, wear,
damage and Ihe sink oflhe seal face.
Valve Guide Replacement
Cheek for cracks, damage
and waler leaks. Remove all
011, sludge, •• alanl
and carbon deposiiS.
If a valve guide is found defective, replace it.
1. Remove the valve guide by pressing at its upper end and
pull it out to the valve seat side.
2. Install the valve guide by press fitting the guide from the
upper side ofthe cylinder head to a height of 14mm
(±O.5) from the valve spring seat face.
0.25mm
I""E'- (0.984 I"'---'~
0.12 mm
(0.472 In)
•
i-«!<---\-- 6.6 ± 0.015 mm
(0.295 In)
PRESS-FITTING THE VALVE GUIDE
mm
60'
\
RESURFACING mE VALVE SEAT
(INTAKE AND EXHAUST)
Installing The Cylinder Head
of Valve Conlacl
.3-1.8mm
Installation of the cylinder head is in the reverSe order of
removal. Pay attention to the following.
1. Renew the cylinder head gasket. No application of
sealant is necessary. On the upper front of the gasket is
the engine model to which the gasket is applicable. Be
careful not to confuse it with a gasket for anolber engine
model.
2. TIghten the cylinder head bolts in the numerical order
shown going through that order two or three times.
Tighten each bolt a little at a time until all are tightened
to the specified torque.
FRONT
•
I~I WESTERBEKE
BOLT TIGHTENING SEQUENCE
I Engines & Generators
10

VALVE AND VALVE SPRING INSPECTION
VALVE REMOVAL
1. Dismount the cylinder head· assembly.
2. Depress the valve retainer (to compress the valve spring)
and remove the retainer lock.
REMOVING VALVES
3. Remove the valve.
4. Inspect aU the components and repair or replace any
defective parts.
SQUARENESS CHECK
SQUARENESS GAUIGE -_..!PI
Squareness Check
Siandard 2°
limit 3°
Valve Spring Squareness Check. Check the squareness of
the valve spring and, if it is more than the limit, replace the
spring.
Valve Spring Fitting Pressure Check. Check the valve
spring fitting pressure with a valve spring tester and, ifthe
pressure is less than the limit, replace the spring.
Pr .... r. (load) T •• I
Siandard 13.095Ib'/1.39Bln (5.94 kg/35.5 mm)
limit -15%
NOTE: Measure the jitting pressure after compressing the
spring several times.
Valve Spring Free Length Check. Measure the free length
of
the valve spring and if the free length is less than the limit,
replace it.
VALVE SPRING
frJ/~~~!::!SPECIMEN VALVE
t!: SPRING
--
Free length To.1
VAlVE SPRING TESTER
Standard
limit
1.595 In (40.5 mm)
1.5 in (39.3 mm)
Valve Inspection
Valve Stem WearInspection. If the valve stem is bent or its
diameter is less than the standard, replace the valve.
Valve Stem
Standard 6.6 mm (0.260 In)
Margin
Standard
limit
1.0 mm (0.039 In)
0.5 mm (0.019 in)
1. If the valve face is found worn down, resurface it with a
valve refacer. If the margin of the resurfaced valve
exceeds the service limit, replace the valve.
2. If the valve stem end has been indented by wear, flatten it
with an oil stone.
----r--~~~~~[~-::: MARGIN
45°Y
/
INSPECTING VALVES
11
\

