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Westerbeke Diesel 63b Four Parts Manual




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SERVICE MANUAL
W5263B and 63CFOUR
MARINE DIESEL ENGINES
15KW60Hz 60Hz 12KW 50Hz WMF
15KW60Hz 12KW50Hz 12KW50Hz BTDB
MARINE DIESEL GENERATORS
SINGLE AND THREE PHASE
PUBLICATION NO 32460
EDITION TWO
JANUARY 1999
WESTERBEKE CORPORATION AVON INDUSTRIAL PARK
AVON MA 02322 TEL 508 5887700 FAX 508 5599323
WEBSITE tVMMA Member Natiollal Marille CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and col
orless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can include
Dizziness Throbbing in Muscular Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are
caused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or death
tions Know when dangerous conditions exist and take the
necessary precautions to protect yourself your personne Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with the pump or other potential sources of spilled fuel or fuel
American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard
Approved flame
arrester removed Backfire can cause severe injury or
death
A WARNING 00 not touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will bum
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions from fuel vapors can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING 00 not touch hot engine parts or Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
exhaust system components A running engine gets spill DO NOT allow any smoking open flames or other
very hot sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
Always check the engine coolant level at the coolant fuel system
recovery tank
Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
A WARNING Steam can cause injury or death Be certain fuel line fittings are adequately tightened and
free of leaks
In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this lVVl WESTERBEKE
I Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas
or death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine
discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect
regularly for leaks and make sure the exhaust manifolds
it last
are securely attached and no warping exists Pay close
Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and
starting exhaust pipe nipple
Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated
installed before starting the engine
In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BAnERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
burns or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp
wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery are
Always turn the battery charger off before disconnecting Vomiting
the battery connections Remove the negative lead first
Dizziness
and reconnect it last when disconnecting the battery
Throbbing in Muscular twitching
Intense headache
A WARNING Sulfuric acid in batteries can cause Weakness and sleepiness
severe injury or death
AVOID MOVING PARTS
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec
tion Batteries contain sulfuric acid which is destructive
A WARNING Rotating parts can cause injury
If it comes in contact with your skin wash it off at once or death
with water Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps Do not service the engine while it is running If a situa
tion arises in which it is absolutely necessary to make
operating adjustments use extreme care to avoid touching
moving parts and hot exhaust system rfJIVl WESTERBEKE
I Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that
INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their recommenda
Make sure all attaching hardware is properly tightened
tions when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 15 East 26th Street
be caught in these rotating parts New York NY 10010
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing National Fire Protection Association
loss 11 Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARNING Do not work on machinery when you are
mentally or physically incapacitated by 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 maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
tfIVl WESTERBEKE
I Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is below
the vessels waterline provisions must be made to install a siphonbreak in the raw
water supply hose to the exhaust elbow TIris hose must be looped a minimum of 20
above the vessels waterline Failure to use a siphonbreak when the injection port is at or below the load waterline will result in raw water
damage to the engine and possible flooding of the 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 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
1fIVI WESTERBEKE
I Engines Generators
TABLE OF 2 Generator Information 62
Engine Chart 3 Generator Control Panel Switches 62
Testing for Overhaul 7 Control Panel Disassembly 8 Electronic Governor Installation 64
Engine Disassembly 9 Electronic Governor 67
Engine Inspection 14 WMF Generator 68
Engine Assembly 24 WMF Wiring Schematics 72
Exhaust ManifoldlHeat Exchanger 31 WTA Generators 74
Fuel Injection Pump 32 WTA 75
Injection Timing 33 WTA 50Hz60Hz Schematics 81
Fuel Lift Pump 34 Rotating Bridge Rectifier 83
Fuel System 36 WTA Wiring Diagrams 85
Glow Plugs 38 WTA 86
Engine Adjustments 39 WTA Electrical Fault Analysis 87
Coolant Circulating Pump 41 WTA Internal Wiring Schematics Oil Pump 42 WTA Connection Schematics 89
Oil Pressure 43 WTA Parts 90
Raw Water Pump 44 BT Generator 91
Starter Motor 45 BT Internal Wiring Schematic 92
Tachometer 49 BT Chart 93
Alternator Testing 50 BT 95
Service Data Standards and Limits 52 BT Voltage Regulator Adjustments 101
Engine Torque 54 BT Internal Wiring 3 Phase 102
Standard Hardware Torques 55 BT 3 Phase 103
W52 Wiring Diagram 51 BT Wiring Diagram l 04
W52 Wiring Schernatic 52 BT Wiring Schematic 105
63B and 63C Wiring Diagram 53 Generator l 08
63B and 63C Wiring Schematic 54 Special l and 63C Engines 60 Metric Conversions 11 0
Index 111
1fIV1 WESTERBEKE
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SOFTWARE CUSTOMER CARD
Product software tech data parts lists and catalogs provided from sources other are not within WESTERBEKES control CANNOT
BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE MAKES NO
Customer OR WITH RESPECT
WESTERBEKE INCLUDING ACCURACY TIMELINESS THEREOF AND WILL IN NO EVENT MAIN STREET
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY HOMETOWN USA
INCURRED IN CONNECTION WITH OR ARISING OUT
Model63B Ser THE FURNISHING OR USE OF SUCH SOFTWARE
Expires customers should also keep in mind the
time span between printings of WESTERBEKE and the unavoidable existence of earlier The WESTERBEKE serial number is an manuals
Product software provided with number that can assist in determining the date of
WESTERBEKE products whether from WESTERBEKE manufacture of your WESTERBEKE The
or other suppliers must not and cannot be relied upon first character indicates the decade A1960s as the definitive authority on the
respective C1980s D1990s the second character represents the year
product It not only makes good sense but is imperative in the decade and the fourth and fifth number represents the
that appropriate of WESTERBEKE or the month of in question be consulted to determine the accuracy
and currentness of the product software being consulted by SERIAL NUMBER LOCATION
the customer
The engine and generator serial numbers and model numbers
are located on a decal on the generator CAUTIONS AND WARNINGS The engine serial number can also be found
stamped into the
As this manual takes you through the disassembly inspection engine block just above the injection pump The generator
and assembly procedure of your critical serial number is stamped into the generator housing on will be highlighted by NOTES CAUTIONS
flat surface on the left side of the WARNINGS An explanation follows
An plate on the engine manifold also An operating procedure essential to note the engine model and serial number
A CAUTION Procedures which if not strictly GENERATOR
IDDECAl
observed can result in the damage or destruction of
your ENGINE
SERIAL
NUMBER
A WARNING Procedures which if not properly
followed can result in personal injury or loss of replacement parts are needed always provide the
generator model number engine serial number and generator ENGINE number as they appear on the silver and located on the generator end You
must provide The following sections contain detailed with this information so we may properly identify relating to the proper
operation of the major
your In addition include a complete part components and systems of the engine Included and part number for each part needed see
disassembly inspection and reassembly instructions for the
the separately furnished Parts List Also insist upon guidance of suitable equipped and staffed marine packaged parts because will fit or
generic service and rebuilding facilities The necessary are frequently not made to the same should be undertaken only by such
original equipment Additional detailed information and are
provided in other sections of this manual covering the
generator alternator starter motor engine adjustments
cooling pumps etc
IvvJ WESTERBEKE
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ENGINE following chart describes certain ing the need for an engine relating to engine service the probable causes of
NOTE The engines electrical system is protected by a 20
these problems and the to overcome ampere manual reset circuit breaker The preheat solenoid is
these problemsThis chart may be of assistance in determin mounted on the same bracket
PROBLEM PROBABLE CAUSE HARD STARTING LOW CRANKING
SPEED
1 Engine oil viscosity too high 1 Replace engine oil with less viscous oil
2 Rundown 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 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
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 3 Correct lead wire connection
4 Incorrect governor lever position 4 Set lever to starting position
5 Governor spring out of POSITION 5 Correct spring
LOW OUTPUT LOW COMPRESSION See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1 Incorrect injection timing 1 Adjust injection timing
2 Insufficient injection 2 Repair or replace injection pump
3 Low injection pressure 3 Check injection nozzle and adjust pressure
INSUFFICIENT FUEL
1 Air trapped in fuel system 1 Check and retighten connector
2 Clogged filter 2 Clean or replace filter
3 Contaminated fuel tank 3 Clean tank
INSUFFICIENT INTAKE AIR
1 Clogged air cleaner 1 Clean or replace air cleaner
Il WESTERBEKE
I Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT coot OVERHEATING
1 Low coolant level 1 Add coolant
2 Loose Vbelt 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low engine oil level 6 Add engine OIL OIL 1 Defective oil seals 1
Replace oil seals
2 Broken gear case gasket 2 Replace gasket
3 Loose gear case attaching bolts 3 Retighten bolts
4 Loose drain plug 4 Retighten plug
5 Loose oil pipe connector 5 Retighten oil connections
6 Broken rocker cover gasket 6 Replace gasket
7 Loose rocker cover attaching bolts 7 Retighten attaching bolts
OIL LEVEL 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 seal
2 Worn valve and valve guide I 2 Replace a valve and valve FUEL ENGINE BODY 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 cornpression 4 See LOW COMPRESSION HARD STARTING
5 Irnproper valve tirning 5 Adjust
6 Irnproper valve clearance 6 Adjust
INSUFFICIENT INTAKE AIR
1 Air intake obstructed 1 Rernove NOZZLE TROUBLES
1 Seized nozzle 1 Replace
2 Worn nozzle 2 Replace
IMPROPER FUEL Replace with proper fuel
FUEL LEAKS Find fuel leaks
SMOKY EXHAUST WHITISH OR PURPLISH
1 Excessive engine oil 1 Correct oil level
2 Excessive rise of oil into combustion charnber
3 Poor piston contact 3 Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
fAT WESTERBEKE
rEngines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST cont WHITISH OR PURPLISH cont
d Worn valve stem and valve guide d Replace
e Low engine oil viscosity e Replace
f Excessive oil pressu reo f Correct
3 Injection timing is too late 3 Adjust
4 Insufficient compression 4 See LOW COMPRESSION HARD STARTING
BLACKISH OR DARK GRAYISH
1 Engine body troubles
a Poor compression a See LOW COMPRESSION HARD STARTING
b Improper valve clearance b Adjust
2 Insufficient intake air air cleaner clogged 2 Clean air cleaner
3 Improper fuel 3 Replace with proper 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 OPERATION INJECTION PUMP SYSTEM
1 Uneven injection 1 Adjust injection or replace parts
2 Inadequate injection nozzle spray 4 Replace injection nozzle
GOVERNING SYSTEM
1 Governor lever 1 Check governor shaft and correct operation
2 Fatigued governor spring 2 Replace
I WESTERBEKE
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ENGINE PROBLEM PROBABLE CAUSE ENGINE KNOCKS WITHOUT MUCH SMOKE
1 Main engine troubles
a Overheated cylinder a See OVERHEATING LOW OUTPUT
b Carbon deposits in cylinder b Clean
2 Too early injection timing 2 Correct
3 Too high injection pressure 3 Correct
4 Improper fuel 4 Replace with proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See LOW COMPRESSION HARD STARTING
2 Injection pump 2 3 Improper nozzle
a Poor spray a Clean or replace nozzle
b Poor chattering b Repair or replace nozzle
c drip c Repair or replace nozzle
d Nozzle needle valve seized d 1 Fuel filter clogged 1 Clean or SOUND 2
Fuel pipe sucks air 2 Retighten pipe joints or replace pipe
3 Water mixed in fuel 3 Replace 1 Vbelt slackening or slippery with oil 1 Adjust replace
or clean
2 Damaged water pump 2 Replace
3 Lack of coolant 3 Add
4 Low oil level or poor oil quality 4 Add or change
5 Knocking 5 See KNOCKING
6 Moving parts seized or damaged 6 Replace
7 Defective thermostat 7 Replace
LOW OIL PRESSURE 1 Worn Bearings 1 Engine overhaul replace bearings
2 Relief valve malfunction 2 Overhaul oil pump
3 Clogged oil cooler 3 Repair
4 Diesel dilution of the oil 4 Injection pump repair
tfIVl WESTERBEKE
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TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL of Low Compression
Compression pressure tends to increase a little in a the time at which an engine should be overhauled engine until piston rings and valve
seats have been broken in
is determined by various conditions such as lowered engine Thereafter it decreases gradually with the progress of wear
power output decreased compression pressure and increased of these parts
fuel and oil consumption The lowered engine power output When decrease of compression pressure reaches the repair
is not necessarily due to trouble with the engine itself but is limit the engine must be caused by injector nozzle wear or injection pump
wear The decrease in compression pressure is caused by The engine requires overhaul when oil consumption is high
many factors It is therefore necessary to determine a cause blowby evident and compression values are at minimum or
or causes on the basis of data produced by periodic inspec below Engine compression should be 30 kgcm2 427 psi at
tion and maintenance Oil analysis on a seasonal basis is a 200 rpm
good means of monitoring engine internal wear When
caused by worn cylinders or piston rings the following will occur 1 Before
disassembly and cleaning carefully check for
1 Low engine power ontpnt defects which cannot be found after disassembly and
2 Increased fuel consumption cleaning
3 Increased oil consumption 2 Drain water fuel and oil before disassembly
4 Hard engine starting 3 Clean or wash the engine exterior
5 Noisy engine operation 4 Do not remove or disassemble the parts that require no
symptoms often appear together Symptoms 2 and 4
can result also from excessive fuel injection improper injec 5 Perform disassembly in a proper order using proper tools
tion timing and wear of plugs and nozzles They are caused Keep disassembled parts in order Apply oil when neces
also by defective electrical devices such as the battery alter sary Take special care to keep the fuel system parts from
nator starter and glow plugs Therefore it is desirable to intrusion of dust and dirt
judge the optimum engine overhaul time by the lowered 6 Carefully check gaskets packings and oil seals even if pressure caused by
worn cylinders and pistons ing is not specified Replace with new ones if increased oil consumption Satisfactory combustion is
obtained only under sufficient compression pressure If an MODELS
engine lacks compression pressure incomplete combustion
The W52 Marine Diesel Engine has gone through several
of fuel will take place even if other parts of the engine are
model designations As the W52 it provides power for the
operating properly To determine the period of engine over
WTA and the WMF Marine Generators Speed it is important to measure the engine compression pres
to the W52 produced the model designations 63B and 63C
sure regularly At the same time the engine speed at which
The 63B model powers the BIDA Generator and the 63C
the measurement of compression pressure is made should be
model powers the BIDB Generator Internally the because the compression pressure varies with engine
and 63C engines are identical The generator back ends
rpm The engine rpm can be measured at the front end of the
BTDA and BIDB are also the WESTERBEKEs current production model in this series
NOTE To test engine compression see the ENGINE the 63C Marine Engine and the 15Kw BTDB section of this manual
fAT WESTERBEKE
I Engines Generators
DISASSEMBLY
GENERATOR PROPULSION ENGINE
Disconnect the AC wiring and unplug the engines DC Unplug the instrument panel wiring harness Drain the trans
wiring harness at the generator control panel Disconnect the mission fluid and the transmission oil cooler hoses Detach
battery cable connections and the engine ground lines the oil cooler hoses and unbolt the transmission from the
Separate the exhaust hose at the water injected elbow and engine
disconnect the fuel supply and return lines If the transmission is not being rebuilt it should be cleaned
and repaired Inspect the transmission coupling vent and
NOTE Label any lines hoses or cables as you separate them shift link Lubricate the moving parts and change the
Drain the engine oil and the coolant from the engine transmission fluid
Carefully support and then unbolt the generator backend For transmission service and maintenance refer to your
from the engine See SPECIAL TOOLS GENERATOR in transmission manual To rebuild a transmission contact your
this manual WES1ERBEKE dealer or an authorized transmission service
Additional generator information will be found in the shop
GENERATOR section of this manual Drain or pump out all the engine oil and drain the coolant
from the engine and engine hoses
GENERATOR
FLYWHEEL
CAREFULLY LABEL
TERMINAL CONNECTIONS
AND CABLES
GENERATOR
BACK END
FLYWHEEL
HOUSING
MOUNT THE TO A
PROPER ENGINE
STAND OR BENCH
BACK PLATE
FLYWHEEL
PLATE
1fAT1 WESTERBEKE
I Engines Generators
ENGINE DISASSEMBLY
DISASSEMBLING THE MAIN ENGINE
With the generator separated from the
engine begin the following step by step procedure to
disassemble the engine
NOTE Mount the engine on a suitable stand or work bench
1 Remove the transmission damper plate from the
engine flywheel 4
o risER PLATE
ImIO
DAMPER t
PLATE 0 O
2 Remove the engine oil cooler and oil hoses Note oil
hose connections from the oil cooler to the engine
3 Remove the engine heat exchanger If possible leave
one end of each hose connected to the part being
removed
4 Remove the bell housing propulsion engine and the
circuit solenoid mounting bracket 11 Remove the air intake silencer and the intake manifold
5 Loosen the front crankshaft pulley bolt and remove the 12 Remove the oil filter and the mounting bracket from the
flywheel engine block
ONE BOLT DEVIATE 13 Unbolt the elbows and remove the exhaust manifold in
FROM THE 6rJ SET UP TABWASHER its entirety Note that the 63 Model exhaust manifold and
elbows are all one casting
FLYWHEEL BOLT
PATTERN
WHEN REMOVING
THE MOUNTING THE FLYWHEEL REMOVING THE FLYWHEEL
WITH A RING GEAR INSERT
BREAK TOOL
6 Remove the engine back plate Injection Disassembly
7 Remove the start motor drive belt and the alternator 14 Detach all the high pressure injection lines from the
Label the wires and cables injection pump to the injectors Leave the two upper line
8 Remove the engine mounted raw water pump adap clamps in place
tor mounting plate and drive from the front cover NOTE Cap the ends of the lines and the connections at
The drive is removed by turning in a counter clockwise the injection pump and at the injectors to prevent entry of
direction See RAW WATER PUMP for parts breakdown foreign material
9 With the hoses disconnected remove the thermostat
15 Remove the fuel return line from the top of the injec
housing and housing gasket leaving the temperature
tors and from the fuel injection pump by removing the
sender in place
four 12 mm attaching bolts Note the washer arrange
10 Remove the coolant circulating pump See COOLANT ment on fuel return line banjo bolts Cap all the openings
CIRCULATING PUMP for parts breakdown on the fuel return line injectors and injection pump
1fIVI WESTERBEKE
I Engines Generators
ENGINE DISASSEMBLY
16 Remove the fuel injectors dust seals and sealing d Place the keyway on the injection pump shaft in the
washers from the cylinder head 1200 position with the aid of the front crankshaft
17 Remove the glow plugs pulley bolt before attempting to remove the
injection pump
18 Remove the crankcase breather hose and rocker arm
cover e With the use of extractor 49 SE 01 157 apply
sufficient pressure to loosen the pump from the keyed
19 Remove the engine mounted fuel filter and fuel line to gear The loose hold down nuts will prevent the pump
the injection pump Note the arrangement of the seal from falling from the engine
ing washers on the banjo bolts at fuel filter and the injec
tion pump
20 Remove the injection pump Scribe the mating marks
on the pump body flange and the timing gear case before
EXTRACTOR TOOL 1149 SE 01157
a Remove the cover and the lock nuts
b Loosen the two injection pump hold down nuts Do not I
remove entirely The hold down nut on the engine side
of the pump can be loosened by using a 114 universal
socket and extension with ratchet
f Once loosened remove the hold down nuts and wash
ers and carefully withdraw the pump from the drive
gear and engine so as to avoid losing the injection
pump drive key inside the timing case
NOTE If an extractor is not available replace the nut
INJECTION on the injection pump shaft loosely and with a
drift and hammer gently tap the injection pump shaft to
dislodge it from the keyed drive gear
If the injection pump requires service or adjustment it
should be taken to an authorized diesel injection
c Remove the nut and lockwasher from the injection pump service shop Contact your WESTERBEKE
pump shaft
dealer
NOTE Take care not to drop the nut and the washer To adjust Injection Pump Timing refer to FUEL
into the timing gear case INJECTION PUMP in this manual
IVVI WESTERBEKE
I Engines Generators
ENGINE Block Disassembly 24 Lift the cylinder head off the engine and remove the engine in the