[
\.
VALVE INSTALLATION I VALVE CLEARANCE
Installation
Install the valve and valve springs. Refer to the illustrations
and callouts shown below.
NOTE: Be careful not to damage the spring and stem seal by
excessively compressing the spring when installing the valve
spring.
Mount the Cylinder Head Assembly and adjust the valve
clearances.
PRESS THIS SURFACE
0.375in
(14.8mm)
With the retainer- 0
depressed to compress
the spring, Instalt the
retainer tock. C:~.-
INSTALLING SPRING
INSTALLING THE
SPRING RETAINER
Torquing The Cylinder Head Bolts
NOTE: Cylinder head bolts must be retightened before adjust-
ing the valve clearances.
Tighten the cylinder head bolts according to the the sequence
shown. Makesure the engine is cold when this is done.
Before applying the specified torque to the bolt, loosen it 114
to 112 of a turn and then apply the torque. Follow this proce-
dure according to the numbered sequence shown in the illus-
tration.
Bolls n, 2, and 3
lorque (12mm socket) 14 - 22 ft-Ib (2.0 - 3.0 kg-m).
Bolls #4, 5, 6, 7, 8, 9,10 and 11
torque (14mm socket) 54 - 61 ft-Ib (7.5 - 8.5 kg-m).
Rockershaft Hold Down Bolls
torque (12mm sockel) 11 ·16 ft·lb (1.5 • 2.2 kg-mm).
FRONT •
CYLINDER HEAD BOLT TIGHTENING SEQUENCE
NOTE: The Rocker Assembly (Rocker Arms, Shaft and Stays)
are not in the engine when the cylinder head bolts are retight-
ened in this procedure.
VAlliE CLEARANCE
O.olOin (0.25mm)
Cold Engine
1. Set the cylinder to be adjusted to the Top Dead Center
(rD.C.) ofthe the compression stroke. Valve clearance:
0.010 in (0.25 mm) cold for both intake and exhaust
valves.
2. The Top Dead Center of the compression stroke can be
obtained by aligning the T.D.C. Mark (notch) on the
crankshaft pulley with the mark on the gear case.
3. First align the T.D.C. mark for the No.1 cylinder.
Confirm that the valves do not move up and down when
the crankshaft is turned 20· in the normal direction of
rotation and in the reverse direction.
4. When setting the T.D.C. For the #3 and #2 cylinders, per-
form as follows. From the T.D.C. for the #1 cylinder, turn
the crankshaft 240· clockwise to set the #3 cylinder
T.D.C. Farther, tum the crankshaft 240· clockwise to set
the #2 cylinder to T.D.C.
MARK ON
GEAR CASE
IT MARK
ON PULLEY
f"'MTl WESIERBEKE
I Engines & Generators
12

GEAR CASE I GOVERNOR
GEAR CASE ASSEMBLY
1. Remove the drive belt and the crankshaft pulley.
2. Remove the alternator.
3. Reillove the water pump assembly.
WATER PUMP
ASSEMBLY
GASKET
For pump brealafown.
see COOLANT
CIRCULATING PUMP.
4. Remove the tie-rod cover from ille side of the injection
pump.
S. Being careful not to let the spring fall into the case,
remove the tie-rod and the tie-rod spring.
6. Remove the governor case cover.
7. Remove the gear case assembly.
8. Inspect the disassembled parts. Replace parts worn
beyond standard and service limits.
~-~/::~;~!;~~~~f~~-~~AR. wear.
CASE
Check for cracks
and damage.
Check Plunger
Assembly for wear
and smooth
L-- ___________ movement.
Front Oil Seal Replacement
Check sprIngs
for fatigue.
Check BRACKETS
for bends and
" ~ twists.
IIW'~ .1{
CheckSHAFT/' ~ ~ ,/.r' Check SLIDING SLEEVE
for flaws. I jOint for wear and
damage.
Governor Shaft Oisassembly/lnspection
NOTE: For additional infonnation refer to the GOVERNOR
SYSTEM section.
L Taking care to not scratch the gear case, remove the
expansion plug.
2. Remove the grooved pin.
3. Draw out the shaft and the two bushings.
WITH
THIS PLANE
PRESS-FITTING THE
GOVERNOR S!!~JFiBIIiSHING
Press-fit two new bushings into place as illustrated.
EXPANSION
PLUG
GEAR
GROI~y~D PIN
INSTALLING THE GOVERNOR SHAFT
S. Check the governor parts for wear, damage, and fatigue.
If any parts are defective, repair or replace them.
Installing the Governor ShaH
Install the governor shaft in the reverse order of removal then
press-fit the expansion plug into the shaft hole in the gear
Remove and replace the front oil seal. Apply a thin coat of case.
engine oil to the circumference and the lip of the new seal
before press-fitting it to the gear case cover.
RELIEF PLUNGER ASSEMBLY
Torque 28.9 - 36.21t-lb (4.0 -1;jjm-kg)
~ WESTERBEKE
Engines & Generators
13
TAPER PLUG
Torque 10.8 -15.9ft-lb (1.5 - 2.2m-kg)
\
OIL PUMP
Torque 5.8 -7 .Oft-Ib
(O.B -1.0m-'