following order
cylinder head gasket
21 Rove the cylinder hrod rofer cover and ket
ROCKER ARM
COVER
CYLINDER HEAD
Remove the cylinder head
NOTE Loosen the cylinder head bolts equally and gradu
ally in the order shown in the diagram
25 Disassemble the rocker arm assembly
TAPER PIN RECESS
1JPER PIN HOLE JAM NUT
ADJUSTING
SCALLOP
Remove the rocker arm assembly ROCKER
a Remove the valve stem caps so as not to lose them
when removing the cylinder head BRACKET
BUSHING
Label each cap as to which valve it belongs
b Remove the push rods ROCKER ARM
Label each rod as to which valve it belongs
ASSEMBLY
26 Remove each valve from the cylinder head assembly
Use an appropriate valve spring compressor to aid in dis
assembly Arrange or label the valves so as to replace
0 9
11jn VAlVESTEM
them in the cylinder and guide from which they were
removed
A j VEOUTffi
ROCKER ARM
PUSH ROn
i i
tINNER
SPRING
SPRING
VALVE STEM REMOVING THE
ASSEMBLY
o VALVES
Il WESTERBEKE
I Engines Generators
ENGINE DISASSEMBLY
31 Remove the crankshaft gear
a Remove the wave washer the friction gear and using a
suitable puller remove the crankshaft gear and its key
32 Turn the engine over and remove the oil pan
33 Loosen the oil pump assembly set screw then remove
the oil pump For oil pump details see OIL PUMP
34 Remove the timing gear case from the front of the
38mm SOCKET engine block Discard the old gasket
REMOVING THE
CRANKSHAFT
PULLEY
27 Remove the crankshaft pulley bolt with the aid of a 38
nun socket and draw the pulley off the front
REMOVING THE TIMING GEAR CASE
35 Remove the camshaft Keep the engine upside down
This allows the valve lifters to seat on the block bosses
away from the cam lobes Ensure that all the pushrod tap
pets are seated into the engine block prior to attempting
to remove the camshaft from the block
FRICTION GEAR MAY NOT
BE FOUND ON ALL MODELS
28 Remove the timing gear cover and remove the injec
tion pump washer injection pump friction gear and
the injection pump drive gear
29 Remove the camshaft gear
a Wedge a clean cloth between the camshaft gear and the
idler gear remove the idler bolt
b Remove the retaining plate friction gear and using a
suitable bearing puller the camshaft gear
30 Remove the two idler gears
a Remove the attaching nuts thrust plates idler gears
and idler gear hubs REMOVING THE CAMSHAFT
b Keep the hubs and the idler gears arranged so that the
combination of them is not confused between left and
right
INJECTION
PUMP
GEAR
IVVI WESTERBEKE
I Engines Generators
ENGINE Remove the rear oil seal by striking out the old seal NOTE The number stamped on the rod shank and cap
with a suitable mandrel should correspond to the cylinder number Sometimes
these numbers are scrambled or missing and the
OIL PASSAGE mechanic must supply them Stamp the correct num
bers on the pads provided and to prevent confusion
deface the originals
CRANKSHAFT
PISTON RINGS
rJ SUB COMBUSTION
bTUBULAR
I CHAMBER
PISTON PIN WRIST PIN or
SMALL END
WBOl1
SNAP RINGS
CONNECTING
ROD CAPS
37 Disassemble the connecting rod caps and line up the PISTON RING
main bearing caps and bearings according to the order of
bearing numbers Also properly arrange the thrust wash
ers taking care not to change the Remove the piston and connecting rod assemblies
Temporarily install the connecting rod cap on the con
necting rod so as to not mix the rods and caps
39 Disassemble the piston assembly
BEARINGS
a Using the piston ring remover remove the piston rings
While removing the piston rings note the order they BEARING CAP
are removed and which side of the ring faces the piston
crown CONNECTING ROD
b Remove the wrist pin snap rings ASSEMBLY
c Using a nylon drift drive the wrist pin from the piston 40 Remove the crankshaft
and rod 41 Remove the tappets
d Protecting your eyes with safety glasses disengage and
withdraw the snap rings Although mechanics generally NOTE After removing the main bearings and bearing caps
press out and sometimes hammer out pistons pins arrange them in order of removal Do not mix caps After
removing the thrust bearings note their positioning for
these practices should be discouraged Instead take the
proper time to heat the pistons either with a heat gun or on a
hot plate Pins will almost fall out
e While the piston is still warm check for bore integrity
Insert the pin from each side If the pin binds at the
center the bore might be tapered if the bore is
misaligned the pin will click or bind as it enters the
far boss
1fAT WESTERBEKE
I Engines Generators
ENGINE THE CYLINDER HEAD
1 Visual Inspection Check the cylinder had for cracks or
any other damage and if necessary reparr or replace It
REMOVING THE
2 Distortion Inspection Measure the cylinder head sur INSERT
face distortion with a straight edge and the thickness
gauge Take 6 measuring positions a sow i the dia
gram If the distortion exceeds permIssIble hrrut replace
the cylinder head The head has no allowance for plan
ing and must be replaced not Cylinder Head Distortion Limit
12 010 mm 0004 in
345 6 025 mm 0010 in
REMOVE LOCATING DOWELS USING STRAIGHTEDGE EDGE
SUITABLE PUNCH WELCH WASHER
INSERT
FEELER GAUGE
DISTORTION INSPECTION
VALVE SPRING
1 Free Length Check Measure the free length of the valve
spring and if free length is less than the limit replace it
Valve Spring Inner 42 mm 1654 in
Outer 436 mm 1717 in
MEASURING FREE
LENGTH
1 2
3 Insert Inspection Check for cracks or damage on the
insert and if detected replace it
4 Insert Replacement To remove the insert place a
suitable drift into the glow plug hole then tap the drift
with a hammer To install set the insert in position and
insert the welch washer into the insert guide hole Secure
2 Squareness Check Cneck the squareness of the valve
the welch washer by tapping the raised center of the
spring and if it is more than the limit replace the spring
welch washer
Squareness Limit Inner 125 mm 0049 in
a Use a new welch washer Outer 137 mm 0054 in
h Insert the welch washer so that its convex surface is
toward the cylinder head gasket 3
c After installation check to see if the insert is com
pletely fixed in place
IfItT1 WESTERBEKE
I Engines Generators
ENGINE INSPECTION
NOTE Measure the fitting pressure after compressing the
spring several times VALVE GUIDE
Spring Fitting Pressure Inner Outer Length 378 mm
149 in 403 mm 159 in
Fitting Pressure Limit 1o3 kg 227Ib 145 kg 320 Ib
VALVE SPRING
TESTER
TESTING THE SPRING
FITTING PRESSURE
HEIGHT ABOVE
SPRING FITTING THE SPRING SEAT
SPECIMEN VALVE 165 mm 065 in
SPRING
GUIDE VALVE GUIDE
1 Inspecting clearance between valve and guide Set a
PROTRUSION
dial gauge with a magnet and check the clearance
between the valve stem and the valve guide If the clear
ance is more than the limit replace the valve or valve
Limit 0127 mm 0005 in 3 Dimension L Check the protruding length of the valve
VALVE GUIDE CLEARANCE stem if it exceeds the correct it as follows
Dimension L Standard 480 mm 1890 in
a When dimension L becomes large 0 05 mm 0
00202 in from the standard it is possible to use both
the valve and the cylinder head
VALVE
2 Valve guide replacement To remove the valve guide
press out the valve guide towards the combustion cham
ber side using the valve guide installer 49 0636 165A
Again using the valve guide installer press in the valve
guide into the cylinder head until the valve guide height
reaches the indicated scale on the valve guide installer
NOTE Be sure to press in the valve guide so that the
inside chamber on the valve guide end faces to the b When dimension L becomes to large 05 15 rnm
combustion chamber side After the pressure fit check the 020 0059 in from the standard adjust the
length of the protruding portion of the valve guide dimension L to the standard by adding some Standard 165 mm 0650
in inner diameter 128 mm 0504 in outer diameter 39
mm 1535 in between the lower spring seat and the
cylinder head
c When dimension L becomes to large more than 15
mm 0059 in from the standards install the valve with
a new one and recheck dimension L
d When dimension L becomes to large 0 05 rnm
0 00202 from the standard replace the valve
Il WESTERBEKE
I Engines Generators
ENGINE INSPECTION
e When dimension L becomes to large 05 15 mm
0020 0059 in from the standard replace the valve
and adjust the dimension L to the standard by adding
some washers between the lower spring seat and the
cylinder head
f When dimension L becomes to large more than 15
mm 0059 in from the standard replace both the
valve and the cylinder head
DIMENSION L I 11
II 1I777n WASHER
VALVE SEAT
CHECKING VALVE STEM WEAR
1 Valve Seat Angle Valve seat angle is 45 and 30
CHECKING DIMENSION L
respectively for intake and exhaust sides The standard
contact width of the valve seat is 20 mm 0079 in for
both intake and exhaust sides If the valve margin is less
than the permissible limit replace the valve
2 Refacing the Valve and Valve Seat Reface in the fol
lowing order
g Check for contact between the valve and valve seat by a Reface the valve with a valve
grinder to the specified
applying a thin coat of Prussian Blue or Redlead on angle
the valve seat contact face then insert the valve into
the valve guide and press fit the valve on the valve seat b Reface the valve seat with a
valve seat cutter while
checking the contact between the valve ancl the valve
NOTE Do not rotate the valve seat
NOTE Reface the valve seat taking care that the valve
CHECKING VALVE seat contacts the center position of the valve
CONTACT
Valve Seat Angle 45 Intake 30 Exhaust
Valve Seat Width 20mm 0079in Intake and Exhaust
CONTACT FACE 2 mm 08 t
45 INTAKE EXHAUST
368 mm 145 in 317 mm 125 in
ONTATFA
INTAKE EXHAUST
CONTACT FACE c Reface the valve and
valve seat with a valve tapping
45 C
compound
d Remeasure dimension L
h Check if the valve seat contact face contacts the center e Adjust dimension L to the
standard by adding some
position of the valve contact face If the contact posi washers between the lower
spring seat and cylinder
tion is not centered recut and surface the valve seat head
and valve
4 Stem Wear Inspection If the valve stem is bent or its
diameter is less than the limit replace the valve
Stem diameter limit Intake 7880 mm 03102 in
Exhaust 7867 mm 03097 in
AT WESTERBEKE
r Engines Generators
ENGINE INSPECTION 1
ROCKER ARM CYLINDER BLOCK
1 Visual Inspection Check each component part of rocker 1 Visual Inspection Check the cylinder block for cracks
arm assembly for cracks or other damage Check if the oil and damage If necessary repair or replace it entirely
passages of the rocker arm and shaft are clogging and if Check to see that oil or cooling water passages are not
necessary repair or replace it RETAINING RING clogged and if clogged remove with compressed air or a
wire probe
JAM NUT REMOVE LOCATING DOWELS
9 I BEFORE INSPECTING
ADJUSTING SCREW BRACKET o
l SPRING WASHER BUSHING o C5UOaO
SPRING
TAPER PIN RECESS
rr 4
ROCKER ARM 2 Distortion Inspection Check the gasket face distortion
of the cylinder block and if it exceeds the limit repair or
ASSEMBLY SCALLOP replace it
Distortion limit 1 2 010 mm 0004 in
2 Inspecting clearance between rocker arm and shaft 3 4 025 mm 0010 in
Check the clearance between the rocker arm and shaft 1
2
and if it exceeds the limit replace the rocker arm bushing
or Standard 00006 00024 in 0016 0003 in O07mm
3 Rocker Arm Bnshing Replacement Using a suitable
mandrel and press press out the old bushing Aligning the
oil passages of the rocker arm bushing press the new
bushing into the rocker arm After the rocker arm bushing
has been replaced ream the bushing bore with a spiral
expansion reamer so that the clearance between the bush
ing and shaft becomes equal to the standard clearance
CYLINDER LINER
1 Wear Inspection Measure the liner bore at three
positions of upper middle and lower portions with a
cylinder gauge in XX and YY directions as shown If
wearing exceeds the limit replace the liner
Cylinder Liner Bore 88925 88950 mm 35010 35020 in
Wear Limit 020 mm 0008 in
REPLACING
THE BUSHING Xl t t X
X X IS THE THRUST DIRECTION
CYLINDER LINER
CYLINDER LINER
WEAR INSPECTION 1VV1 WESTERBEKE
I Engines Generators
ENGINE INSPECTION
2 Cylinder Liner Replacement Hydraulic press or similar c Measure the piston diameter at 90 0 to
device is needed the pin bore axis and 315in 80rum below the piston
a Attach the cylinder liner puller and installer to the top
lower rim of the cylinder liner then press out the liner CHAMBER
b Check for scratches on the cylinder block side and if
any remove them by using extremely fine emery paper
with engine oil 315in
80mm
c To install the liner apply engine oil on the cylinder
block bore and the liner exterior then set the liner on
the cylinder block Using the cylinder liner puller and
installer press the liner into the cylinder block
NOTE Press the liner in straight When press fitting the
liner keep the pressure within a range 02200 6600 Standard Piston Diameter 34987 34797 in 88867 88893mm
lb 2 Piston Ring Inspection Check the piston ring for
Measure the liner protrusion and correct it if necessary breaks seizure and wear and if any of these conditions
exist replace the ring Check the clearance between Limits 0026 0031 in 0659 0790 mm
piston ring and the ring groove and if it exceeds the limit
PROTRUDING LENGTH replace the ring
Side Clearance Limit 0012 in 030 mm
CYLINDER 3 Inspecting the piston ring end gap Position the piston
ring into the bottom of the cylinder liner Measure the pis
ton ring end gap and if it exceeds the limit replace the
ring Be sure to position the piston ring below the ring
sliding surface of the cylinder AND PISTON RING
1 Visual Inspection Check the sliding surface and
ring groove of the piston for Wear scratches or any
other damage
a Inspecting the clearance between the piston and the
cylinder liner
b Check the clearance between the piston and the cylin
der liner by measuring the cylinder bore and the piston
diameter and if the clearance exceeds the limit replace
the cylinder liner and the piston
Piston Ring End Gap Limit 0591 in Clearance 00017 00028 in 0044 070 mm
IfATI WESTERBEKE
I Engines Generators
ENGINE ROD
1 Visual Inspection Check the connecting rod for cracks
or other damage and if necessary replace it PISTON PIN
SMALL END
INSTALL NEW
BEARING CAP 4 Small end bushing replacement Using a press press
BOLTS
out the old bushing Align the oil passages of the connect
ing rod and the small end bushing press in the new bush
ing to the connecting rod bore After a small end bushing
has been replaced ream the bushing bore to obtain the
CONNECTING ROO specified clearance between the small end bushing and
the piston pin
PRESS
CONNECTING
ROD CAP
EARIHGS REMOVING THE
SMALL END
BUSHING
MANDREL
PRESSING IN
THE NEW
BUSHING
CONNECTING ROD
ASSEMBLY OIL HOLES III SMALLEND
BUSHING
2 Bend Inspection Using a connecting rod aligner check o END BUSHING
Oil HOLES
the bend and twist of the connecting rod and if exceeding NOTE When reaming the bushing correctly insert the
the limit repair it with a press or replace it
reamer in the bushing In order to prevent unevenness on
Bend Limit 0002 in per 39 in 005 mm per 100 mm the bushing surface the reaming should always be made
in the cutting direction Make certain the reamer is
stopped at different positions at all times
CONNECTING ROD
ALIGNER 5 Inspecting connecting rod side play Check the connect
ing rod side play with the dial gauge and if it exceeds the
limit replace the connecting rod and crankshaft
Side Play Limit 0016 in 040 mm
Inspect the clearance between the piston pin and
small end bushing Check the clearance between the
piston pin and the small end bushing and if it exceeds the
limit replace the piston pin or small bushing
CONNECTING ROD
Clearance Standard 00006 00016 in 0014 0041 mm SIDE PLAY limit 0002 in 005 mm
1v1 WESTERBEKE
rEngines Generators
ENGINE INSPECTION
6 Inspecting connecting rod bearing Check the connect
ing rod bearing for peeling and thelmal damage If it is
severe replace the beming CRANKSHAFT RUNOUT
7 Inspecting connecting rod bearing clearance Using the INSPECTION
plastigauge measure the oil clearance of the connecting
rod bearing and if it exceeds the limit replace the CRANKlHAIFT RUNOUT
connecting rod Rod Cap Torque 50 54 fIlb 69 75 Rod Bearing 00014 00030 in 0036 0076 mm
DIAL GAUGE
Limit 00039 in 010 mm
3 Inspecting crank pin and journal Support the Bearing 0010 in 0254 mm
0020 in 0508 mm
shaft on both ends using Vblocks Measure the diameter
0030 in 0762 mm of each crank pin and crankshaft main journal and if the
diameter is less than the limit refinish the crank pin and
CONNECTING ROD BEARING CLEARANCE main journal to size for the next undersize bearing
Ii Crank pin diameter
Standard 20861 20866 in 52987 53000 mm
Wear limit 0002 in 005 mm
Main journal diameter
Standard 25585 25591 in 64987 65000 mm
Wear limit 0002 in 005 mm
a For the measurement on both the crank pin and the
main journal measure them at vertical and horizontal
directions on front and rear places
b When refinishing the crankshaft its finish to Rl mm
as shown in the diagram
c Refer to the chart for refinishing dimensions of crankshaft where an
undersize bearing is used
1 Visual Inspection Check the crankshaft for cracks or
other damage If cracking is suspected thoroughly clean
the crankshaft and perform a color test on the shaft or
run a candle flame over the crankshaft and look for oil
seepage from cracks If any cracks are detected replace
the crankshaft
PERFORMING A COLOR TEST
R1 371 399 mm
0146 0157 in
Undersize bearing Main journal diameter
Check for clogging of oil passages and if clogged 001 in 0254 mm 25485 25491 in 64733 64746 mm
remove with compressed air or wire 002 in 0508 mm 25385 25391 in 64479 64492 mm
2 Runout inspection Check the crankshaft runout and if it 003 in 0762 mm 25285 25291 in 64225 64238 mm
exceeds the limit replace the crankshaft Undersize bearing Crankpin 00020 in 005 mm
001 in 0254 mm 20761 20766 in 52733 52746 mm
002 in 0508 mm 20661 20666 in 52479 52492 mm
003 in 0762 mm 20561 20566 in 52225 52238 mm
Ivvl WESTERBEKE
I Engines Generators
ENGINE INSPECTION
4 Inspecting crankshaft end play Check the end play of 3 Inspecting camshaft journal Check the camshaft
the crankshaft and if the end play exceeds the limit journal and if wearing exceeds the limit replace the
replace the thrust washer with 0007 in 0178 mm over camshaft
size Crankshaft end play is measured by setting a dial Diameter of Journal Wear Limit
gauge on the rear end of the crankshaft and moving the No1 20437 20449 in 51910 51940 mm 0008mm
crankshaft in the axial direction No2 20339 20350 in 51660 51690 mm 00003 in
NO3 20142 20154 in 51160 51190 mm
Crankshaft End Play Standard 00055 00153 in 014 039 mm
Crankshaft End play limit 00157 in 040 mm 4 Inspecting camshaft oil clearance Check the clearance
between the camshaft journal and the camshaft support
MAIN BEARING bore as follows
1 Inspecting main bearing Check the main bearing a Measure the camshaft journal diameter and the
for peeling seizure or fusion and if necessary replace camshaft support bore
the bearing b Calculate the clearance and replace the camshaft or
cylinder block if the clearance exceeds the limit
2 Inspecting main bearing clearance Using the
plastigauge measure the oil clearance and if it exceeds Oil clearance limit 00057 in 0145 mm
the limit replace the main bearing 5 Checking camshaft alignment and if it exceeds the
limit replace the camshaft
Maximum allowable runout 00031 in 008 mm
6 Inspecting camshaft end play
a Install the thrust plate camshaft gear friction gear
lock plate and camshaft gear lock bolt on the camshaft
PLASTIGAUGE
b Tighten the lock bolt to the specified torque
Lock Bolt Torque 19mm socket 45 51 IbH 62 70 kgm
c Measure the clearance between the thrust plate and
camshaft If it exceeds the limit replace the thrust
plate
Oil Clearance Standard 00016 00036 in 0040 0091 mm End play limit 00118 in 03 mm
Oil Clearance Limit 0005 in 012 mm
TESTING CAMSHAFT
END PLAY
CAMSHAFT
1 Visual Inspection Check the camshaft for cracks and
damage If necessary replace the camshaft
NOTE lfthe damage is slight you may be able to correct
the camshaft with an oil soaked fine emery grindstone
Take special care to not damage the original cam form
2 Inspecting cam height Measure the cam height and if it
is less than the limit replace the camshaft
I IDLER GEAR BUSHING AND IDLER GEAR SPINDLE
Cam height limit 16767 in 42587 mm
1 Visual inspection Check for damage on the bushing
inner surface of the idler gear and the spindle sliding sur
INTAKE AND EXHAUST CAM
face and if necessary replace the idler gear or spindle
Check the oil passage for clogging and if necessary
clean the passage with compressed air or wire
CAM HEIGHT
2 Inspecting clearance between bushing and spindle
Check the clearance between the idler gear bushing and
the spindle and if it exceeds the limit replace the idler
gear or spindle
Clearance Standard 00013 00033 in 0034 0084 mm
Clearance Limit 0006 in 015 mm
tJ WESTERBEKE
I Engines Generators
ENGINE INSPECTION
TAPPET
1 Visual inspection Check the tappet for cracks and other
damage and if damaged replace the tappet Check for
abnormal wear of the portion of the tappets that make
contact with the cam and if anyone is abnormally worn
replace the tappet
IDLER GEAR 2 Inspecting Clearance Between Tappet and Tappet
Bore Check the clearance between the tappet and tappet
CHECKING bore and if the clearance is greater than the limit replace
CLEARANCE
the tappet or cylinder block
BETWEEN THE
BUSHING Clearance Limit 00039 in 010 mm
AND THE GEARS
1 Visual Inspection Check each gear idler gears injection
pump drive gear crankshaft gear camshaft gear for LIMIT 010 mm 0004 cracks or other damage If necessary replace as
required
2 Inspecting end play of idler gear Check the end play of
the idler gear with a dial indicator as shown If it exceeds TAPPET
the specified limit replace the thrust plate or idler gear CLEARANCE
PUSH RODS
1 Visual Inspection Check each push rod for damage to
either end If damage is severe replace the push rod
2 Bend Inspection Check the push rod for bend and if it
exceeds the limit replace it Place the push rod on a flat
surface and measure the clearance between the center of
the push rod and the flat surface Replace the push rod if
the wear limit is exceeded
Bend limit 00075 in 019 mm
TESTING THE
NOTE Measure the end play after tightening the idler PUSH ROD
gear attaching nuts to the specified torque value PLACE ON GAUGE PLATE
Thrust plate torque 12 socket 17 23 HIb 23 32 end play 00079 00118 in 020 030 mm
3 Check backlash between gears Check the backlash
between each gear with a dial indicator
NOTE Check the backlash after assuring that the idler
gear end play and the clearance between the idle gear
PUSH RODS
bushing and spindle are within the Standard 00039 00067 in 110 017 mm
Backlash Limit 00118 in 030 mm
lVVI WESTERBEKE
I Engines Generators
ENGINE GEAR COVER OIL SEAL REAR OIL SEAL
1 Inspecting timing gear cover oil seal Check the timing 1 Inspecting oil seal Check the oil seal lip for wear
gear cover and the lip of the oil seal for any damage If fraying or other damage and if necessary replace it
necessary replace the cover or oil seal 2 Oil seal Oil seal replacement To remove the oil seal use the oil
a Strike out the old rear oil seal with a suitable mandrel
seal puller and installer and pull out the oil seal To
b Apply engine oil onto the outside of a new seal and
install apply engine oil on the outside of a new oil seal
press fit the seal in the rear oil seal cap equally
then press fit the oil seal with oil seal puller and installer
until the installer comes in contact with the cover NOTE In case the crankshaft is worn the oil seal must be
fitted on the oil seal cap with its fitting position moved by
approximately 01 181 in 3 mrn so that the seal does not
touch the worn down portion of the crankshaft
OIL SEAL PULLER
AND INSTALLER
TAP EVENLY
OIL SEAL
TlMING GEAR COVER
REAR OIL SEAL
INSTALLATION
REMOVAL
TIMING GEAR COVER OIL SEAL
IJ WESTERBEKE
I Engines Generators
ENGINE Precautions ENGINE ASSEMBLY
Be careful not to mix bolts and nuts Metric and SAE 1 Install the valves in cylinder head Using the valve
bolts are used on various engine assemblies spring lifter arm and pivot assemble the valve lower
During assembly recheck clearances and insure that parts spring seat oil deflector inner valve spring outer valve
are being assembled in their proper order and facing in the spring upper spring seat and taper sleeve in this order
correct direction in relation to the engine block such as NOTE The oil deflector should be installed on the intake
pistons piston rings bearings and bearing caps valve only
Apply lubricating oil to moving parts during assembly
2 Assemble the rocker arm shaft rocker shaft brackets
Insure that moving parts when assembled on the engine
and rocker arms Note that the front end of the rocker
rotate or slide and are not subject to binding or
shaft is identified by a pin protruding from the top and a
excessive tension
larger oil hole between the supply holes serving 1 and
If there are mating marks scribed during disassembly 2 rocker arms This pin fits a slot in the 1 rocker shaft
reference them correctly for assembly support which prevents the shaft from turning and cutting
Use new gaskets lockwashers orings etc off the lube oil to the rocker arms and valves Use the fol
Tighten the bolts and nuts on important parts of engine to lowing order of assembly
specified torques using a reliable torque wrench a Spring d Rocker
b Rocker e Wave washer
Use liquid sealants when required on nuts bolts and c Rocker shaft support f snap ring
gaskets Refrain from using tape sealants
Be aware of these common problems that can occur during ROCKER ARM TAPER PIN
assembly ASSEMBLY Lubrication Heavily oil sliding parts
lightly oil head bolts and other those that penetrate into the water jacket These
fasteners should be sealed with Permatex No2 or the 00 TAPER PIN
orientation Most gaskets many bolt washers and i I TAR PIN HOLE
all thermostats are asymmetrical 112 ROCKER damage Run fasteners
down in approved ROCKER
SUPPORT sequences and in three steps1I2 23 and 111 are bolts and rocker arm The former are torqued as indicated The
3 Assemble the connecting rod piston and piston shaft be brought down in very Arrange the piston and the connecting
rod as shown and
small increments working from the center bolts out Gaskets using the piston pin installer insert the piston pin head gaskets might be
damaged during assembly the piston and connecting rod until the piston pin wrist
they should be positioned with great care pin snap rings can be fitted Fit the piston pin snap rings
to their respective grooves Install the piston rings to ring
grooves on the piston with the inscription mark on ring
upward using a suitable piston ring expander
PISTON RINGS
FRONT 4IIt
FRONT OF PISTON
IS INDICATED BY mRDOILRING
A BOSS ON THE
BOTTOM NEAR THE
OIL HOLE
CIRCLIPS
CHECK THE PISTON RING
GAPS WITH CARE NEW
RINGS ARE PACKAGED
WITH DETAILED INSTRUCTIONS
THAT OFTEN SUPERSEDE
THE SERVICE MANUAL
IMTI WESTERBEKE
I Engines Generators
ENGINE ASSEMBLY
4 Main Bearings and Bearing Caps PLACE A HEAVY HAMMER AND
GENTLY PRESS DOWN WITH
NOTE Do not apply oil to the backsides of the main THE FORCE OF YOUR HAND
THE ENTIRE SURFACE SHOULD
bearing shells BE COATED WITH FRESH LUBE OIL
a Fit the main bearings on the cylinder block and the
bearing caps respectively Check that the oil ways align
perfectly with those in the block
b Fit the thrustwashers to the cylinder block so that the
oil grooves on thrustwashers face to crankshaft side
c Position the crankshaft to the cylinder block being
careful not to drop the thrustwashers as the crankshaft
settles into place
1 r
c Install the caps to the connecting rods ensuring that
the numbers on the cap and connecting
rod are matched
Cap Torque 14 mm socket 50 54 ftIb 69 75 mkg
install new connecting rod bolts
d Fit the thrust washer to the main bearing cap so that
the oil grooves on thrust washer face to crankshaft
side Then install the main bearing cap to the cylinder 8 Installation of the crankshaft
block with arrow mark of the main bearing cap facing
a Insert the tappets into the cylinder block Apply engine
the crankshaft pulley side
oil to the sliding face of the tappet
Main Bearing Cap Torque 110 117 mkg 80 85 ftIb
FITTING THE
THRUST
WASHERS
b Insert the camshaft into the cylinder block Apply oil to
the camshaft journal and bearing surfaces
c Install the camshaft thrust plate
NOTE Ensure the crankshaft rotates smoothly after Thrust Plate Torque 12 in socket 116 174 ftIll 16 24 mkg
installing
9 Install the idler gear spindle Align the oil passages of
6 Install the rear oil seal Apply oil to the oil seal lip the idler gear spindle and cylinder block
7 Install the piston and connecting rod assembly o
a Place the piston rings so that the ring ends are
properly spaced around the circumference of the piston
as shown on the previous page
b Using a ring compressor fit the piston into the cylinder
in the position as is shown Apply oil onto the sliding
face of the piston and the cylinder bore
I WESTERBEKE
I Engines Generators
ENGINE ASSEMBLY
10 Fuel Injection Pump
NOTE It is easier to first install the injection pump to the
timing gear case and the entire assembly onto the engine
Install the injection pump aligning the marks
Mount the injection pump on the gear case then tighten
the pump drive gear attaching nuts
Attaching Nut Torque 29 51 Mb 4070
mkg
II I j
r
a
13 Install the friction gear
NOTE The friction gears are not found on all models
11 Install the timing gear case Attach the straight edge on
the cylinder block then match the surfaces of the timing 14 Install the camshaft gear lock bolt
gear case end and that of the cylinder block If the gasket NOTE Wedge a clean cloth between the camshaft gear and
protrudes from the mating surface cut away the excess the idler gear
with a knife Lock Bolt Torque 19 mm socket 45 51 ftIb 62 70 mkg
Attaching BoltTorque 12 in socket 12 17 Mb 16 24 mkg
15 Install the inject pump drive gear lock nut
12 Install each gear While aligning the timing mark of each
gear install the following gears on each position NOTE Wedge a clean cloth between the injection pump
a Camshaft gear drive gear and the idler gear
b Idler gears Lock Bolt Torque 1 in socket 29 51 ftIb 40 70 mkg
c Injection pump drive gear
d Install the idler gear thrust plate then tighten the nuts OIL DEFLECTOR
Idler Gear Thrust Plate
NutTorque 12 in socket 23 32 mkg 166 231 ftIb
e Tighten the camshaft gear attaching bolts
Camshaft Gear Attaching
Bolt Torque 19 mm socket 45 51 ftIb 62 70 mkg
16 Install the oil deflector on the crankshaft
17 Install the timing gear cover
a Install the bearing housing cover on the timing
gear cover
b Install the injection pump drive gear cover on the
timing gear cover
c Install the timing gear cover and tighten the timing
gear cover attaching nuts and bolts after the crankshaft
CRANKSHAFT GEAR pulley has been installed temporarily to center the seal
1 MARK
TIMING GEAR Timing Gear Cover Torque 16 24 mkg116 174 ftIb
ASSEMBLY
18 Mount the oil pump assembly Apply the sealing agent
on the set screw thread and tighten the screw Ensure the
oil pump drive gear and the driven gear mesh
VVI WESTERBEKE
I Engines Generators
ENGINE ASSEMBLY
19 Position the new oil pan gasket set 25 Install the two tubular dowels adjacent to cylinders I
a Position the gasket ends A on the gaskets B and and 4 if they were removed earlier during disassembly
C Position the gasket on cylinder block Do not use any liq
uid seal or cement
b Apply a silicon sealing agent on the mating surfaces of
the gasket and that between the cylinder block and the REINSTALL TWO DOWELS
timing gear case
26 Position the cylinder head
20 Install the oil pan 27 Insert the pushrod Check if the push rod is securely set
Oil Pan Bolts Torque 12 in socket 5 9 HIb 07 12 mkg in the tappet concavity
21 Attach the back plate
Back Plate Torque 916 in socket 239 35 Hlb33 48 mkg
22 Install the flywheel Install the flywheel onto the rear end
of the crankshaft by placing it on the crankshaft and rotat
ing it to properly align the mounting bolt holes Install the
tabwasher and the attaching bolts After torquing bend
one tab against the flat of each attaching Bolts Torque 19 mm socket 95 HIb 131 mkg
ONE BOLT DEVIATES S
TAB WASHER
FROM THE 6 SET UP 28 Position the valve cap on the top of the valve stem It
should be set squarely on the valve stem
29 Install the rocker arm assembly onto the cylinder
head Remember that the end of the rocker shaft having
the pin occupying the slot in 1 rocker support points
toward the front pulley end of the engine
30 Tighten the cylinder head bolts Tighten the cylinder
head bolts evenly in the sequence shown After tightening
the cylinder head bolts make certain the rocker arms
23 Install the raw water pump Mount the raw water pump move smoothly
on its adapter plate and assemble it to the engine Do not Cylinder Head Bolts
tighten Torque 34 in socket 80 85 HIb 110 117 mkg
24 Install the crankshaft pulley Apply engine oil onto the
lip of the oil seal Carefully slide the front crankshaft pul
ley onto the crankshaft ensuring that the key in the crank
shaft and the keyway in the pulley mate properly Apply
Loctite high temperature to the threads of the front
crankshaft pulley holddown bolt when installing it
Ensure the flat washer is under the head of the bolt
Front CrankshaH Pulley
Bolt Torque 38 mm socket 145 181 HIb 20 25 mkg
CYLINDER HEAD BOLT PATTERN
1fIt71 WESTERBEKE
I Engines Generators
ENGINE ASSEMBLY
30 Adjust the valve clearance Adjust the No1 2 3 and 6 c Install a new thermostat and gasket the old
valves when the No1 piston is on Top Dead Center thermostat can become a spare When installing the
TDC or the compression stroke new thermostat and gasket apply a thin coat of
Tum the crankshaft once setting the No4 cylinder piston sealant to both sides of the gasket
at IDC compression and adjust the No4 5 7 and 8 d The old thermostat can be checked for proper opera
valves The valves are numbered 1 8 from front of the tion by placing it in a pan of cold water and then rais
engine ing the temperature of the water to a boil The
WHEN NO 4 CYLINDER IS AT TOP DEAD CENTER thermostat should open noticeably with travel on the
4 INTAKE 3 INTAKE order of
4 EXHAUST 2 HAUST 114 in 112 in and be fully opened when the water
is boiling
OIL FILTER
OIL FILTER ASSEMBLY
W63 SHOWN
2 INTAKE 1 INTAKE
3 EXHAUST 1 EXHAUST
I I
WHEN NO 1 CYLINDER IS AT TOP DEAD CENTER
34 Attach the engine coolant circulating pump
VALVE CLEARANCE Coolant Pump Assembly
Bolts Torque use 12 socket 12 17 ftIb 16 23 mkg
31 Adjust each valves clearance by inserting a 0012 in A complete breakdown of the COOLANT PUMP ASSEMBLY
003 mm feeler gauge between the rocker arm and the is covered elsewhere in this manual
valve stem
Valve Clearance 030 mm 12 in cold 35 Adjust the injection When the engine overhaul is complete run the
engine Refer to INJECTION TIMING elsewhere in this manual
under load to check its performance Allow the engine to cool
36 Mount the oil filter bracket and install a new filter
to room temperature and retorque the cylinder head hold
When installing the new filter apply a thin coat of clean
down nuts and readjust valves The cylinder head holddown
engine oil to the rubber gasket Tighten by hand
bolts and valve adjustment should be rechecked again after
50 hours and periodically thereafter 37 Mount the front engine mounting bracket
32 Install the cylinder head cover Mounting Bracket Torque 33 49 ftIb 46 68 Head Cover Bolts Torque
03 04 mkg 2 3 ftIb 38 Install the intake manifold Replace the four After the engine has been reassembled readjust the
Intake Manifold Torque 116 174 ItIb 16 24 mkg
valve clearances with a warm engine see ENGINE
39 Mount the fuel filter Attaching Nuts Torque 33 49 ftIb 46 68
33 Install the thermostat and thermostat housing
40 Mount the rocker arm cover using a new gasket
a Inspect the thermostat housing and the housing
Apply sealant to that portion of the gasket that contacts
gasket Apply some sealant to the gasket when
the gasket only
Rocker Arm Cover Torque 18 29 ftIb 025 040 mkg
b Install the temperature switch and sender and
reconnect their wires 41 Attach the crankcase vent hose
Il WESTERBEKE
I Engines 11 Generators
ENGINE ASSEMBLY
42 Install the fuel injection nozzles and return lines Use a Install the alternator support bolt through the alternator
new sealing washers throughout in the same order as leg underside into the engine casting
were the old washers
b Swing the alternator into position on the Torque 27mm deep socket 43 51 ftIb 60 70 mkg bracket and fasten Lightly tighten
See FUEL INJECTORS c Adjust belt tension
43 Install the glow plugs and connectors Use antiseize d Tighten both bolts and recheck belt tension
compound on the threads Support bolt Torque and
Glow Plug Torque 72 108 ftIb 10 15 mkg Adjusting bracket bolt Torque 27 38 ftIbs 38 53 mKg
To test the glow plugs see GLOW PLUGS NOTE Make certain the belts are perfectly aligned with
the alternator and engine pulleys If not insert or remove
44 Connect the fuel line to the engine mounted fuel filter spacers as needed to align the alternator
and the injection pump Use new sealing washers
See ALTERNATOR for testing
45 Connect the high pressure injector lines from the
injection pump to injectors Reinstall the line clamp 51 Install the raw water pump and drive belt Insure it is
in proper alignment with the crankshaft pulley Check the
Attaching Nuts Torque 18 22 ftIb 25 30 mkg
belt tension
46 Install the bellhousing
Refer to RAW WATER PUMP
47 Mount the engine heat exchanger
52 Install the oil and water sender and switch
The heat exchanger should be serviced at engine overhaul
53 Install the starter motor
Refer to HEAT EXCHANGER
54 Install the breaker panel and the preheat solenoid
48 Install the intake manifold Replace the four gaskets
49 Assemble the engine oil cooler Install a new oil filter 55 Reinstall the engine electrical harness
tightening the filter by hand 56 Mount the complete exhaust manifold and the
50 Install the alternator and drive belt expansion tank to the cylinder head
Manifold Mounting Bolts Torque 12 17 ftIb 16 24 mkg
A CAUTION Connect the alternator properly
Should the polarity be reversed a powerful current See EXHAUST MANIFOW for service and inspection
would flow from the battery into the alternator
57 Install the preformed metal tube that connects the
damaging the diodes and wiring harness
cooling system Inspect the pipe before installing If it is
corroded it should be II WESTERBEKE
I Engines Generators
ENGINE TRANSMISSION GENERATOR
58 Assemble the damper plate to the flywheel 58 Mount the generator back end assembly with its
control panel Reconnect all DC wiring and reconnect
59 Reinstall the marine transmission and fill with ATF
all AC connections
Dextron III
NOTE Some such as the Borg Warner
Velvet Drive require oil coolers Oil coolers should be
A CAUTION Check all AC and DC wiring
connections to WESTERBEKE wiring schematics and
cleaned pressure tested and repainted at engine over diagrams
haul The transmission oil cooler hoses should also be
inspected Refer to the text on Heat Exchangers
59 Fill the engine cooling system with antifreeze mixture
60 Fill the engine cooling system with antifreeze mixture and the engine oil sump with lube oil API spec CF
and the engine oil sump with lube oil API spec CF or CG4
or CG4 The engine should be test run under load prior to rein
The engine should be test run under load pnor to rein stalling At this time readjust the valve clearances on the
stalling At this time readjust the valve clearances on the hot engine
hot engine Allow the engine to cool to room temperature and
Allow the engine to cool to room temperature and retorque the cylinder head bolts and recheck the valve
retorque the cylinder head bolts and recheck the valve clearances
clearances See ENGINE ADJUSTMENTS
See ENGINE COOLERS
fATl WESTERBEKE
I Engines Generators
EXHAUST MANIFOLD I HEAT MANIFOLD d Reinstall the exhaust connections and plugs into the
manifold using on the threads
The exhaust manifold which was disassembled from the
cylinder head should be inspected before reassembly 3 Check the manifold pressure cap Open the valve by
pulling it and make sure it closes when released Make
1 Remove the exhaust elbows from the lower surface of the
certain the upper and lower seals are in good condition If
manifold Clean and inspect for cracks and defects
any doubt replace the cap
Replace as needed
2 Remove the exhaust nipples elbows and plugs from the
manifold
3 Remove water connectors from the ends of the manifold
and the end plates W52 Be sure to note the proper
location and arrangement of each for proper alignment
4 Examine all parts for defects corrosion and wear and
replace as needed HEAT EXCHANGER
5 Flush out the manifolds interior with a liquid cleaner and The heat exchanger should be inspected and serviced during
rinse thoroughly with fresh water an engine overhaul
6 Use a pipe cleaner to clear the passage that connects the 1 Disconnect the hoses and remove the hose fittings
coolant recovery tank tubing petcock drain plugs and zinc anode Also remove the
7 Flush out the coolant recovery tank and its connecting tube end fittings and gaskets
2 Inspect the tube casing for wear and dents if at all
suspect replace the heat MANIFOLD 3 Clean out any zinc debris and pressure test the
coolant
63 ENGINE and raw water passages
SHOWN
4 When reassembling install new gaskets and Orings
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them
5 Install a new zinc anode
NOTE All of the above can be accomplished by sending the
heat exchanger to a heat exchanger service shop They will
also service transmission and engine oil coolers
6 Repaint the assembled heat exchanger with Westerbeke
heat resistant spray enamel
REPLACE HOSES
EXHAUST If the manifold was removed as an assembly and left
intact it can be replaced on the cylinder head in the
reverse order of removal
Do not reuse the gaskets install new Mounting Bolts Torque 10 12 HIb 13 16 mkg
2 If the manifold has been disassembled follow the steps
below
a Loosely attach the elbows to the cylinder head and the
manifold using new gaskets Do not use any gasket
sealant on these gaskets
b Gradually tighten each fitting to make sure of proper
alignment of all the parts This should be done in three
Mounting Bolts Torque 10 12 HIb 13 16 mkg 7 Reconnect all hoses replacing them as needed
c Reassemble the manifold end plates W52 and the 8 Refill the system with coolant as detailed above
connectors to the manifold Be sure to use new gaskets 9 Pressure test system and check for leaks
and coat the gasket surfaces with a suitable gasket
cement such as High End Plate Bolts Torque 8 10 HIb 11 13 mkg
lI WESTERBEKE
I Engines Generators
FUEL INJECTION PUMP
TESTING INJECTION TIMING 12 Remove the plug and sealing washer from the aft center
of the injection pump The plug is centrally located where
1 Remove the air assembly
the four high pressure injector lines attach to the pump In
2 Remove the four high pressure injector lines that connect place of the plug install the 499140074 measuring
between the injection pump and injectors device Ensure the measuring device rod contacts the
3 Remove the bolt and gasket installed on the distributor plunger inside the pump and then zero the gauge
head of the injection pump ay
4 Remove the valve rocker cover A
5 Rotate the crankshaft in normal direction of rotation using 1
the front crankshaft pulley nut and place the No1 piston
at IDC of its compression stroke
NOTE To verify the rocker arms of No4 cylinder should
be rocking one opening one closing
6 Remove the snap ring from the end of the rocker shaft at
cylinder No1 along with the retaining washer
7 Loosen the rocker arm adjusting bolt so as to allow the
arm to be removed from the push rod and slide it off the INJECTION PUMP
rocker shaft
8 Press down on the valve and spring assembly and ensure
the valve is hitting the top ofthe No1 piston Then
remove the cap keepers and valve springs from the No1
valve NOTE When setting the dial gauge confirm that the dial
gauge pointer does not deviate from the scale mark of
NOTE Ensure the valve moves freely in its guide Take zero by slightly turning the engine crankshaft from left to
care to not drop the keepers down the push rod hole right
9 Position a dial indicator gauge on the valve stem and
Turn the engine crankshaft in the normal direction of
using the front crankshaft pulley nut rock the crankshaft
rotation to bring the No1 piston up to IDC The dial
and clockwise to to locate the exact
IDC of the compression stroke for the No1 piston indicator on the valve stem should zero and the indicator
on the injection pump should show 0039 inches 1 mm
Then zero the indicator gauge to the valve stem the
gauge should be able to measure up to 03 inch of valve of movement
movement
ADJUSTING INJECTION TIMING
521 mm BlDC 1 Loosen the nuts holding the injection pump to the engine
DIAL GUAGE 0205 in The high pressure injector lines should not be attached to
the injection pump
2 Make the adjustment by moving the injection pump itself
When the amount of movement of the measuring device
VALVE STEM t indicator on the injection pump is too large first tum the
injection pump in the reverse direction of the engine rota
tion so that the dial gauge pointer indicates less than the
scale mark of 0039 inches 1 mm These adjustments are
to tighten the gear backlash
Injection Pump Gear Lock Nut Torque 29 51 ftIb 40 74 mkg
When the amount of the measuring device indicator on
10 Slowly tum the crankshaft in the opposite direction of the injection purnp is too small tum the injection pump in
normal rotation until the indicator reads 0207 inches the direction of normal engine rotation so that the measur
BIDe It is advisable to go slightly more than 0207 ing device indicator points to the scale mark of 0039
inches and then return to that figure to remove gear lash inches 1 mm
The No1 piston is now at 30 BTDe 3 After the adjustment tighten the injection pump hold
Verify the scribe mark on the injection pump outboard down nuts and then confirm again that the adjustment has
mounting flange is properly aligned with the scribe mark been done correctly
on the engine mounting case At the six oclock position
on the outboard side of the injection pump is a semioval
cover with two screws Remove this cover and locate the
sealing Oring and timing washer 0032 inches in thick
ness Remove this washer and replace the cover
vvJ WESTERBEKE
r Engines Generators
FUEL INJECTION PUMP I FUEL LIFT CAM LIFT FUEL LIFT PUMP Early Models
1 Tum the crankshaft in the direction of nonnal engine The fuel lift pump should be cleaned and repainted Install a
rotation and read the maximum value which the dial new filter as illustrated and clean the ground wire tenninal
indicator pointer on the measuring device shows This
value is cam lift
Amount of Cam Lift 008 in 22 mm
2 After this check remove the measuring device and install
the plug and sealing washer
3 Reinstall the 0032 inch thick timing washer in the injec
tion THE INJECTION PUMP
1 The injector pump and injector high pressure lines will
have to be bled of air after the lines have been reinstalled
To bleed the injection pump first loosen the return con
nection Then by priming with the lever on the engine
mounted fuel filter supply fuel to the injection pump to
remove the air from the injection pump Continue until
fuel clear of air passes out of the loosened return connec FUEL LIFT PUMP
tion
2 Next bleed the high pressure lines by loosening them at
their attachment to the fuel injectors Loosen the attach GROUND
ing nuts one to two turns on all four fuel lines Tum the
key on and crank the engine with the starter until fuel spurts by the loosened connections Stop cranking the This pump
operates during the start sequence when preheat is
engine Tighten the attaching nuts and start the engine in pressed Simulate a start and depress preheat the pump
the usual manner should produce a clicking sound indicating the piston in the
pump is working If no clickirig is heard check that 12 volts
are present at the pump connection and the pump is properly
grounded
1 Test the pump by connecting a battery and fuel line as
illustrated Fuel delivery must be 05 pints 225 cc or
more every fifteen seconds
TESTING THE FUEL PUMP
FUEL LIFT PUMP
CYLINDER
SUCTION HEAD
APPRDX 500 mm
TYPE VE INJECTION PUMP
FUEL LIFT PUMP
IVV WESTERBEKE
I Engines Generators
FUEL THE INJECTORS c Mount the nozzle and nozzle holder on the nozzle
tester
NOTE Injector must be serviced in a clean room environ d Use the fuel at the approximate temperature of 68 F 0
ment
200 C
1 Disconnect the high pressure lines from the injectors and e Operate the hand lever of nozzle tester several times to
loosen the lines at their attachment to the injection pump bleed the air in the nozzle line then move the hand
and move them out of the way of the injectors Avoid lever at intervals of one stroke per second while read
bending the lines ing the injection starting pressure
2 Remove the fuel return line in its entirety from the top of Injector Starting Pressure 1920 Ibin 135 kgem
the injectors Take care not to lose the two sealing wash
ers and banjo bolt that attaches the fuel return line to each f If the fuel injection starting pressure is not within the
injector it can be adjusted by removing or adding
shims in the injector body to achieve proper pressure
3 Unscrew the injector from the cylinder head using a suit
able 27 mrn deep socket NOTE The shims are available in 53 kinds ranging
from 05 mm to 154 mm at 002 increments An incre
NOTE Clean the area around the base of the injector ment of o 02 mm causes the starting pressure to rise by
prior to lifting it out of the cylinder head to help prevent approximately 34 Ibin2 24 kgcm 2
any rust or debris from falling down into the injector
hole If the injector will not lift out easily and is held in
by carbon build up or the like work the injector side to
side with the aid of the socket wrench to free it and then
lift it out
4 The injector seats in the cylinder head on a copper seal INJECTOR
ing washer This washer should be removed with the PRESSURE ADJUSTMENT SHIM
injector and replaced with a new washer when the injec
tor is Using the nozzle tester check the spray pattern and injec
tion starting pressure of nozzle and if it exceeds the limit
adjust or replace the nozzle When using nozzle tester
take the following A CAUTION The spray injected from the
nozzle is of such velocity that it may penetrate
deeply into the skin of fingers and hands destroying
tissue If it enters the bloodstream it may cause
blood poisoning When replacing the shim grip the retaining nut in a
vise and remove the body with a wrench Tighten the
a If the diesel fuel of the nozzle tester is discolored retaining nut to the specified torque
replace it At the same time clean or replace the filter
b Set the nozzle tester in a clean place where there is no
dust or dirt
INJECTION TORQUE
PRESSURE TEST WRENCH
MiTl WESTERBEKE
I Engines Generators
FUEL SPRAY PATTERN
1 Operate the hand lever of the nozzle tester at intervals of 5 Assure the needle valve when it is pushed in the nozzle
one stroke per second to check if the fuel is injected cor body comes down into the valve seat by its weight about
rectly in its axial direction A nozzle is defective if it 00708 in 18 mm If it does not replace the assembly
injects fuel in an oblique direction or in several separate If any defect is found always replace the needle valve
strips Also a spray in the form of particles indicates a and the nozzle body as a unit
defect These defects may sometimes be caused by clog 6 Check that there is no flaw or other damage on mating
ging with dust and therefore all parts should be carefully surfaces and sliding surfaces of the nozzle body and the
cleaned before reassembly needle valve and if present replace the nozzle assembly
CHATTERING ASSEMBLING THE INJECTOR
TEST
1 Assemble in the reverse order of disassembly
NOTE After assembling the injector test it
2 Tighten the nozzle body on the nozzle holder to the speci
Jlh I fied torque
GOOD BAD BAD Nozzle Body Torque 24 mm socket 43 511bft 60 70 kgm
2 Operate the hand lever to raise the pressure up to 1635
Ibin2 115 kgcm2 which is 280 Ibin2 20 kgcm2 lower INSTALLING
than the starting pressure If with pressure applied fuel
1 Install in the reverse order of removal
does not drip from the nozzle oil tightness is Dripping of fuel with pressure applied is indicative of NOTE The copper washers
should not be reused Replace
damage to the needle valve or valve body or poor contact with new washers
between both In that event both needle valve and valve
2 Tighten the nozzle on the cylinder head to the specified
body should be considered defective and replaced
torque
M TES
Nozzle Torque 27 mm socket 43 51 Ibft 60 70 kgm
INJECTOR ASSEMBLY
MOD AmR Dmp
INJECTOR
RETURN
AND INSPECTION
1 Clamp the nozzle holder in a vise remove the nozzle nut
and disassemble the nozzle body spring and needle
2 Clean the disassembled parts with clean diesel fuel
NOTE Greatest possible care should be taken in handling
the nozzles as they are precisely machined The nozzle
and the needle valve are matched parts Do not mix their
original combinations Disassemble and wash each noz
zle assembly separately
Carbon deposits on the nozzle body must be removed
with a piece of hard wood However it would be advis
able not to clean the surrounding area of the nozzle ori
fice to avoid possible damage to the orifice When immersed
Iron dust on the magnetic jilter top must be removed in kerosene check
completely for smooth sliding
WASHERS fATl WESTERBEKE
I Engines Generators
FUEL SYSTEM PROBLEM PROBABLE CAUSE hard to start or
fails to start 1 No fuel at injectors 1 Check causes a th rough e
a No fuel in fuel tank andor fuel shut off a Fill tank Open shutoff and bleed system
b Fuel filter clogged b Replace filter and bleed
c Fuel filter clogged c Bleed pump Check fittings for suction leak
on fuel supply
d Fuel shutoff solenoid not working d Trouble shoot as described in previous section
e Injection pump faulty e Inspect pump Repair or replace pump as needed
2 Fuel injectors faulty 2 Remove and test nozzles Repair nozzles as needed
3 Water andor air in fuel filters 3 Remove water andor bleed air from system Check
system for leaks and fuel tank for water 4 Injection timing incorrect 4 Check and adjust the
timing
5 Glow plugs not working 5 Check glow plug circuit and repair as amount of
black exhaust smoke 1 Clogged fuel filter 1 Replace the fuel filter and bleed the system
2 Restricted air intake 2 Remove air obstruction
3 Engine overloaded 3 Check engine propeller size and engine
performance no load through fully loaded
4 Injection timing 4 Check the injection pump timing and adjust as needed
5 Fuel injectors not operating properly 5 Check nozzle spray idling too low 1 Idle speed too low
1 Adjust idle stop as needed
2 Fuel filter clogged 2 Replace filter and bleed fuel system
3 Incorrect injection pump timing 3 Check timing and adjust as needed
4 High pressure injection line leaking 4 Slacken attaching nut and retighten
5 Fuel injector leaking at sealing gasket in head 5 Retighten injector andor replace sealing washer
6 Injection nozzle not operating properly 6 Check nozzle and adjust as needed
7 Engine air intake obstructed 7 Check air flow intake silencer and air flow into engine
consumption too high 1 Idle speed too high 1 Check engine speed
2 Engine air intake restricted 2 Check intake and correct
3 Injection timing incorrect 3 Check timing and readjust pump as needed
4 Injector nozzle leaking 4 Tighten nozzle or replace sealing gasket
5 Injector not operating properly 5 Remove injector and adjust nozzle spray pressure
6 Engine overloaded 6 Check propeller size and engine performance
at rated rpm
rJ WESTERBEKE
r Engines Generators
FUEL SYSTEM PROBLEM PROBABLE CAUSE output poor 1
Contaminated or inferior fuel 1 Purge fuel system and replace with quality fuel
2 Fuel filter obstructed 2 Remove and replace filter element
3 Air in fuel system 3 Bleed and check for source
4 Injection pump timing incorrect 4 Check the timing and adjust pump as needed
5 Injector high pressure lines leaking 5 Loosen and then retighten injector line attachment
nut or replace the complete line
6 Injectors not operating properly 6 Remove injectors and adjust spray pressure to proper
setting
7 Shaft stuffing box too tight 7 Check shaft free movement and for heat
8 Valves improperly adjusted 8 Check valve adjustment and noise from engine 1 Poor quality andor incorrect fuel
1 Use No2 diesel fuel
2 Incorrect injection timing Timing too advanced 2 Check injection timing
3 Fuel injector stuck open 3 Locate and remove faulty injector Replace or rebuild
IVVJ WESTERBEKE
I Engines Generators
GLOW Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 20 to
The glow plugs are wired through the preheat solenoid
25 seconds If the plugs dont heat up quickly check for a
When PREHEAT is pressed at the control panel this solenoid
short circuit When reinstalling the glow plugs usc click on and the glow plug should begin to get hot
compound on the inspcct the plug remove the electrical terminal connec A WARNING Do not keep a glow plug on for more
tions then unscrew or unclamp each plug from the cylinder than 30 Thoroughly clean each plugs tip and threads with a
soft brush and cleaning solution to remove all the carbon and Glow Plug Tightening Torque 7 11 fHb 10 15 mkg
oil deposits While cleaning examine the tip for wear and
TERMINAL END
burn erosion if it has eroded too much replace the accurate way to test glow plugs is with an one prod to the glow plugs wire connection and the
other to the body of the glow plug as shown A good glow
plug will hav0 a 10 to 15ohm resistance This method can
be used with the plug in or out of the engine You can also
use an ammeter to test the power drain 8 to 9 amps per plug
A WARNING These glow plugs will become very hot
to the touch Be careful not to burn your fingers when
testing the plugs
GLOW PLUG
THE OHMMETER TEST
l WESTERBEKE
I Engines Generators
ENGINE CLEARANCE ADJUSTMENT 8 Adjust each valves clearance by inserting a 0012 in
003 mm feeler gauge between the rocker arm and the
1 Warm the engine to normal operating temperature
valve stem Make sure to adjust all valves when the
2 Pull off the air breather pipe from the rocker cover engine is cold
Remove the rocker cover bolts and remove the rocker
cover to expose the rocker shaft and valve assembly
3 Remove the glow plugs from each of the cylinders to
enable the crankshaft to be easily rotated by hand to posi
tion each cylinder for valve adjustment
Valves are adjusted with the piston in the cylinder being
adjusted at IDC of its compression stroke
NOTE Retorque the cylinder head bolts before adjusting the
engines valves
4 Loosen the head bolts in the reverse order of tightening
6 3 11
10 CD cp
9 Install the cylinder head cover
Head Cover Bolt Torque 2 3 n Ib 03 045 mkg
ENGINE COMPRESSION
12 Check the compression pressure To do this warm the engine
5 Tighten the head bolts in the order shown remove all fuel injectors or glow plugs disconnect the fuel
shutoff solenoid wire and install a compression adapter in
Cylinder Head Bolt Torque n
80 85 Ib 110 117 mkg
the injector hole or glow plug hole Connect a Set the piston of No 1 cylinder to IDC compression tester on the adapter
and crank the engine with the starter
and check the valve clearance at each position indicated motor until the pressure reaches a maximum value Repeat
If the clearance is incorrect adjust to this process for each cylinder Look for cylinders with dra
Intake No 1 and No2 cylinders and matically at least 20 lower compression than the average
Exhaust No 1 and No3 cylinders of the others Compression pressure should not differ by
7 Turn the crankshaft once setting the piston of No4 more than 427 psi 30 kgcm2 at 200 rpm
cylinder at TDC compression and adjust to the follow
ing Intake No3 and No4 cylinders and
Exhaust No2 and No4 cylinders
MEASURING
WHEN NO 4 CYLINDER IS AT TOP DEAD CENTER COMPRESSION
14 INTAKE 3 INtAKE 1
4 EXHAUST 2 EXHAUST
Compression pressure standard 427 psi at 200 rpm 300 kgem
Compression pressure limit 384 psi at 200 rpm 270 kgem
2 INTAKE 1 INTAKE
If a weak cylinder is flanked by healthy cylinder the problem
3 EXAUST 11 EXHtUST I is either valve or piston related Check the valve clearances
for the weak cylinder adjust as needed and test again
WHEN NO 1 CYLINDER IS AT TOP DEAD CENTER If the cylinder is still low apply a small amount of oil into
the cylinder to seal the rings and repeat the test
If compression comes up the rings are faulty
fIV1 WESTERBEKE
I Engines Generators
ENGINE high readings on all cylinders indicates heavy When servicing the injection pump the service shop must be
carbon a condition that might be advised if the pump is to be used in a generator by high pressures and noise
The service shop will have to remove and replace the gover
nor spring with a propulsion spring Once the pump is set to
NOTE In case of severe vibrations and detonation noise have
propulsion the generator spring is injectors checked and overhauled by an authorized fuel
in the injection pump and the pump remounted on the
injection service center Poor fuel quality contaminates and
engine The throttle is then set for the proper engine noload
loss of positive fuel pressure to the injection pump will result
speed hertz
in injector faults
For disassembly inspection reassembly and internal
When reinstalling the glow plugs use antiseize compound adjustments of the injection pump it is recommended the
pump be taken to a qualified injection service shop
SEnlNG THE IDLE SPEED PROPULSION ENGINE authorized to service Diesel KiKi injection equipment
1 Warm the engine to normal operating Stick a piece of suitable reflecting tape on the crankshaft
pulley
3 Idle the engine
4 Use the light of a photoelectric strobe type tachometer on
the reflecting tape and check the value shown by the
idle speed 580 630 rpm
WIRE LOCKED
NOTE The idle speed may vary according to the
transmission and propeller
5 To adjust the engine idle speed loosen the lock nut of the
idle adjustment boIt and turn the bolt clockwise to
increase idle speed and to reduce
ENGINE STOP SOLENOID
This solenoid is installed on the top rear of the injection
NOTE Should engine rpm be in question verify pump and is activated by 12 VDC electrical current
tachometer readings as shown at the instrument panel
See TACHOMETER NOTE To service generator applications refer to the
IDLE AOJUSTMENT GENERATOR section of this manual
BOLT
1 The solenoid does not operate when the
keyswitch is turned ON
a Are the engine batteries turned ON I
THROTTLE STOP b Is the 20 amp circuit breaker set SOLENOID
SCREW
c Is 12 VDC present at the solenoid
connection SPRING
KEEP LINKAGE
WELL LUBRICATED 2 The solenoid does not stop the engine
when the keyswitch is switched OFF LUN
SPEED ADJUSTMENT GENERATOR a Check to see if 12 VDC is still present
at the solenoid electrical lead with the
NOTE Speed adjustment of the generator hertz is controlled key off
by the electronic governor see ELECTRONIC GOVERNOR
b Remove solenoid from injection
for speed and gain adjustments pump and ensure plunger and spring
in the solenoid are not Models Without Electronic speed is maintained by the governor mechanism
INJECTION PUMP
inside the fuel injection pump 615 620 hertz at noload
and 585 590 hertz at full rated generator noload speed is adjusted by positioning the
throttle lever against the adjustable throttle stop screw
lock wiring it at that position and tensioning the throttle
stop screw against the throttle lever and securing it with its
lock nut
lfAiTl WESTERBEKE
I Engines Generators
COOLANT CIRCULATING PUMP
APPL Y A THIN COAT OF OIL
REMOVING THE PUMP TO SPRING LOADED SEAL
Remove in the following order coolant drain as needed water hoses water pump attaching nuts and water
pump
Remove the pump pulley boss by using a support and
press
2 Remove the bearing shaft from the impeller and bearing
FLANGE
housing by using a support block and press
APPLY A THIN COAT
3 Remove the snap ring with snap ring pliers and press out OF OIL
the water pump shaft from the bearings
PUMP HOUSING
APPL Y LITHIUM GREASE
COLLAR TOOL
490636 the shaft bearings and impeller Look for cracks and COOLANT PUMP
damage Check the housing gasket and inspect the rear seals NOTE Do not allow oil or grease to contaminate the
and small end gaskets
sUrfaces of the ceramic ring or the graphite small end
Replace any parts that show wear of the springloaded seal
3 After the water pump has been assembled check if the
ASSEMBLY pump shaft rotates the water pump in the reverse order using the
following procedure INSTALLING THE PUMP
1 Fill lithium grease lithium base NLGI No2 into the 1 Install in the reverse order of removal
following positions
III Ball bearings NOTE Use a new gasket
III Approximately 13 space between both ball bearings 2 After installing the pump fill the system with coolant and
III Space between the ball bearing and water baffle plate operate the engine to check for leaks
2 Apply a thin coat of engine oil to the press fit surface
of the water seal and press the larger end into the
proper aperture of the pump using a tubular
mandrel 49 0636 145
SPRING LOAOED SEAL
DUST SEAL PLATE
WATER PUMP BODY
Il WESTERBEKE
I Engines Generators
LUBRICATING OIL PUMP
REMOVING THE OIL PUMP 3 Clearance between inner rotor and outer rotor Check
the clearance between the lobes of the rotors with a feeler
Remove in the following order
gauge If the clearance exceeds the limit replace
1 Oil Pan both rotors
2 Oil Pump Set Screw OUTER ROTOR
3 Oil Pipe Attaching Bolts and
INNER ROTOR
4 Oil JjTALLY in the following order Oil Pipe
and Gasket
Oil Strainer and Gasket Oil Pump Cover Drive Gear use a
press and suitable mandrel Inner Rotor and Shaft Rotor Relief Valve Assembly and Oil Pump Body Clearance Limit 0012 in 03 mm
4 Clearance between outer rotor and pump body the clearance between the outer
rotor and pump body
1 Visually check the disassembled parts and replace faulty with a feeler gauge If the clearance exceeds the limit
parts Check the sliding surface of pump cover with replace the rotor or pump body
special care and replace the cover If the surface has steps
or excessive streaks Minor steps streaks may be repaired
by rubbing them with a compound on a surface plate
OIL PUMP
SET SCREW OUTER ROTOR
LUBRICATING
OIL PUMP
Clearance Limit 0012 in 03 mm
ROTOR ASSEMBLY 1
5 Clearance between rotor and pump cover Check the
end float of the rotors Place a straightedge across the
RELIEF VALVE
pump body and measure the clearance between the rotor
CONTROL and straight edge with a feeler gauge If the clearance
r COVER exceeds the limit replace the drive gear drive shaft inner
rotor outer rotor and pump body
OIAL GAUGE
CHECKING
END FLOAT
DRIVEGEAR
Clearance Limit 0006 in 015 mm
2 Clearance between pnmp body and shaft Measure the
above clearance with a dial gauge and magnet Limit 00039 in 01 mm
When the clearance exceeds the limit replace the pump
drive shaft inner rotor pump body and drive gear
fAT WESTERBEKE
rEngines Generators
LUBRICATING OIL PUMP
6 Measure the free length of the plunger spring Check ASSEMBLY
the relief valve for worn plunger and fatigued spring
7 Assemble in the reverse order of disassembly
NOTE When installing the rotors into the body be sure
that the tally marks on the rotors are positioned toward
Spring free Limit 182 in 462 mm
the cover
Cover Tightening Torque 716 socket 58 87 fIlb 08 12 mkg
INSTALLING THE OIL PUMP
1 Install in reverse order of removal
NOTE When installing the set screw apply sealing com
pound on the set screw threads
OIL OIL PRESSURE LOW OIL PRESSURE
The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 43 14 psi 03
oil pump The engine oil is drawn from the oil sump by the 01 kglcm2 A gradual loss of oil pressure usually indicates
oil pump which drives the oil under pressure through the a worn bearings For additional information on low oil pres
oil filter oil cooler and various lubricating points in the sure readings see the ENGINE The oil then returns to the oil sump to
repeat the con
tinuous cycle When the oil pressure exceeds the specified OIL PRESSURE the oil pushes open the relief valve in the oil pump
When performing an engine overhaul replace the oil pres
and returns to the oil sump keeping the oil pressure within
sure switch and the oil pressure sender
its specified range
When installing the new parts apply a teflon sealant to the
To test the oil pressure remove the oil pressure sender then
threaded ends being careful not to close off the oil hole in the
install a mechanical oil pressure gauge in its place After
up the engine set the engine speed at 3600 rpm and
read the oil pressure gauge Oil Pressure Sender and Switch Torque 9 13 fIlb 12 18 mkg
A CAUTION Oil Pressure Switch Do not use lock
pliers vise grips or pipe wrenches on the oil pressure
switch Use the correct socket which is available from
SnapOn Proto New Britain and others Damage to the
switch will cause oil leaks anelor switch faiure
CURRENT ENGINES
AND Pressure 5404 Ibin 38 kgem or more at 3600 rpm
EARLY MODEL
ENGINES
fIV WESTERBEKE
I Engines Generators
RAW WATER PUMP
PUMP OVERHAUL 5 Inspect all parts and replace those showing wear or
6 Use the illustration to assist in reassembling the raw
water pump
The pump as removed from the engine will have nipples threaded into its inlet and outlet port a Apply a small amount of petroleum jelly
to the seals
They may be left in place or removed if they interfere with inner race and to the impeller shaft at pump disassembly Note the port
location and positioning b When positioning the cam in the housing use a small
if removed amount of Pennatex 1 on the inner cam surface and
1 Loosen the set screw with an allen wrench and remove cam screw heads remove any excess from the impeller
the water pump pulley from the shaft housing
2 Remove the four cover plate screws the cover plate and c Apply a light film of silicon or petroleum jelly to the
the cover plate gasket inner surface of the housing for the impeller
7 When the pump is assembled reposition and tighten the
NOTE Replacement of the cover plate gasket is
hose nipples Assemble the pump to the engine and attach
recommended however it you are going to reuse it
the hoses and the belt
keep the gasket well lubricated until the pump is
reassembled If its allowed to dry the gasket will
shrink and not be reusable
3 Pull out the impeller with long nose pliers or pry out with
a pair of Remove the bearing assembly releasing the shaft bearing
and seal assembly This will allow the bearings and seals
to be disassembled for inspection
NOTE It may be necessary to use a drift and arbor press
to press the bearing and seal assembly from the shaft
COVER PLATE GASKET
IMPEllER
HOUSING
USING GASKET
SHAFT
RAW WATER PUMP
fAT WESTERBEKE
I Engines Generators
STARTER NoLoad Test
The starter can be roughly divided into the following sections 1 Connect the ammeter voltmeter and battery to the starter
A motor section which generates a drive power as An overrunning clutch section which transmits an arma 2 When
the switch is closed the pinion must protrude and
ture torque preventing motor overrun after starting the starter must run smoothly at 3000 rpm or more If
the current or starter speed is out of disas
A switch section solenoid which is operated when actu
semble the starter and repair it
ating the overrunning clutch through a lever and which
supplies load current to the motor
The starter is a new type small lightweight and is called a
highspeed starter The pinion shaft is sep
arate from the motor shaft the pinion slides only on the pin
ion shaft A reduction gear is installed between the motor
shaft and a pinion shaft The pinion sliding part is not
exposed outside the starter so that the pinion may without becoming fouled with dust and grease The
motor shaft is supported at both ends on ball bearings The
lever mechanism switch and overrunning clutch inner circuit
are identical to conventional AND REPAIR
If any abnormality is found by the following tests the starter A CAUTION Use thick wires as much as possible and
should be disassembled and repaired tighten every terminal securely This is a solenoid shift
NOTE Early model engines were equipped with DELCO type starter which makes a rotating sound louder than
starter motors If a DELCO starter needs serving contact a that of a directdrive type starter When service shop or your WESTERBEKE dealer
starter rotation at the pinion tip be careful not to come
in contact with the pinion gear when it Gap Inspection
1 Connect a battery 12V between the starter terminal S SOLENOID
and the starter body and the pinion drive should rotate
Perform the following tests If any test result is not
out and stop
satisfactory replace the solenoid assembly
1 Inspect the solenoid for continuity between terminals
A CAUTION Never apply battery voltage for over 10 and and between terminals S and the body and M and
the body There should be no continuity found between
terminals Sand M Continuity will be found between ter
2 Lightly push the pinion back and measure the return minals S and the body and terminal M and the body
stroke called pinion gap
3 If the pinion gap is not within the standard range 00197
00788in 05 to 2Omm adjust it by increasing or
decreasing the number of shims on the solenoid The gap
is decreased as the number of shims MULTIMETER
NOTE Disconnect the wire from terminal M
2 Connect a battery to the solenoids terminal S for and
M for Have a switch in the lead and close it Te
pinion drive should extend fully out
05 20 mm
A CAUTION Do not apply battery current for more than
10 seconds when tesHng the solenoid
PINION GAP
IMTI WESTERBEKE
I Engines Generators
STARTER MOTOR
4 Return test With a battery connected to the solenoid
terminal M and to the starter body manually pull out
the pinion fully The pinion must return to its original
position when released from holding by hand
HOLDING TEST
3 Holding test With a battery connected to the solenoid
terminal S and to the starter body manually pull out
the pinion fully The pinion must remain at that position
even when released from holding with your hand
RETURN TEST
ATIRACTION TEST
7 Pull out the reduction gear lever and lever spring from the
STARTER ASSEMBLY front bracket
1 Disconnect the wire from the solenoid terminal M
8 On the pinion side pry the snap ring out and pull out the
2 Loosen the two screws fastening the solenoid Remove pinion and pinion shaft
the solenoid assembly
9 At each end of the armature remove the ball bearing with
3 Remove the two long through bolts and two screws a bearing puller It is impossible to replace the baTlbear
fastening the brush holder Remove the rear bracket ing pressfitted in the front bracket If that bearing has
4 With the brushes pulled away from the armature worn off replace the front bracket assembly
remove the yoke and brush holder assembly Then pull TERMINAL M
the armature out
SolENolD
5 Remove the cover pry the snap ring out and remove the
washer
6 Unscrew the bolts and remove the center bracket At the
same time the washers for the pinion shaft end play
adjustment will come off
INSPECT FOR
WEAR CHIPPING BRUSH HOLDER
STARTER
MOTOR
NOTE Inspect clean and replace
if necessary solenoid armature etc See the
following SHAFT
tffIVJ WESTERBEKE
r Engines Generators
STARTER MOTOR
STARTER INSPECTION
CROCUS the solenoid for continuity between tenninals Sand
M and between tenninals S and body No continuity should
be found between Sand M Continuity should be found
between S and the body and M and the body
Brush and Brush Holder Inspection
1 Check the brushes If worn out beyond the service limit
replace the brushes
CONTINUITY The Armature BRUSHES
1 Check the annature with a growler tester If its short NEW USED
circuited replace the annature Also check for insulation
Brush Height Standard 0669 in 17 mm
between the commutator and its shaft If poorly
Brush Height limit 02363 in 6 mm
insulated replace the annature
2 Check the brush spring tension A weak or defective
ARMATURE spring will cause excessive brush wear replace the
CHECK springs if suspect
BRUSH HOLDER
ASSEMBLY Measure the commutator aD and the depth of undercut
Repair or replace it if the service limit is exceeded Also 3 Check for insulation between the positive brush holder
check the commutator outside surface for dirtiness and and holder base If poorly insulated replace the holder
roughness If rough polish the commutator with fine assembly Also check the brush holders for proper staking
crocus cloth
COMMUTATOR Outside Diameter Standard 387 mm 1523 Outside Diameter Limit 10 mm 0039 in
II WESTERBEKE
I Engines Generators
STARTER MOTOR
Field Coil Inspection 2 Greasing Whenever the starter has been overhauled
apply grease to the following parts
1 Check for insulation between one end brush of the
coil and yoke a Annature shaft gear and reduction gear
2 Check for continuity between both ends brushes h All bearings
of the coil c Bearing shaft washers and snap rings
3 Check the poles and coil for tightness d Bearing sleeves
e Pinion
f Sliding portion of lever
MULTIMETER
A CAUTION Never smear the starter fitting surface
terminals brushes or commutator with grease
3 After reassembly check by conducting a noload
test COIL TEST ADJUSTMENT AND REASSEMBLY
SNAP RING
A CAUTION Before installing thoroughly clean the IO5 mm MAX
starter flange and mounting surfaces remove all oil old
paint and rust Starter performance largely depends on
the quality of the wiring Use wire of sufHcient size and PINION SHAFT END PLAY
grade between the battery and starter and fully tighten
to the the starter assembly in the reverse order making sure of the following
1 Pinion shaft end play adjustment Set the end play
thrust gap to between 00197 00788in 05 to 2mm
by inserting an adjusting washer between the center
bracket and the reduction gear
a Fit the pinion shaft reduction gear washer and snap
ring to the center bracket
h Measure end play by moving the pinion shaft in the
axial direction If the end play exceeds 00788in
O5mm increase the number of adjusting washers
Il WESTERBEKE
I Engines Generators
METER Tachometer meter used in propulsion engine instru a With a handheld tach on the
front of the panels contains two separate electrical circuits with a pulley retaining nut or with a strobetype tach read the
common ground One circuit operates the hour meter and the front crankshaft pulley rpm at idle
other the tachometer The hour meter circuit operates on 12 b Adjust the tachometer with a small Phillips type screw
volts alternator charging voltage supplied to the terminal driver through the calibration access hole in the rear of
on the back of the instrument the tachometer Zero the tach and bring it to the rpm
The tachometer circuit operates on AC voltage 68 volts fed indicated by the strobe or hand tach Verify the rpm at
from one of the diodes in the alternator and supplied to the idle and at high speed 25003000 rpm Adjust the input terminal while the
engine is running and as needed
the alternator producing battery charging voltage DC NOTE Current model tachometers use a
coarse adjustment
dial to set the tachometer to the crankshaft pulley rpms The
The following are procedures to follow when calibrating screw is then used jar fine tuning
a fault in either of the two circuits in a meter for the proper DC voltage between and
Voltage present meter is defective repair or replace
2 Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter
terminal to verify the operation Inoperative
CALIBRATION TACHOMETER INPUT
AC for the proper AC voltage between tachometer input CURRENT and terminal with the engine running
1 Voltage present attempt adjusting meter through calibra
tion access hole No results repair or replace meter
2 AC voltage not present check for proper alternator DC
output voltage
3 Check for AC voltage at tach terminal on alternator to
ground
4 Check electrical connections from tachometer input ter
minal to alternator connection
Sticking
1 Check for proper AC voltage between tach inp terminal
and terminal
EARLY MODEL TACHOMETER GROUND
2 Check for good ground connection between meter ter TERMINAL
minal and Check that alternator is well grounded to engine block at
alternator pivot bolt
GROUND
GROUND TACHOMETER INPUT
TERMINAL LIGHT I AC VOLTAGE
TERMINAL
EARLY MODEL TACHOMETER
tl WESTERBEKE
I Engines Generators
ALTERNATOR TESTING
DESCRIPTION 1 Start the Engine
The charging system consists of an alternator with a voltage 2 After a few minutes of running measure the starting bat
regulator an engine DC wiring harness a mounted DC cir tery voltage at the battery terminals using a multimeter
cuit breaker and a battery with connecting cables Because of set on DC volts
the use of integrated circuits Ies the electronic voltage reg The voltage should be increasing toward 14 volts If it is
ulator is very compact and is mounted internally or on the the alternator is working Turn to Step 4
back of the alternator
140
14 14 14 BROWN
MULTIMETER
COM
14 BLUE
ffir to TESTING THE STARTING
to Fuel Solenoid 14 PINK BATTERY
Pump ENGINE RUNNING
10 RED
B OUTPUT
to Starter Motor
51 AMP DC GROUND
ALTERNATOR 51 AMP
GENERATOR CONNECTIONS ALTERNATOR REFER TO THE WIRING
DIAGRAM FOR W52
ALTERNATOR CONNECTIONS
A WARNING A failed alternator can become very GROUND
hot 00 not touch until the alternator has cooled down 3 If the starting battery voltage remains around 12 volts
after the engine is started and run for a few minutes a
This section is to determine if a problem problem exists with the alternator or the charging circuit
exists with the charging circuit or with the alternator If it is
determined that the alternator or voltage regulator is bad it is a Turn off the engine Inspect all wiring and connections
best to have a qualified technician check it out Ensure that the battery terminals and the engine ground
connections are tight and clean
The alternator charging circuit charges the starting battery
and the service battery An isolator with a diode a solenoid
or a battery selector switch is usually mounted in the circuit A CAUTION To avoid damage to the battery
to isolate the batteries so the service battery is not discharged charging circuit never shut off the engine battery
along with the service battery If the alternator is charging the switch when the engine is running
starting battery but not the service battery the problem is in
the service battery charging circuit and not with the alterna b If a battery selector switch is in the charging circuit
tor ensure that it is on the correct setting
c Turn on the ignition switch but do not start the engine
Testing the Alternator d Check the battery voltage If your battery is in good
condition the reading should be 12 to 13 volts
A WARNING Before starting the engine make certain
that everyone is clear of moving parts Keep away from
sheaves and belts during test A WARNING MULTIMETERS AND DC CIRCUITS
DC and AC circuits are often mixed together in marine
applications Always disconnect shore power cords
isolate DC and AC converters and shut down generators
before performing DC testing No AC tests should be
made without proper knowledge of AC VVI WESTERBEKE
I Engines Generators
ALTERNATOR TESTING
e Now check the voltage between the alternator output Alternator is Working
terminal B and ground If the circuit is good the
4 Check the voltage of the service battery This battery
voltage at the alternator should be the same as the bat
should have a voltage between 13 and 14 volts when the
tery or if an isolator is in the circuit e lternatr vlt
engine is running If not there is a problem in the service
age will be zero If not a problem eXIsts In the CIrCUIt
battery charging circuit Troubleshoot the service battery
between the alternator and the battery Check all the
charging circuit by checking the wiring and connections
connections look for an opening in the charging cir
the solenoid isolator battery switch and the battery itself
cuit
MULTIMETER
MULTIMETER G
BATTERY SWITCH COM COM
J
I
BATTERY SWITCH
TESTING THE STARTING
BATTERY ALTERNATOR ENGINE
ENGINE RUNNING
IGROUND SERVICE
BATTERY
f Start the engine again Check the voltage between the
alternator output and ground TESTING THE SERVICE
GROUND
The voltage reading for a properly operating alternator BATTERY ENGINE RUNNING
should be between 135 and 145 volts If your alterna
tor is over or have it repaired at a reli
able service shop
A CAUTION When performing tests on the alter
NOTE Before removing the alternator for repair use a nator charging circuit do not use a high voltage
voltmeter to ensure that 12 volts DC excitation is pre tester ie Megger You can damage the alternator
sent at the EXC terminal if the previous test showed
diodes
only battery voltage at the B output terminal
If 12 volts are not present at the EXC terminal trace
the wiring looking for breaks and poor connections
ALTERNATOR INSPECTION
When rebuilding the engine the alternator should be cleaned
and inspected The housing can be wiped off with a solvent
and the alternator terminal studs should be cleaned with a
wire brush Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness
Tum the rotor pulley by hand It should tum smoothly
Depending on when the alternator was last serviced the
brushes may need replacing If the alternator is at all suspect
send it to a service shop for testing and 1fIV1 WESTERBEKE
I Engines Generators
SERVICE DATA I STANDARDS AND LIMITS W5263B 163C Specified Value I Standard Repair Limit
Component Specified Value I Standard Repair Limit
inchesmm inchesmm inchesmm
I TIMING TIMING Compression psi at 200 rpm psi
Backlash 300 kgcm 270 kgcm Gears in Mesh
00039 00067 010 017 0012 between 427 psi Idler Gear Bushing
Cylinders max 30kgcm Clearance between
Bushing and 0001 0010 003 007 Timing at BTDC
on compression stroke 15 19 2 ROCKER ARM
Spill Timing static Rocker Arm Bore 07196 18258 Spray
Pressure psi 71 OPSI Rocker Arm Bushing
135 50kgcm Inner diameter 06250 06258 15876 HEAD
Outer diameter 07200 07208 18288 Distortion 01 Rocker Arm
Shaft
Outer diameter 06234 06244 15835 15860
Valve Guide 66 Clearance 00006 00024 0016 0061 00028 Exhaust
TAPPET
Intake Valve Guide Angle 45
Outer diameter 05610 14224 Valve Guide Angle 30
Bore in cylinder block 05625 05637 14288 Valve Seat Width 0079 20 0004 01
Clearance In
Exhaust Valve Seat Width 0079 20 01 Cylinder Block bore 00015 00037 00039 010 00039 010
Valve Clearance 030 Warm VALVE Exhaust
Journal No 1 Front 20437 20449 51910
51940
No2 Center 20339 20351 51660 51690
Valve Head Diameter No3 Rear 20154 51160 51190
Intake 405 0004 01 Wear limit 0008
Exhaust 1417 36 0005 013
Cam Length Intake and Exhaust 42587 16728
42485
Intake 1145
Exhaust 1146 Camshaft End 00008 00071 0020 0180 00118 030
Valve Stem 00 Camshaft RunOut 008
Intake 03130 7925 7950 03102 7880
Exhaust 03125 7912 7937 03097 7867 Camshaft Support Bore
No1 Front 20473 20485 52000 52030
Stem to Guide Clearance No2 Center 20374 20386 51750
51780
Intake Exhaust 00015 00035 0038 0089 00050 0127 No3 Rear 20177 20189 51250 51280
Valve Contact Width 0079 20 Oil Clearance
No1 Front 00024 00047 0060 0120 00057 0145
Valve Face Angle No2 Center 00024 00047 0060
0120 00057 0145
Intake No3 Rear 00024 00047 0060 0120 00057 0145
Exhaust Backlash between gears
00039 00067 010 017 00118 030
Valve Guide Cylinder Head 165 PUSH RODS
Dimension L sinking 1890 480 495 Bend Limit 019
Valve Spring outer IDLER GEAR
Wire 45 Boss bore 18898 18908 48000 48025
Outer coil diameter 380 Boss bore Iimit 00118 020 030
Free Length 1807 459 436
Fitting Length 1587 403 Bushing
Preload 20 Ib180 09 kg 320 Ib145 kg Inner Diameter 17327 17336 44009 44034
Squareness 137 Outer Diameter 18915 18925 48043 48068
Valve Spring inner Spindle
Wire diameter 35 Length 11437 2895 2905
Outer coil diameter 1083 275 Outer Diameter 17303 17313 43950 43975
Free Length 1736 441 420
Fitting Length 1488 378 Spindle and
Preload 280 13Ib127 06 kg 227Ib103 kg Bushing Clearance 00013 00033 0034 0084 00059 015
Squareness 125 Backlash between gears 00039 00067 010 017 00118 030
IVVI WESTERBEKE
I Engines Generators
SERVICE DATA I STANDARDS AND LIMITS W5263B 163C Specified Value I Standard Repair Limit
Component Specified Value I Standard Repair Limit
inchesmm inchesmm inchesmm
ROD MAIN BEARING
Bend and Twist 0002 in 4 005 in 100 Clearance 00036 0040 0091 00047 012
Side Play 00094 00134 0239 0340 0Q157 040 Available undersize 001 002 003 0254 0508 0762
Small End Bore 1222 31000 31039 CYLINDER ROD BEARING
Cylinder Bore 38135 96838 96863
Oil Clearance 00014 00030 0036 0076 0039 010 Warpage Iimit undersize 001 002 003 0255 0508 0762
Cylinder Liner
Length 64075 16250 Inner diameter
35020 88925 88950
Oiameter 34987 34997 88867 88893 Outer diameter 38145 38155 96888 96914
Protrusion 00259 00311 0659 0790
Piston Ring Hole Bore 11024 11028 2800 2801
Piston to Liner Clearance Flywheel to Crankshaft runout 020
Side Clearance 00017 00028 0044 070 FUEL SYSTEM
Ring Groove Width Idle speed 630 rpm
Top 0966 2433 2453
Second 00954 0962 2423 2443 Fuel Injection Pump
Oil 01895 4793 4813 Plunger diameter 0393 100
Cam Lift 22
PISTON RINGS
Nozzle 080
Top 01382 349 351
Second 01400 3429 3556 Injection Pressure 1920 710 psi 135 50 kgcm
Oil 01240 2750 3150
LUBRICATION Top 0938 2363 2383 Oil Pressure psi 40 kgcm
Second 0938 2363 2383 Min Safe pressure idle 43 14 psi 03 01 kgcm
Oil 01875 4743 4763 Oil Capacity sump 53 Ots 50 L
Side Clearance Oil Pump
Top 00035 0050 0090 00591 15 Outer Rotor and
Second 00016 00031 0040 0080 00591 15 Body Clearance 00055 00079 014 020 0012 03
Oil 00028 0030 0070 0118 030 Rotor Lobe
End Gap Clearance 00016 00079 004
020 0012 03
Top 00217 040 055 15 Rotor End Float 00016 00039 004 010 00059 015
Second 00157 030 040 00591 15 Pump Shaft and Body Clearance 010
Oil 00217 035 055 00591 15 Spring Free Length 462
PISTON PIN STARTER MOTOR
11021 11024 27994 28000 Oepth of Brush Undercut 0019 05 02
Pin to Piston Clearance 0 0006 0 0016 Height of Brush 17
Spring Pressure IbM 3 kgcm
Main Journal diameter 25585 25591 64987 65000 0002 005 Commutator 00 387 0039 10
Crankpin diameter 20861 20866 52987 53000 0002 005 Pinion Shaft End Play 0014 05
Processing diameter 0762
End 00154 0140 0390 0Q157 040
Runout 005
IVVI WESTERBEKE
I Engines Generators
TORQUE W52 I 63B 163C FHB MKG COMPONENT FTLB
Bracket 27 38 38 53 Injection Pipe Flare Nut 22 16 30
Back Plate 35 33 48 Injection Pump Gear 45 51 62 70 Valve Holder M16 17 253 282 35 Thrust Plate 12 17 16 24
Injection Pump Locknut Gear 29 51 40 70
Injectors 38 50 Rod Cap 50 54 69 75
Intake Manifold 12 17 16 24
Coolant Pump 17 16 24
Main Bearing Cap 80 85 110 117
Coolant Pump Pulley 12 17 16 24
Oil Pan 9 07 Sender 9 13 12 18
Oil Pan Pipe 17 16 23
Coolant Temperature Switch 9 13 12 Pulley Nut 181 20 25 Oil Pressure Sender 9 13 12 18
Oil Pressure Switch 9 13 12 18
Cylinder Head Bolts 85 90 118 125
Oil Pump Cover 9 08 12
Cylinder Head Cover 2 3 03 045
Oil Pump Pipe 9 08 12
Damper Plate 14 20 19 27
Rear Oil Seal Cap 11 15 15 20
Engine Mounts 34 32 47
Rocker Arm Assembly 80 85 110 117
Exhaust Manifold 17 16 24
Rocker Arm Cover 18 29 025 040
Fuel Solenoid Locknut M30 36 289 362 40 50
Thermostat Housing 8 08 11
Flywheel bolt M1 0 12 61 68 85 95
Thrust Plate 16 23 23 32
Glow Plug 11 10 15
Timing Gear Case 12 17 16 24
Idler Gear 23 22 32
Timing Gear 12 17 16 Nozzle 170 16 24
NOTE Formula to conven FtLbs to Nm Newton Meters is
multiply FtLbs by 1356
Example 45 FtLbs 45 x 1356 61 Nm
fATl WESTERBEKE
I Engines Generators
STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt Metric bolt class numbers identity bolts by their strength with 109
Customary inch bolts are identifed by markings two to grade eight The marks correspond to two marks less than the actual grade
ie a grade seven bolt will display five embossed 1 Use the torque values listed below when specific torque values are not available
2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used
3 Reduce torques by 30 or more when threading capscrews into aluminum
STANDARD BOLT NUT TORQUE METRIC BOLT NUT TORQUE SAE Grade 5 SAE Grade 67
SAE Grade 8
Capsrew Body Size Torque Torque Torque Boll Grade 46 Grade 48 Grade 88 98 Grade
Inches Thread FILb Nm FILb Nm FILb Nm Dia Wrench Size FILbNm FILb Nm FILb Nm FILb Nm
14 20 8 11 10 14 12 16
28 10 14 14 19 M3 55mm 03 05 05 07 1 13 15 2
M4 7mm 08 11 1 15 2 3 3 45
51618 17 23 19 26 24 33 M5 8mm 15 25 2 3 45 6 65 9
24 19 26 27 37
31816 31 42 34 46 44 60 M8 10mm 3 4 4 55 75 10 11 15
24 35 47 49 66 M9 13mm 7 95 10 13 18 25 35 26
716 14 49 66 55 75 70 95 M10 16mm 14 19 18 25 37 50 55 75
20 55 75 78 106
12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 63 85 97 130
20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205
M16 24mm 59 80 85 115 159 215 232 315
91612 110 149 120 163 155 210
18 120 163 170 231
M18 27mm 81 110 118 160 225 305 321 435
58 11 150 203 167 226 210 285 M20 30mm 118 160 166 225 321 435 457 620
18 170 231 240 325 M22 33mm 159 215 225 305 435 590 620 840
314 10 270 366 280 380 375 508
16 295 400 420 569 M24 36mm 203 275 288 390 553 750 789 1070
M27 41 mm 295 400 417 565 811 1100 1154 1565
78 9 395 536 440 597 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130
14 435 590 675 915
1 8 590 800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900
14 660 895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720
SEALANTS Oil based PERMATEX 2 and its HIGH TACK equivalent are excellent all Use LIQUID TEFLON for sealing pipe plugs and fillings that
connect coolant
purpose sealers They are effective in just about any joint in contact with passages Do not use tape raw water oil or fuel
A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets BOLTS Orings
Lightly oil head bolts and other fasteners as you assemble them Bolts and
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil plugs that penetrate the water jacket should be sealed with PERMATEX 2
filter assembly HIGH TACK
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When assembling the flywheel coat the bolt threads with LOCTITE blue
When installing gaskets that seal around water coolant passages coat both Antiseize compounds and thread locking adhesives such as LOCTITE protect
sides with WHITE SILICONE grease threaded components yet allows them to came apart when necessary
LOCTITE offers levels of locking according to the ADHESIVE SPRAYS are useful for holding gaskets in position dur
ing assembly LITHIUM based grease is waterproof ideal for water pump bearings and
stuff
ing gasket sealers such as HYLOMAR work well in applications requir
ing nonhardening properties HYLOMAR is particlarly effective on Heavily oil all sliding and reciprocating components when assembling
Always
copper cylinderhead gaskets as it resists fuel oil and water use clean engine oil
IJ WESTERBEKE
rEngines Generators
W52 MARINE ENGINE
WIRING DIAGRAM 33685
BUTTON
WTSENDER RN
WATt TtPT
SWfTCH OIL 5WITCH
ALARM
I fUEl 50L I
PREHEAT SOL
mNOua
oP5ENOER USD
SERifS to 12VOLT to AMP
34 0594 At ERNATOl l2v SOh 1
33 24151 PANEl kESS
3Z 24J80 PANEL COMP4Ere
31 4777 KY SWITCH I
30 13355 LARIi I
2 30944 OIl PRESS siN NC
28 30125
27 2483
WAitE r4MPr W MO
FUGL LIFT PUMP I
2c 11781 AMMETtR OpnONAL I
25 20654 SPLrr1Z OPuOIVAl
24 4529 GLOW PLUGS WJOW6l 4EAC1
123 11530 GLOW PlUGS W40 I
NEUTRAl SAFe SW PAAC I
NEGTHAt sAETY SW WANEe
PANEL ErS
I7F PANEl COMPLiErS I
ITs k1r ALr
ji

rate SI A
F WAree tEMP I
4 24338
OLENOID FUEL
SENDER oIL plerlR
HI 24i378
I2433
PItHeATEte W511
SONOID PIIEHAr
10 24683 CllCVlr fREAKEe 20AHA I
Ib72 SrANQ HAIiN4 ENCN I
rlANtSS GNtNE
24133
HARNE PtlIlEL
KGysWITCH
VOLrMErE2
sWITH
PREHeAT
GAUGe
1154S
wAree rsup
GAUGE
ITE PART NO DESCRIPTION OTY ASS oTyoN
WESTERBEKE
I Engines Generators
W52 MARINE ENGINE
WIRING SCHEMATIC 33685
BUTTON
2VOC BATTERY 8ATTRY ReTURN
START lTARTCR
NOTES ON PtolEMAT
AN OrlOF JNITCH lJusr eli INJP LID IN rillS 1 TO DISCONNGcr
rHE STArE CINCUlr FIOM rHE BATrEIiPY I A
EGI7GENC WHeN
ALTERNATOR LEAt rue BOAT IVOLr DIESl ENNVE STArEfPS TYPICALAW
200 TO 300AMP5 WHEN CNKIN rE DuRATiOAl OF INONIJUA eANKIG
CycES SJlOtJlD NOr EXCEED o sECONDS A SWIrt1I wlrA CONnNUOUS
eATING O 175 AS AT 12 IIDC WILL NOIMAtLr SRVG TIIS UNCTiON
aur sUCH A SWlrCH MuST NJVIiR tJE uJID TO WAKE THE STAlreR OTHER NOTES
i sENDE 0
WARNING
CONTACT WlrH e
MAY OAMAGE SENDER
PRtHEAT ALL IETUIHS ARE rNROuGH ENGINE 8LOC
FOI WIRING or AUXILLAJY AlrEINArOS SEe nte FOLLOWING DIIiGRAUS
I ss MP 11232
START SWI MOTOROLA
EECE NEVillE
120 AMP I 1123 I
53 AUP cO
LEEceNEVilLE 105 AMP 1t4
IF ADOlrONAL PRESrllfE SWITCHeS AI RP TO srART
BOAr A LeXleJ HOSE Musr 8E RUN FloM
THE OIL PvcsSUR MANPOID To A NGAINY 8uLKHEAD AND
ALL PESSJg sWIFOIES MOUNTED AT TH
CAuTION
oe TIGHT WOUND ElECTRICAl
APPLY SILASTIC
TAPE AROUND CONNEcrORS THIS PRlKT IS PROTECTED BY A MAWUAL REUT
CLllr EJJEAJE LOCArD NEAR nlE SrArEI AND AS etos
TO He SOtlC OF CUIERENr AS passeLc
EACESSIVE CURrENr lIA ANYWHERE IN TH 5TPUMENr PANEL
WIRING O FNtiE W4 CIISE THE 8IEAKC TO TRIP IN TIIJ EllcNr
MOSr ENIiNE MQDlS WIl SHUT DOWN EJECAUsS rHE opeNED
I AK R DI CONNE ell J EL SUPPL HEvEFOtE nll
6UfLpEe OWNER Musr BE SUIE THAr TiS ttISnUMcNr PANEl
WIIlNG AND ENINE RE INJrALLlrD ro PIrVENr CONTACT
BETWeeN DIVtCt AND SALr WArelZ I
Il WESTERBEKE
I Engines Generators
63B63C MARINE ENGINES
WIRING DIAGRAM 039144
IIOR D
PMII
I T I U
12 vOC
AIlW
NOTE An onoff switch so
should be installed in this
circuit to disconnect the
starter from the battery in
an emergency and when
AUIM the boat Twelve C JUUO
PANEL
volt diesel engine draw 200 to 300
amps when cranking A I
switch with a of 175 amps at 12
VDC will normally serve
this junction but a switch
must never be used to
make the starter circuit
lOIn I
CAPTAIN
PANEL
r
I ell
t I I I I I
Il WESTERBEKE
I Engines Generators
63B63C MARINE ENGINES
WIRING SCHEMATIC 039144
It VDC HAlll
SOL
LIFT PUI4P
FUEL twtlU
NOII
ADMIRAL
TACNOMTU
PANEL
STAU
0 ALAIIM
GAUGE
GAUGE
CAPTAIN
PANEL
51 AMP ALTERNATOR PRESTOLITE 72 AMP ALT
STANOARD ALTERNATOR ON THE
c Iff n m n 114 BRN
114 GRA
t4 P NK
1 LT BL
UNIVERSAI PROPUlSION
PRESTOLITE 51 AMP AIT
fAT WESTERBEKE
r Engines Generators
W52 638 AND 63C ENGINE
ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming one bleed point
watercooled vertical inline overhead valve Fuel No2 diesel oil cetane rating of 45 or higher
mechanism 52 hp at 3000 rpm maximum Fuel Injection Pump Distributor Type VE Diesel KiKi Zexel
63 hp at 3600 rpm maximum
Fuel Injection Timing 0 TDC Top Dead 1348 cUin 221 Liter Nozzle Throttle
Naturally aspirated Fuel Filter Spinon Replaceable Centrifugal type
Air cleaner Metal screen type Chamber Swirl type
AirFlow 700 cfm 19 cmm
Bore Stroke 350 x 351 inches 889 x 891 mm engine Displacement 1348 cubic inches 221 Order 1342
ELECTRICAL of Rotation Clockwise when viewed from the front
Starting Battery 12Volt negative Ratio 21 1 Battery Capacity 400
600 Cold Cranking Amps Height 2493 inches 6332 mm DC Charging Alternator 51 Amp rated belt driven
Width 2263 inches 5746 mm Starter 12Volt reduction gear
Length 3875 inches 9843 mm
Starting Aid Glow plugs sheathed type
Weight 614 Ibs 2787 kgs
DC NoLoad Current 2 of rated Amps
Fuel Consumption 18 US gph 681 Iph at 2500 rpm
DC Cranking Current 280 Amps engine Continuous 15
Temporary 25 not to exceed 30 min
COOLING SYSTEM
Power Take Off 30 HP maximum Generator end
General Fresh watercooled block
controlled with heat exchanger
TUNEUP Operating Temperature 170 190 F 77 88 Pressure 427 psi 30 kgcm at 280 rpm limit
Fresh Water Pump Centrifugal type metal impeller 384 psi 27 kgcm Raw Water
Pump Positive displacement rubber Timing Intake Opens 17 BTDC
geardriven
Intake Closes 47 ABDC Raw Water Flow 60 US gpm 227 Ipm measured
Exhaust Opens 51 BBDC at 3600 rpm before discharging into exhaust elbow
Exhaust Closes 13 ATDC System Capacity 100 qts 946 liters
Spill Timing Static 1915 fresh water
Valve Seat Angle Intake 45
Exhaust 45 LUBRICATION SYSTEM
Engine Speed 1800 rpm 60 Hertz General Pressure fed system
1500 rpm 50 Hertz
Oil Filter Full flow paper element spinon type
Valve Clearance Intake 0012 inches 030 mm engine Exhaust 0012 inches 030
Sump Capacity 53 US qts 50 Pressure 1920 71 0 psi 135 5 0 kgcm2 not including filter plus
filtercooler Timing Static timed drop valve method 0205 005 in Operating Oil Pressure 50 65 psi 35 457 kgcm2
BTDC or 0 TDC 1 cylinder 1mm of cam lift engine hot
using measuring device for injection pump
Oil Grade API Specification CF or CG4
SAE 30 10W30 15W40
fATl WESTERBEKE
I Engines 8 Generators
GENERATOR OF ELECTRIC MOTORS Generator Frequency power required to start an electric motor is
considerably Frequency is a direct result of speed as
more than is required to keep it running after it is started indicated by the motors require much more current to start them than
o When the generator is run at 1800 RPM the AC Splitphase AC motors require more current to start output frequency is 60
Hertz
under similar than other types They are com
monly used on easystarting loads such as washing
o When the generator is run at 1500 RPM the AC voltage
output frequency is 50 or where loads are applied after the motor is
started such as small power tools Because they require 5 to Therefore to change the generators frequency the genera
7 times as much current to start as to run their use should be tors drive engines speed must be changed Along with a
avoided whenever possible if the electric motor is to be dri reconfiguring of the AC output connections at the by a small generator
Capacitor and a regulator board voltage output adjustment must also be
motors require from 2 to 4 times as much current to start as made See ELECTRONIC GOVERNOR in this manual
to run The current required to start any motor varies with the
load connected to it An electric motor connected to an air GENERATOR for example will require more current than a o
Maintaining reasonable cleanliness is to which no load is connected Connections of terminal boards and
rectifiers may become
In general the current required to start 115Volt motors connected corroded and insulation surfaces may start conducting if
to medium starting loads will be approximately as follows salts dust engine exhaust carbon etc are allowed to
build up Clogged ventilation openings may cause exces
MOTOR SIZE AMPS FOR AMPS FOR sive heating and reduced life of windings
HP RUNNING STARTING
AMPERES AMPERES o Inspect the exhaust elbow for corrosion and soot Check
16 32 64 to 224 the tightness of the mounting flange and exhaust mani
14 46 92 to 322 fold Inspect the exhaust hose and tighten the hose
13 52 104 to 728 clamps
144 to 292
102 204 to 408
o The drive discs on single bearing generators should be
checked periodically if possible for tightness of screws
1 13 26 to 52
and for any evidence of incipient cracking failure Discs
NOTE In the above table the maximum Amps for Starting is should not be allowed to become rusty because rust may
more for some small motors than for larger ones The reason accelerate cracking The bolts which fasten the drive disc
for this is that the hardest starting types splitphase are not to the generator shaft must be hardened steel SAE grade
made in larger sizes 8 identified by 6 radial marks one at each of the 6 cor
ners of the head
Because the heavy surge of current needed for is required for only an instant the generator will not
o The rear armature bearing is lubricated and sealed no
maintenance is required However if the bearing becomes
be damaged if it can bring the motor up to speed in a few
noisy or have it If difficulty is experienced in starting motors tum
off all other electrical loads and if possible reduce the load o Examine bearing at periodic intervals No side movement
on the electric motor of shaft should be detected when force is applied if side
motion is detectable bearings are wearing or wear on
Required Operating Speed shaft of bearing socket outside bearing has occurred
Run the generator first with no load applied then at half the Repair must be made quickly or major components capacity and finally
loaded to its full capacity as rub and cause major damage to on the generators dati plate The output voltage Carbon
Monoxide be checked periodically to ensure proper operation of
the generating plant and the appliances it supplies If an AC WESTERBEKE recommends mounting a or ampmeter is not installed to monitor
voltage and monoxide detector in the vessels living quarters Carbon
load check it with a portable meter and amp probe monoxide even in small amounts is deadly
NOTE When the vessel in which the generator is installed The presence of carbon momoxide indicates an AC equipment of 120 volts only
it is recommended leak from the engine or generator from the exhaust
that the generators AC terminal block be configured to pro elbowexhaust hose or that fumes from a nearby vessel
vide one 120 volt AC hot leg for the vessels distribution are entering your boat
panel This will ensure good motor starting response from If carbon monoxide is
present ventilate the area with clean
air and correct the problem Il WESTERBEKE
I Engines Generators
GENERATOR CONTROL PANEL 3 START The START toggle switch is a double pole single
throw switch The switch serves two purposes starting
This manually controlled series of WESTERBEKE marine
the engine and defeating of bypassing the engine oil pres
diesel generators is equipped with toggle switches on the
sure switch The defeat function turns on the fuel sole
engine control panel and optionally at remote panels The
noid instrument power and alternator instructions and methods of correcting minor prob
While the PREHEAT switch is still depressed apply only to such toggle switch controls
the START switch engages the start solenoid Panel
All three switches are momentary contact type and serve the power and the fuel solenoid will be activated When the
following functions engine begins to fire the START switch should be
1 PREHEAT The PREHEAT toggle switch is a double pole released The PREHEAT switch should not be released
single throw switch The switch serves two purposes pre until the oil pressure reaches alarm stops
heating the engine for easy starting and defeating of
bypassing the engine oil pressure switch The defeat func
NOTE When the engine is shut down the water tempera
tion turns on the fuel solenoid instrument power and ture gauge and the oil pressure gauge will continue to
register the last temperature and oil pressure readings
alternator excitation
displayed They will return to zero once electrical power
When the PREHEAT switch is depressed the voltmeter
is restored
panel lights gauges and meters and fuel solenoid will
activate The PREHEAT switch should be depressed for 4 EMERGENCY STOP The EMERGENCY stop switch at
twenty seconds the rear of the control box is normally closed When
2 STOP The STOP toggle switch is a single pole single depressed it will open the DC circuit to the control panel
throw normally closed switch The switch provides and shut the engine down As the switch is not toggled it
power to the fuel solenoid instrument cluster and alterna can be used when performing maintenance
tor excitation after the oil pressure switch has closed
upon starting Opening of this switch opens the power
REMOTE PANEL
circuit to the fuel solenoid stopping the flow of fuel to For remote operation of the generator system the same three
the engine and shuts down the engine switches are used The PREHEAT and START switches are
To stop the engine depress the STOP switch When the connected in parallel with the gauge panels switches and
STOP switch is depressed the power feed to the fuel serve the same functions as in the gauge panel The STOP
solenoid is opened and the fuel flow to the engine is switch is in series with the gauge panels STOP switch and
stopped The STOP switch should be depressed until the serves the same function
generator stops rotating
CONTROL PANEL 4
1 o o
2 0
STOP
RElEASE
STAHlER
START
3IJI MUST PRESS
PRESS 2ND
FIRST
a GENERATOR
0 0
REMOTE PANEL tJ WESTERBEKE
r Engines Generators
CONTROL PANEL MANUAL STARTER DISCONNECT TOGGLE SWITCHES
NOTE The engine control system is protected by a 20 amp manual reset circuit breaker
located on the engine as close as possible to the power source
Problem Probable Cause PREHEAT depressed no panel indications 1 Oil Pressure
switch 1 Check switches andor battery connections
electric fuel pump and preheat solenoid
not energized 2 20 amp circuit breaker tripped 2 Reset breaker If it opens again check preheat solenoid circuit
and run circuit for shorts to ground
START SWITCH DEPRESSED no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Faulty switch 2 Check switch with ohmmeter
3 Faulty solenoid 3 Check that 12 volts are present at the solenoid connection
4 Loose battery connections 4 Check battery connections
5 Low battery 5 Check battery charge state
ENGINE CRANKS does not start 1 Faulty fueling system 1 Check for fuel
2 Check for air in the fuel system 2 Allow system to bleed
3 Faulty fuel lift pump 3 Replace fuel lift pump
NOT CHARGING BATTERY 1 Faulty alternator drive 1 Check the drive belt and its tension Be sure the alternator
turns freely Check for loose connections Check the
output with a voltmeter Ensure 12V are present at the
regulator terminal
BATTERY RUNS DOWN 1 Oil pressure switch 1 Observe if the gauges and panel lights are activated when the
engine is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check the wiring Insert sensitive 025 amp meter in battery
lines Do NOT start engine Remove connections and replace
after short is located
3 Low resistance leak to ground 3 Check all wires for temperature rise to locate the fault
4 Faulty alternator 4 After a good battery charging disconnect alternator at output
If leakage stops Rernove alternator and bench test Repair or
replace
WATER TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the conduc
step is to check for 12 volts DC between the ignition B tor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the instru probably defective and should be panel energized and perform the
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this sit Check that the engine block is connected to the ground
uation Some starters have isolated ground terminals and if the bat
2 Remove the wire attached to the sender terminal at the tery is connected to the starter both plus and minus termi
gauge and connect it to ground See if the gauge reads full nals the ground side will not necessarily be connected to the
scale which is the normal reading for this situation block
lfATl WESTERBEKE
I Engines Generators
ELECTRONIC GOVERNOR KIT INSTALLATION
Model WTA WTF WMF Single and Three Phase Models
SENSOR
INSTALLATION INSTRUCTIONS DRILL HOLE
Injection Pump HOUSING
LOCKNUT
The injection pump governor spring must be changed to the FLYWHEEL ir t
propulsion style spring A propulsion spring is enclosed with TEETH I v v
this kit along with a new cover gasket
To change the governor spring remove the lock wire Sensor PN 039172
presently securing the throttle arm Remove the heavy duty
The sensor is installed in the bellhousing over the flywheel
throttle return spring that is attached to the throttle arm Do
teeth This is a small threaded device with a lock nut The
not remove the throttle arm from the splined shaft to do this
threads are 38 x 24 Use an R drill and a bottoming tap
just disconnect the spring so it has no effect on the arm
Be careful when drilling the hole not to put too much pres
Back off and remove the two throttle stop screws sure on the drill for when you go through the housing you do
There are four heavy duty slotted machine screws that secure not want to break the drill bit The hole for the sensor is
the pump cover to the pump housing Loosen and remove located on the bellhousing on the side opposite the starter
these four screws Lift the cover carefully It is positioned on motor at about 1000 oclock when you view the bellhousing
the housing by a dowel at one of the machine screw holes looking from the generator end In this area you will note a
The cover will move towards the engine bellhousing when raised area on the side of the bellhousing Measure in on this
lifted beyond the dowel due to tension from the throttle plate area from the flat surface of the bellhousing that mates
against the fuel screw in the cover against the engine block 1 114 inches and drill and tap a hole
Lift the cover up and back slightly to expose the governor as perpendicular to the flywheel as you can Once the hole is
spring The spring is connected between the control lever drilled look through the hole at the flywheel teeth and if
shackle and the idle spring pin With long thin needle nose needed turn the engine to position the teeth with the space in
pliers unhook the spring from the throttle shackle and lift the the middle of the hole This will allow the tap to go well
cover away through the hole to open the threads up Once the hole is
tapped turn the engine by hand to position the flat of one of
Remove the other end of the governor spring from the idle the flywheel teeth in the middle of the hole Thread the sen
spring pin Take care that this pin and spring do not fallout sor into the hole it should thread smoothly until it touches
of the plate and into the pump With the cover in hand the flat on the flywheel tooth Then back it out 112 34 of a
inspect the gasket in the cover recess A replacement is with turn and secure it in position with the lock nut This will
the kit Replace the gasket Install the gasket so it sits position the end of the sensor approximately 0030 inches
squarely in the recess and that it is not twisted otherwise a away from the flats of the ring gear teeth
leak will result once installed and the pump is primed with
diesel Connect the replacement governor spring propulsion NOTE To ensure the sensor is positioned correctly slowly
to this idle spring pin and the other end to the throttle rotate the crankshaft 360 0 by hand and assure there is no
shackle Take care not to stretch the spring Position the cover physical contact between the sensor and the ring gear teeth
on the pump with the fuel screw against the connector lever If contact is felt between the sensor and the flywheel teeth
and move the cover towards the front of the engine slightly remove the sensor and repeat the above procedures
until the dowel tits and seats in the machine screw hole Hold
the cover in position and install the machine screws securely NOTE This sensor has a grey covering on it and two connec
tion points on the terminal block Note the connection points
when you remove the sensor to install it
OVERFLOW VALVE
Actuator PN 303007
CONTROL LEVER
The actuator is already mounted on a bracket This bracket
mounts on the front gear case cover on the two studs sticking
out of the cover Remove the nuts and lock washers LEVER SHAFT on the studs and slide the bracket on
with the arm and link
age towards to injection pump The bolt with spacer will
attach to the outer hole of the throttle arm Connect the
SHACKLE LEVER bracket and spacer from the actuator
swivel to the outer hole
1 of the throttle arm When connected the throttle levers idle
stop should almost be touching the open boss where the idle
stop screw was removed
NOTE Ensure that the return spring for the throttle arm is
disconnected because it applies too much tension on the
TYPE VE INJECTION PUMP throttle arm and the actuator cannot work against it Do not
remove the throttle arm from the throttle shaft to do this
II WESTERBEKE
I Engines Generators
ELECTRONIC GOVERNOR KIT INSTALLATION
Model WTA WTF WMF Single and Three Phase PN 303008 Cl
TB2 TO lOA CIRCUIT
The controller and tenninal board can be mounted in the con BREAKER
trol panel box Use the controller and tenninal block as a
template to mark mounting holes on the outside of the panel
box to be drilled then mount the components on the inside of
RELAY
WIRING
the box
If you need to remove wire connections from the terminal 114 RED
block note their position for correct A draw
ing of the wire positions on the tenninal block is attached
12VDC Wires to the Controller 30 81
There is a red positive wire and a black negative wire for
12VDC to the controller These are tagged and marked They TOTB31 1114 RED
should be attached on the positive and negative side of the Preparation to Start
panels DC volt meter
Push the exciter circuit breaker so it will pop out This is
NOTE The controller operates on 12VDC The voltage range located on the side of the control panel box on the generator
is 20 96 VDC 12VDC 144VDC Ifvoltage varies This will eliminate AC output from the generator other than
above or below these ranges the controller will not operate residual voltage The controller in the control panel has two
and the engine will run in an idle mode until proper voltage adjustment pods You need a mini screw driver to adjust
is supplied to the controller these One is speed and the other gain These are noted on
the drawing of the controller
When you press the preheat switch the actuator linkage
attached to the throttle arm of the injection pump should
move outward towards the injection pump and return back
KEEP ACTUATOR
into the actuator in a quick motion
LINKAGE WELL Start the engine The speed should be in the low idle range
LUBRICATED
600700 rpm If the engine speed is higher than this idle
range shut the engine down Check the linkage between the
actuator and throttle arm The throttle arm stop should be
about touching the open idle stop screw boss Adjust the link
age to position the throttle lever The controller has an adjust
ment screw for speed adjustment Turn this screw outward
counter clockwise a few turns Restart the engine
NOTE If there is any oscillating of the actuator linkage pro
ducing hunting adjust the gain towards zero 0 until this
hunting is removed
Increase the engine speed slowly with the speed CONTROllER screw turning it inward clockwise In some
instances this
screw may need to be turned 610 turns before an increase in
engine speed is noted Bring the engine speed to 1800 rpm
60 Hz 1500 rpm 50 Hz Momentarily push the actuator
linkage towards the actuator and release The actuator should
quickly regain proper speed If there is any hunting adjust the
gain towards zero 0 until this hunting is removed
When the gain is adjusted you may need to readjust the
speed at no load shut the generator down
Push the DC exciter circuit breaker in Start the generator
Check speed Hertz set at 60 Hz
Load the generator
If the governor is slow to react and maintain 60 Hertz adjust
the gain clockwise Again you may need to adjust the speed
at no load
You will find the governor will maintain 60 05 Hertz right
up to the full rated amperage output for the generator
IVVI WESTERBEKE
I Engines Generators
ELECTRONIC GOVERNOR
Electronic Governor System Calibration
The system is composed of three basic components 1 With no power to the governor adjust the GAIN to 900
1 Controller Mounted in the instrument panel oclock
2 Sensor Installed on the bellhousing over the flywheel 2 Start the engine and adjust the speed by turning the speed
ring gear pot clockwise to desired speed
3 Actuator Mounted at the front of the engine and NOTE Controllers are factory adjusted to minimum rpm
attached with linkage to the throttle arm of the injection However for safety one should be capable of disabling
pump the engine if an overspeed should exist
3 At noload turn the GAIN potentiometer clockwise until
Controller Adjustment the engine begins to hunt if the engine does not hunt
1 Speed This adjustment is used to raise or lower the physically upset the governor linkage
engines speed to the desired hertz 4 Turn the GAIN potentiometer 2 Gain This adjustment affects the reaction time of
the until stable
actuator to the load changes
SENSOR
NOTE A high gain adjustment can induce an oscillating
of the actuator producing a hunting mode In such cases
lessen the gain
FLYWHEEL HOUSING
SPEED m
GAIN iJ
KEEP ACTUATOR
LINKAGE WELL
LINEAR ACTUATOR
TO ELECTRONIC
SENSOR CONTROLLER
PV 039172
TO 14 1 RED I
ELECTRONIC GOVERNOR TERMINAL
LINEAR
BOARD1 14 BLACK
BLACK I
ACTUATOR BLACKIWHITE I
SHIELDED T8 GOVERNOR
Til SENSOR CABLE WHITE CONTROL
TO LINEAR ACTUATOR
114 PURPLE
PURPLE
PURPLE j
TERMINAL BOARD 3
IJ WESTERBEKE
rEngines Generators
THE ELECTRONIC GOVERNOR
Problem Probable Cause appears dead 1 Low battery voltage at
controller 1 Check wiring for cause Check battery state of runs at idle
2 Stuck linkage 12 Lubricate free up linkage between controller and throttle arm
3 No signal or weak signal from sensor 3 Check for improperly installed or damaged sensor in flywheel
Measure AC voltage from sensor while housing Replace or adjust
engine is running at idle Voltage should
be 25 volts or greater
4 Check Actuator depress PREHEAT and
check for battery voltage between
negative black lead at terminal block
a Purple lead to black 4 Replace controller if battery voltage is not present at both
leads
b Second purple to black
5 Perform the following check between
terminals at the actuator and the negative
DC lead at the controller terminal block
Preheat depressed
a Low voltage 12020 VDC at either a Broken actuator lead
actuator connection
b Battery voltage at both actuator b Broken actuator lead
connections
c Battery voltage at one actuator lead c Replace the actuator
but not the fully extends when PREHEAT 1 Check controller Lift one of the purple
is depressed and stays extended actuator leads from the terminal block
Depress PREHEAT
a Actuator fully extends a Short in lead to actuator
b Actuator does not fully extend and b Replace controller
connections
NOTE Release PREHEAT and reconnect
the purple hunts oscillates and 1 Linkage between actuator and throttle 1 running binding
2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the Controller
controller
3 Inadequate DC power supply to
controller complete the following tests
Connect a DC voltmeter across the
plus and negative leads at the
controller terminal block
Lift both purple leads from the
terminal block
Connect one purple lead to the
Cplus terminal and the other to the
DC negative
Momentarily depress PREHEAT
The actuator should fully extend 3 If actuator does not fully extend check the actuator leads
If the voltage is less than specified check for loose or poor
connections low battery voltage voltage drop in DC circuit
due to remote panel installation and small wire sizes making
connections
DC voltage registering on the meter should be
12 VDC System 96 VDC or higher
24 VDC System 192 VDC or higher
NOTE Reconnect actuator leads properly after making this test
3a Sensor positioned marginally too far 3a Check the position of the sensor
away from flywheel teeth giving
erratic signal voltage to II WESTERBEKE
I Engines Generators
WMF ELECTRONIC REGULATED BRUSH LESS Brushless Rotating Field
Speed 60Hz 1800 rpm
50Hz 1500 rpm
Cooling Fan cooled
Max Ambient Temp 40 degrees C
Insulation Class H
NOTE If the generator is operated at 1500 rpm the voltage
and kW rating will be 56 of the 1800 rpm rating Consult if a higher voltage or kW rating is required at
50 Hz 1500 reinstalling the generator the generator must be
mounted securely Use shims as necessary under the genera
tor feet to ensure the feet are uniformly supported the holddown bolts If the generator is not uni MOUNTING BOLT
formly supported the frame could become distorted resulting
in noise and vibration that could damage the generator 9 After the armature is removed the rotor shaft and drive
disk assembly can be pulled from the frame
EXCITER ARMATURE DRIVE
A CAUTION Do not scratch or cut the copper stator
windings when removing rotor
10 DO NOT LOSE the bearing anchor when the bearing is
removed from exciter end bracket
11 Bolt the rotor and drive disk to the engine flywheel using
the proper size lock washers and SAE grade 8 bolts
12 Push the generator frame assembly carefully back over
the rotor Replace the bearing anchor and carefully align
the groove in the bearing with the bearing anchor before
the bearing enters the bearing bracket
13 Mount the frame assembly to the engine flywheel hous
ing with the proper size bolts lock washers and nut
FAN COVER 14 Remount the fan cover and hood
ROTOR SHAFT 15 To reassemble the exciter armature pull the rotor leads
through the opening in the armature spider Tum Mounting armature until it slips over the pins in
the shaft
To mount a generator to an engine Follow below
1 Disconnect the positive terminal from battery
IA CAUTION Do not pinch rotor leads
2 Place a jack or other support under the engine flywheel
3 Remove the pot cover or control box cover from the back ROTOR ASSEMLY
of the generator and disconnect all incoming power leads
4 Detach the ground lead Q and R lead from the BALL BEARING
rotor on the exciter armature RETAINING
RING
5 Remove the armature fastening bolt from the center of the
shaft mark the position of the armature so it can be
replaced in the same position
6 Remove the armature from the shaft take care not to
BEARING ANCHOR BEARING GROVE
damage the Remove the fan cover EXCITER END
BRACKET
S Use a strap around the generator rotor and shaft assembly
and support from hoist
II WESTERBEKE
I Engines Generators
WMF ELECTRONIC REGULATED BRUSHLESS GENERATOR
16 Reassemble the armature to the shaft with the bolt and Examine ratings and actual load applied to determine if the
lock washer using LOCTITE Use a 916 socket on the generator rating may be too low for the load applied
torque wrench and torque to 25 ft lb The ambient temperature must not exceed 104F40C For
17 Reconnect the Q and R leads to the proper connec operation at ambient temperatures above 104F40C derate
tions kW rating 1 percent for each degree C above 40C
For operations at high altitudes ratings must be derated 2
18 Reconnect all incoming power leads to their proper con percent for each 1000 ft above sea level
nections as shown on the wiring diagram Frame temperatures above 140F 60C are too high and
19 Return pot cover or control box cover indicate a temperature rise in the copper windings of 221F
20 Remove the jack support from under engine flywheel lOSOC or higher
housing
Ie l
21 Reconnect the positive battery HZ
ELECTRONIC VOLTAGE REGULATOR E1
Electrical Connections VOLTAGE F
i The proper electrical connections required for your Single REGULATOR VAR
Phase or Three Phase generator can be found on the VAR
ADJUST I
SCHEMATIC WIRING DIAGRAM J
NOTE Be sure all electrical connections are correct before ELECTRONIC REGULATION
starting the generator An regulated generator has superior voltage
regulation than other types 2 within rated loads
Initial Startup The electronic voltage regulator regulates the voltage using a
Carefully inspect the unit before startup Check all electrical solidstate electronic circuit of transistors integrated circuits
connections and be sure that all bolts have been securely SCRs resistors etc The electronic voltage regulator senses
mounted the generator voltage and feeds a DC currentinto the exciter
field of the proper average value to hold the generator voltage
1 Rotate the shaft by turning the armature bolt the shaft
constant from noload to full rated load and above
and rotor assembly are balanced and should turn freely
2 Start engine eD
3 Check vibration If excessive check all mechanical J con I I
nections 100
I I
The generator voltage is adjusted at the factory to a specified I II II I
speed however verify upon installation To supply 60 Hz eo I 50Hy I
the speed should be 1800 to 1860 rpm at no load and should I 7 I
not fall below 1800 rpm by more than one percent at full I 1 I I I
load To supply 50 Hz the speed should be 1500 to 1550 rpm
at no load and 1500 rpm at full load The generator voltage
I lL1610Hz
rI Ii I
should build to its rated value within 5 seconds after rated 40
II I
speed is attained If voltage does not build the cause may be
I I I
loss of residual magnetism in the exciter field due to 1V V I I I
improper installation See the section
of this manual for more information To ensure that the gen
ff I I I
erator voltage will always build the generator should operate FREQUENCY
VI 0
I 10
I 20 O 40 50
bO 70 80
at full load before being installed in service RPM 900 200 1500 1800
Observe and record the generator voltage at no load and at LOAD FREQUENCY CHART
full load Immediately after startup cold and after 30 min
utes of full load hot The voltage is easily adjusted to opti
mum values at no load and full load See the ELECTRONIC of the 34615 Regulator
REGULATION section Test at actual load if possible If the 1 Overload Protection
voltage cannot be adjusted refer to the To prevent damage to devices receiving electrical power
section of this manual from the generator The regulator provides both under
Check the temperature rise after running for 30 minutes at load frequency and over load protection The voltage reg
full load If excessive examine the generator for obstructed ulator operates at 50 Hz or 60 Hz or both If the fre
air flow hot air feeding into the inlet of the generator or quency and engine speed falls below the rated value the
bypassed air air not pulled through generator because of air generator voltage decreases to provide under frequency
opening into unbaffled fan at engine side of generator fan protection but if the engine is over the speed required to
give 50 Hz or 50 Hz the voltage does not rise above that
value set at the proper frequency proper engine speed
rfIVl WESTERBEKE
I Engines Generators
WMF ELECTRONIC REGULATED BRUSHLESS GENERATOR
2 AC Power Input All EVRs must supply up to 4 amperes of DC output
This section is intended to help the user isolate the cause of
current into the exciter field at a voltage up to 70 volts
the most common generator DC This voltage and current constitutes a power output
of about 280 watts This output power must come from
the generator The exciter field input power must be sup Visual Examination
plied at 190 to 240 volts AC at a voltampere burden of Inspect the generator visually Look for obvious evidence burned
500 VA maximum areas pinched wires cracked insulation all connections should
When the generator is operated at 208 volts to 240 volts be fastened securely Check the operating speed and see that
this power comes from the generator load lines When the unit has been reassembled and reconnected correctly
generator is connected to deliver 120 volts a separate
winding in the stator provides 208 to 240 volts for the Very Low Voltage Output or No Voltage Buildup
voltage regulator power input When a generator delivers
1 Loose or Broken Lead wires
390 volts to 480 volts center taps on the phase windings
Check lead wires and connections Tighten securely
provide 190 volts to 240 volts for both voltage sensing
Compare connections with the wiring diagram supplied
and power input for the exciter field The AC power input
with unit
always has one tenninal common with one of the sensing
voltage tenninals This common lead is identified by the 2 Rotor Opened or Shorted
lead or tenninallabel 4 in the drawing below Measure the resistance between R and Q leads
see chart for normal ohm ratings
VOLTAGE REGULATOR
3 Stator Ground or Shorted
Run the generator for 5 minutes
I Stop immediately if smoke or a hot smell is detected
If the voltage does not build and the generator is hot
4 3 E1t
there is a short circuit in the stator windings Examine the
stator for burned insulation
DO NOT REMOVE from the frame
Measure stator resistance Tl and T2 and from T3 to T4
each should have equal resistance See WIRING
SCHEMATICS Disconnect leads at the tenninal board
JOIN BOTH and measure
HZ LEADS FOR
E1 50Hz If one of the voltage readings is lower than the other the
VOLTAGE REGULATOR F3 low voltage winding is shorted Replace stator
F 4 Exciter Field Opened or
VARI Measure the resistance at 77 degrees F see GENERA
VARI TOR RESISTANCE VALUES for normal ohm ratings
5 Defective Diodes in the Armature See Section 10
6 Defective Voltage Regulator See Section 9
3 DC Output Power for the Exciter Field
The EVR rectifies the AC power input with a full wave
rectifier to provide DC current a series of half sine
High Voltage Output
waves with a high ripple content at a frequency of 120 1 Defective 165K ohm Resistor on 1201240 volts only
Hz This DC current is fed to the exciter field through one Test and replace if necessary
or two SCRs to provide a pulsed output in one direction 2 Defective Electronic Regulator Replace do not flash
only The resistance and impedance within the regulator is
very low and the peak value of the current into the exciter Voltage Builds But Oscillates Excessively
field is limited only by the impedance and resistance of
the exciter field For this reason the exciter fields must 1 Defective Electronic Regulator
have a minimum specified resistance or the peak current
delivered by the regulator will be so high that the regula Generator Resistance Values
tor components will be damaged The regulator is com Armature 470 520 ohms per phase 5 10 kW
monly designed for a minimurn exciter field resistance of 655 720 ohms per phase 125 50 kW
20 ohms 8lOkW 25 ohms 1250kW although some Field 18 22 ohms 5 10 kW
times a slightly lower resistance can be tolerated 23 28 ohms 125 50 kW
Connections to the exciter field are made at two DC out Stator ohms vary with XW rating
put tenninals F and F but less than 10 ohm per phase
Rotor
kWs 8 10 125 15 175 20 25 30 to 50
ohms 1147 158 173 184 200 21 22 25 to 38
rflVl WESTERBEKE
I Engines Generators
WMF ELECTRONIC REGULATED BRUSHLESS GENERATOR
Flashing The Field WMF GENERATORS
EXCITER ROTORS
To detennine if the regulator is defective disconnect unncn MODELS
the F and c leads from the exciter field and open the THREE POSITIVE
DIODES 1139772
circuit in lead 3 or 4 to the regulator Using a
12 volt battery connect the battery to the regulator
3F Connect the battery to the regulator F THREE NEGATIVE
Run generator at 1800 rpm See WIRING SCHEMATICS DIODES 1139773
1 If the residual voltage is now nOTIllal the electronic
regulator is defective and must be replaced ROTOR fIIL
1137128
2 If there is no voltage check the exciter field
3 If the voltage reading differs from what would be a nor
mal reading the electronic regulator is working properly
and the problem is elsewhere
Return to the section
Checking Diodes In The Armature
All Fidelity Electric annatures have 6 diode rectifiers
arranged in a full wave pattern Three forward biased diodes
are mounted on a heat sink and three reversed biased diodes
mounted on the annature hub
5 Disconnect tenninals to each diode Check the Forward
1 Use a Basic Analog ohmmeter and set to R1 scale Biased Diode FWD group first 3 diodes on heat sink
ohmmeter leads red black ohmmeter lead to R tenninal on annature hub
2 Check the diodes as a group with the following connec ohmmeter lead to the on diode indicated by red dot
tions 6 Check for leakage in each diode by reversing polarity
ohmmeter lead to R tenninal on annature hub Resistance infinite
ohmmeter lead to Q ground
Diodes are good if the resistance reading is approxi 7 Check Reversed Biased Diode RVS group
mately 50 ohms ohmmeter lead to Q ground on annature hub
ohmmeter lead to the on each diode
3 Check for leakage in the diodes by reversing their polar Resistance infinite
ity Diodes are good if the resistance reading is infinite
8 Check for leakage in each diode by reversing polarity
4 Resistance values other than those indicated suggest one Resistance 10 ohms
or more faulty diodes Check each diode separately to
isolate the defective diode NOTE Resistance values other than those indicated
means that the diode is defective Replace the defective
diode and reconnect terminals to each diode
Maintenance and Repair
1 Periodic Cleaning and Inspection
Clean and inspect the generator every 200 hours of nor
mal operating time If the generator is housed in a harsh
environment clean and inspect more frequently If dirt and
grease is allowed to buildup the generator will run hot
ter loose efficiency and reduce the life of the generator
2 Cleaning
Remove all dust dirt oil and grease buildup from all
external surfaces Use a low pressure air hose 25 PSI
maximum to blow dirt and grease from the internal com
ponents through the fan opening Clean inside the control
box Check for loose or damaged lead wires and loose
components mounted in the box Do not remove internal
generator parts or the warranty is void
AC RECTIFIERS 3 Inspection
DCAC With the pot cover or control box cover removed exam
WMF ine rotor shaft and bearing for excessive wear ROTORS RedDot
EARLIER MODELS bearings after 10000 hours of nOTIllal operating time or
ACDC sooner if wear is evident
AC III WESTERBEKE
I Engines Generators
WMF GENERATOR WIRING SCHEMATICS
i0T Main field
1
ll Go 120V G G
I
lm
51010
Excite
Armaure
Two3PH fW
CIllI H
t 1
Gi 24 0v
120v
n F
W leadtie up or tape 00 connection
with olectronlc rogulalor
1I0T
Wlead lie up or lope no
connoction with olochonlc
Single Phase 4 Lead Yellow
regUlator
Electronic Regulation
I J
120240V Connections Exclle lIold
1 Cut Hzjumperfor 60 Hz

Leave intact for 50 Hz
J
2 Remove resistor when o
wired for 120V output 120240 Voll
Connoct Iogelbor
120 Voll
andhp
OJ 0 T4
E4 0
ELECTRONIC I
VOLTAGE
REGULATOR f1
VAn 1
VARI
Single Phase 4 Lead o o
Electronic Regulation Vollage Adjustment
If no terminal boofd
boll loads and lape
220V Connections
Connecl grounds 85
shown
1 Join both leads together for 50 Hz
PH I t A t i
I I I
220Yolt
l e YLl
Single Phase
Electronic Regulation
120V Connections
WI d U up or tp no connection
c F
L oQ with electronic regUlator
Q Y HOT
Ellcltr field EF1

Exciter field
o E4 may be ab nt
220 Volt
4
o o
L3 TO
L1 Hot
o Tl ELECTRONIC
o o
VOLTAGE
II no erminal boarG
bolt dl end tape
REGULATOR
Voltage Adj tmnt l
BehiMl egulator Board
Connect grouftds a
ahowft
o
o o
II WESTERBEKE Voltage Adjustmpnt
I Engines Generators
WMF GENERATOR WIRING DIAGRAMS 40438
12 VDC
L I
BATTERY
SWITCH
nARTER
SOLENOID STARTER
m 1 l 4
run SQINQID
I
ALTRHATOR
IiTl
I
Iii I 1 r I
tREREAT
SOLENOID
r alOWflues
i

I l I
fiGzo
r6 10 AMP
IIJ CIRCUIT
g
i
I
BATTERY SfITCH ICIRCUIT
BRUKER
L r BRUKU
I fl
12 VDC I
WATER TENP
SWITCH SWITCH
OIlll1l
UQUllt
START
fUEL PUNP
IU
SWITCH
fUEL SOLENO I D
11
I
GAUGr
i
CCa
14atl
GENERATOR I
z
120240 VAt I PHASE
I WAUl OIL
Urb UI
ElliE
10lRNOR
I RElAY
I r I I cI
CIRCUIT
IIREAKER
2S A
011
GOo crUTO
MAGNETIC PICKuP
OVERO
COOllER
ELECTRONIC
grlU
i rES I
I GOVERNOR SYSTEM
I I
86 85
rI OPTIONAL
cur feR I
I I I I
iNiT fOR J J
I
UtJ I
L I
I 1411 I
I I
I
I vaT I
I
WTA GENERATORS SINGLE AND THREE Output Voltage WTA generator is a brushless selfexcited
type requiring There are no setup adjustments for the generator However if
only driving force the value of the output voltage is inconsistent with given spe
One pennanent magnet in the six pole exciter stator is cific requirements it may be adjusted over a narrow for the selfexciting
feature of the alternator Its range and will not nonnally require field causes a voltage to be induced into the associ To adjust
the output voltage remove the cover from the con
ated exciter rotor coils during rotation This AC voltage is full trol box and locate the voltage setting control Using an insu
wave rectified and applied to the main rotating field coil The lated tool operate this control to obtain the desired field induces an
alternating voltage voltage Right hand rotation of this control increases the out
into the associated main stator coils and a resulting current put voltage
will flow to the output terminals VOLTAGE an auxiliary coil on the main stator
generates
an AC voltage which is full wave rectified and employed as a
source of supply for the remaining five on the exciter stator The voltage regulator controls the
CMIOO
current to these poles regulating the voltage
D oceJ
1 The generator air intake and exhaust airways must be
kept free of obstructions If the flow of cooling intake air
or heated exhaust air is inhibited eventual generator over
11 Ir
heating and subsequent failure of the generator may
VOLTAGE REGULATOR BOARDS
occur
2 Care should be exercised when installing the electrical
connections to the generator output to avoid damaging
the voltage regulating circuits found in the control box
Refer to the generator control diagrams
A WARNING Terminals and components carrying line
voltage may be exposed within the control box and volt
age regulating circuits when the generator is Therefore the use of tools is
essential
1 Do not exceed the maximum generator shaft speed of for safety reasons Only qualified electricians or persons
2200 rpm as pennanent generator damage may result
thoroughly familiar with electrical equipment should
2 If there are unusual noises from the generator at any time attempt this adjustment
during its operation shut it down and check for internal
mechanical wear andor damage
The generator is virtually maintenance free Periodic
3 For the protection of line frequency sensitive loads that inspection is suggested to assure the generator airways
may be connected to the generator only operate at a gen do not become obstructed
erator shaft speed of 1800 rpm 60 Hz
These generators are classified as drip proof The air intake
and outlets are covered with an expanded metal screen to
protect against the ingestion of airborne litter Do not operate
the generator without these screens in place
11 WESTERBEKE
I Engines Generators
WTA GENERATOR Bring basic repair parts with you on the initial trip to the
problem equipment such as a regulator board housing diode
The following text is designed to give insight into problems
and bridge rectifier so that if the problem should be found in
which may be encountered with the WESTERBEKE WTA
one of these easily replaceable parts the problem can be
brushless generators Owing to the simplicity of the equip
remedied early and and controls is relatively easy once between cause and effect is understood Should a situation arise where the
generator fails to operate
properly and all mechanical conditions are found to be satis
Keep in mind that basic fundamental knowledge of electricity
factory refer to ELECTRICAL FAULT ANALYSIS
is required for this and always remember that
lethal voltages are present in the circuitry and caution is essential when working on or trouble Replacing the Shaft Mounted a
generator 1 Remove the hole cover on top of the antidrive end of the
Only a few basic tools are necessary for diagnosis and repair are hand tools an amp probe and a quality voltohm 2 Crank the
engine until the rectifier comes into view and
meter capable of reading less than one ohm due to the preci lock it to prevent the engine from turning the shaft
sion required in reading component winding resistances 3 Unsolder the four wires from the attempting repair get as clear an
explanation of the 4 Remove the rectifier by unscrewing in a as possible preferably from an individual witness wise direction
then follow the testing and the problem In some cases this may bring to light a procedures described in GENERATOR which is related
to the method of operation rather
than equipment fault 5 Replace or reinstall the rectifier by reversing the above
THE RECTIFIER USING RECTIFIER ACCESS HOLE
HEATSINK COMPOUND DC 340
OR EQUIVALENT TIGHTEN TO
A TORQUE OF 30 INCH POUNDS
BEND THE TERMINAL TO CLEAR
THE GENERATOR RED SPOT
RECTIFIER OUTPUT
THE RECTIFIER OUTPUT LEAD
HAS A TWIN SOLID MAGNET
WIRE AND TAN COLORED
INSULATION SLEEVE AND
SHOWS A LOW ELECTRICAL
RESISTANCE WHEN MEASURED
TO THE SHAFT
rvvl WESTERBEKE
I Engines Generators
WTA GENERATOR for Overload NOTE F3 and F4 are tied
together with the butt
1 Check the generator data plate and load the generator per connector in a harness from the
generator to the control
the data plate Monitor the load with an amprobe clipped panel Al and A2 are accessible only at
diodes located in
to output leads of the generator the generator housing F1 black is a
16 wire connected
to a ground stud 3 white is a 16 wire which originates
at the regulator plug and connects to the ground stud
Field voltage supplied to the exciter field via the voltage reg
ulator will always be greater in an overload condition than in
nonnal operating conditions When only a small difference or
no difference between the auxiliary voltage pin 2 and the
exciter field voltage pin 1 is found it could be an indica
tion of a generator overload On a fully loaded generator
nonnal auxiliary voltage is between 2729 volts DC and nor
mal exciter field voltage is between 1520 volts DC
The DC voltage measurements being discussed here are the
simplest indication although not completely accurate that a
low level power factor overload motor load is present The
2 If an amprobe isnt available the generator load can be low power factor motor load portion of
the load is not felt
checked for possible overload with a voltage regulator by the engine and is indicated only
partially in output current
boardfield saturation check but is indicated clearly and relative to
rotor current by mea
suring the exciter field voltage
1 STEPONE
Measure the auxiliary voltage of the loaded alternator
R15R17 Place the plus of the meter DC scale 50 volts to the gen
CR4o P2 5 erator case or common ground stud and the negative to
point A on the regulator board refer to the c W4
or Pin 2 of the plug This voltage
5R19 0
DC at rated fullload should be approximately 2729
CAS Y aD
volts
STEP TWO
Measure the field voltage of the loaded alternator Check
4 aD
R R1D P1 0
the voltage between the plus lead remaining as ground
on the generator case or the common ground stud and
POINT A c
nL 0 1 lZY place the negative lead on one of the screws Point B hold
J 0 VOLTAGE ADJ
COURSE
0 ing Q3 or Q4 to the heatsink on the regulator board or
Pin 1 of the plug This voltage DC
EARLY MODEL REGULATOR BOARD CURRENT REGULATOR BOARD should read between 1720 volts DC
at full rated load on
With the generator loaded and displaying low voltage the generator
symptoms check the DC voltage present in the field cir NOTE If removal of the load corrects the
voltage prob
cuit for a possible indication of generator overload when lem an overload or a problem in the
load is likely to be
an amprobe or ampmeter for the system is not available the problem
or suspect for inaccuracy
I For a better understanding of this check refer also to the
MEASURING POINTS
generator internal schematic
FOR AUXILUARY VOLTAGE OC
INTERNAL WIRING SCHEMATIC
iEXCITER ROTOR l r PERMANENT MAGNET
I I I 3
I II MEASURING POINTS
I I GROUND
EXCITER FIELD VOLTAGE DC
I TO CASE
I I
I I 1 BUTT CONNECTOR
T41tc11
L J
MAIN STATOR
I
J ltJ
EXCITER STATOR
fAT1 WESTERBEKE
I Engines Generators
WTA GENERATOR Voltage adjustment are located on the Restart the unit and check for balanced voltages off all main
early and present regulator boards Refer to the diagram for output leads Tl T2 and T3 T4 120 volts AC for each
locations These allow for a noload voltage pair Unbalanced voltages indicate a problem within for the rated voltage A e of the generator
main stator output leads or connections Check 60 Hertz The potentiometer adjusters should be values and tighten connections as
needed
used to adjust to these exact voltages The regulator board
should maintain this voltage within 2 from noload to Residual Voltage
This refers to the measurement of auxiliary and main output
Check for underspeed condition at a full rated load The voltages while the generator is operating with the pump governor should maintain
engine rpm and disconnected and is under the influence of its internal frequency to 2 Should the frequency drop as nent
magnets only Comparison of residual voltages to the
the load is being applied this may be an indication of conta voltages attained while flashing the exciter field see or poor quality fuel
clogged filters air or faulty ING THE FIELD can give valuable insight in pump governor Check system as needed Running ing a
defective generator
at less than rated speed can damage electrical loads Main output residual voltages are best measured as for an unbalanced load being
taken off the generator groups of coils Tl and T2 T3 and T4 the 120 volt leads
output leads Noload being taken off the sensedlead Tl This avoids the possibility of mistaking an open coil as no
with the unsensed T4 line loaded would show as a low output for both on the loaded un sensed line T4 1 With
the generator stopped unplug the regulator board
NOTE Generator output voltage is sensed off output lead and expose the two generator output lines Tl and T4 so
T1 through Pin 4 on the plug to ground that measurements can be read from them
The regulator senses 120 volts only Start the generator and measure the AC voltage found
between leads Tl T2 and T3 T4 This should be 25
If no problems are found to this point disconnect the load 35 volts AC between each of these two pairs of leads with
from the generator and measure the residual voltage output of no load on the generator This is best done right at the output lead at the
2 Measure auxiliary voltage next Measure DC Try to insure that no load is on the generator Any
between Pin 2 plug and the breaker or ship to shore switch between the generator
This voltage should be between 5 6 volts DC noload
and load must be open
on the generator If access to the diodes in the Voltages Regulator board plugged in housing is available measure directly at
each diode to the
Model NoLoad FullLoad generator case ground Measure the AC voltage across
WfA15 Measured between Aux diodes 39a VAC 405 VAC the diodes AI and A2 This should be 10 12 volts AC
Measured Aux Diode to ground 265 VDC 275 VDC
5OOE
CONTROL PANEL
VOLTAGE REGULATOR BOARDS
SHOWN WIRED FOR
120240 VOLT OUTPUT
GROUNO
WTA GENERATOR I
I
TO CASE i EXCITER ROTa l IC PERMANENT MAGNET
T11 I I I 3
T2 I
I I
I GROUND
j TO CASE
I I tl
I i
I F4 BUTT CONNECTOR
I I I I
L I I I F2 I
MAIN STATOR L J Lt J
EXCITER Low Voltage 5070 Volts NOTE This check does not draw reference to the possibil
ity of one diode being open these diodes are in stator residual voltage check indicates a voltage 50 70 volts AC measured between T1 T4 or
therefore if this check does not show any problems it is
best to check the diodes individually with their leads
25 35 volts AC measured between T1 T2 and T3 T4
This indicates that a fault is preventing the energizing of
the stationary exciter field and that only the permanent If continuity is indicated both ways or not at all you
magnets in the stationary exciter field are having an effect should check the diodes individually by unsoldering the
on voltage output from the generators rotating parts lead Al and A2 at the diodes Also check the resistance
values of the auxiliary coil windings AI A2
NOTE F3 and F4 are tied together with a butt connector A2 A3AI A3
in harness from the generator to the control panel A1
and A2 are accessible only at the diodes located in the NOTE A chart of complete resistance values for the WTA
generator housing F1 black is a 16 wire connected to 15 kW 20 kW and 25 kW generators both early and late
the ground stud 3 is a white 16 wire from the regulator models is found at the end of this text Check the resis
plug connected to the ground stud tance of these auxiliary coil windings by placing your
ohmmeter leads between Points A1 A2 A2 A3
2 Check continuity and resistance of the field windings andA1 A3
between FI and F2 in the exciter stator This resistance
check is best made between the heatsink on the voltage Two diodes 32609 are pressed into the alternator hous
regulator board and the alternators common ground stud ing behind the cover on later models and behind the regu
in the control box erly models This check takes into latoroutput box on early models located on the lefthand
consideration all connections within the stationary field side generator viewed from the rear These diodes rec
circuit of the exciter stator Total resistance is 56 ohm tify AC power from an auxiliary single phase winding
Should an open be found infinite resistance refer to the within the main stator to supply DC power through Pin
generator internal schematic to check further and locate 2 on the plug to the regulator board
the open Should less than 5 ohm be measured indicating for the field windings of the stationary exciter stator
a short or partial short to ground unplug the regulator and NOTE Early model generators had the regulator board
measure between Pin 1 of the generator plug and the and output leads located in a box in place of the cover
common ground stud If low ohms are still measured lift shown
the FI ground connection from the common ground stud
isolating the exciter field coil windings of the generator If The diodes are pressed into the generator housing to
low ohms are still measured the windings are shorted to achieve good electrical contact in replacing them the
the generator case Refer to the internal generator diode should be driven out with a suitable drift and the
schematic to determine which pair of windings is shorted diode replaced with the aid of a deep well socket that will
to ground Some shorts are undetectable with a YOM or catch the outside edge of the diode A Cclamp should be
DMM In some cases a winding repair shop may have to used to press it into the generator housing and to aid in
be consulted for insulation testing maintaining good alignment and diode contact with the
housing
3 If the stationary field windings FI F3 and F2 F4 are
found to be OK the problem could be in the auxiliary cir 4 If both the auxiliary coil and exciter field windings cir
cuit supplying DC power to the voltage regulator through cuits check OK but the alternators output voltage is still
Pin 2 of the plug Check the resis low flashing the field is recommended This is outlined in
tance of the diodes in this circuit by placing an ohmmeter FIELD FLASHING
between the negative side of the large capacitor on the
regulator board Pin 2 and the case of the generator
Resistance should be 85 ohm in one direction and with
reversing the ohmmeter leads infinite in the other
rfIVl WESTERBEKE
I Engines Generators
WTA GENERATOR Output Voltage Is Extremely Low Symptoms Experienced While Field Flashing
Less than 50 volts AC TlT 4 or 25 volts AC TlT2 and AUXILIARY MAIN LINE PROBABLE CAUSE
T3T4 VOLTAGE VOLTAGE AND ITEMS TO CHECK
INCREASE INCREASE
1 This could be the result of very weak or loose permanent NO YES Auxiliary winding circuit problem Check
magnets in the stationary exciter stator These can be diodes and winding resistances Normal
viewed and checked with the aid of a steel screw driver auxiliary voltage should be through the access hole in
the rear of the generator hous 14 line to neutral voltage in DC
ing The stator exciter has six poles one of which is a YES NO If all lines are same check for short circuit or
permanent magnet all lines open If only some lines are affected
check for open or shorted coils
2 Field flashing can rectify a weak magnet Loose or dis NO NO Check stationary exciter for open or short
lodged magnets will have a tendency to fall onto the YES YES If OK check all rotating components
rotating exciter and short out its windings as it wears on PARTIAL PARTIAL Resistance or exciter and main rotor bridge
the exciter rotor surface Magnets can be weakened either rectifier current test of main rotor
by opening the field circuit while the unit is operating or YES YES If voltages drop after flashing is removed
by prolonged storage Weakened magnets should charge voltage regulator needs replacement
themselves sufficiently under normal operation to prevent YES YES If normal operation is restored permanent
magnets have been weakened
future needs for flashing Normal operation should restore charge
3 Check the voltage regulator visually including the plug
connection Look for any burned components foil strips NOTE A 9 volt power source capable of 2 amps applied to
or dislodged parts the field is sufficient to duplicate a normal generator output
voltage at noload If output voltage increase is only partial
4 Record auxiliary DC voltage and main output line voltage this would indicate a problem
before field flashing with the generator running DC aux Refer to bridge rectifier test procedures and main rotor test
iliary voltage should be measured from Pin 2 at the gen procedures
plug and the common ground stud Main
output voltage AC should be measured from each hot line
to neutral Tl T2 and T3 T4 This is to avoid measur Checking Exciter Rotor Resistance
ing an open main stator coil as having no voltage This can be done with the bridge rectifier still connected
Measure the resistance of the exciter rotor windings with an
Field Flashing ohmmeter measuring between points 1 2 2 3 and 3
Apply 12 VDC to the stationary exciter stator windings This 1 07 08 ohm If 0 ohm short or infinite open exist in
is done by connecting the DC battery negative to the heatsink the windings unsolder the leads from the bridge rectifier
of the regulator board and the positive DC connection to the connections and check the windings case These connections need only be made for a
The DC connection to the rotating field identified by the red
few seconds while the generator is running for field flashing dot on the winding and the two solid wires connected to it
This unit is with a stationary armature Brush type units
have a rotating armature
A WARNING The DC battery used for field
flashing must be completely independent from the gen CHECKING
erators DC starting battery to prevent a short EXCITER
circuit in the regulator board from damaging it ROTOR
flashing using 12 volts DC AC output voltage from
each line to neutral should peak at 140 150 volts When
flashing voltage is removed it should drop back to 120 volts
as the regulator board maintains to generator output If volt
age is maintained by the board all is well except that the
permanent magnets are weak voltage adjustment with may be needed to finally adjust the AC volt
age to 120 volts
Apply load several times and allow the unit to run loaded for
some time Shut the unit down and restart to assure in the future
Refer to the CHART for comparison
to actual results if normal operation is not lfAT WESTERBEKE
I Engines Generators
WTA GENERATOR the Main Rotor Winding an ohmmeter Rxl scale place the plus lead on to the DC output connection on the bridge recti
fier red dot point 4 and the negative lead to the rotor
shaft or rotor ground terminal when accessible 30 32 GROUND FROM
ohm should be read Please bear in mind that a shorted MAIN ROTOR
rectifier can influence this reading
If any variation in the above readings are found isolate the
rotor windings by unsoldering the DC lead from the rectifier
and lifting the ground lead from the shaft if accessible and
measure the resistance with the rectifier removed from the
circuit If ground connection to shaft early models is measure resistance from DC lead to shaft With
the ground lead disconnected from the shaft there should be
no continuity to the shaft from these windings
Bridge Rectifier Test Procedures
GENERATOR In order to test the rectifier without removing it from the cir
cuit the main rotor DC connection must be completely
HOUSING
removed either at the ground connection to the main rotor
shaft late model units or from the soldered DC output con
nection on the bridge rectifier marked with a red dot
Test the rectifier with an ohmmeter set on low scale Rxl as
follows refer to the Readings are taken using a
Simpson Meter 260 analog
1 Connect the lead of the ohmmeter to the DC lead of
the rectifier red dot and with the negative lead contact
points 123 and 4 No deflection of the meter should
occur
2 Reverse the connections and with the lead Main Rotor Windings For A Short points 123 and 4 Half to threequarter
scale deflection
of the meter needle should occur
With Outer Generator Housing Removed Points 123 8 9 ohm
Make this check by disconnecting the two main rotor wind Point 4 30 40 ohm
ing leads DC leads off the bridge rectifier and the ground Readings are approximate and may vary with meter
lead from the rotor shaft and attach a 24 volt DC source If readings between points I 2 and 3 vary the bridge
across these leads to the DC lead and to the ground rectifier should be removed tested independently and
lead off the shaft This will create a magnetic field in the then resistance between the three rotor rectifier of the main rotor Pass a
long metal scale or hack should be checked for blade around the armature outer surface and observe for
an obvious difference in the magnetic strength that may indi RED DOT
cate a shorted area Allow the DC voltage passing through
the armature windings to heat the windings until they BRIDGE uncomfortable to the touch then remove the DC
EARLY MODEL
source and measure the resistance of the windings again If
some of the poles in the armature showed a noticeable weak
ness and the resistance measured hot is much lower than the
cold measurement the main rotor most likely has Note that this is intended only as a final check to
confirm suspicions of a rotor winding defect
NOTE The possibility of thermal damage from the 24 volt DC
battery does exist if not monitored and controlled during the 3
test
IVVI WESTERBEKE
r Engines Generators
WTA 50HZ60Hz SERIES SCHEMATICS
JIN STl i RE I EXCITERRar
r
I EXCITER I
Tl tll T8
I I II
II II
I 10 TS II II II
N 9 II I II
I II II 1I F I
SPEED
ILL
LMAIN ROTOR
I INDICATOR
1 FIELD POWER 1
I METER
AND 1 2 INPUT POWER
SPEED I
SENSING MODULE 3 GROUND
I I 4 SENSING I
1 OPTIONAL J AAE VOLTAGE REGULATOR
1 R308
J MAIN i
STOR 1 llhE r
J 1 I I
II I
I T9
II II
I 1I I
I f3 I F2
1 1 I
I I
3 4 El E3 F
INPUT POWER SENSING FIELD POWER I
I 500 Ohm 120 VAC 2SA VOLTAGE
2SA AT 63VDC I
MAX CONT
I
BASLER KR4F VOLTAGE REGULATOR
1 I
8
1fAT WESTERBEKE
r Engines Generators
WTA GENERATOR Replacing the Bridge Rectifier Fluctuating Voltage
To replace the early single style rectifier use the dual rectifier Voltage fluctuation can be caused usually by one of these
assembly 035301 as shown below problems
1 Check for an overload condition Check load with the
BLACK DDT NEGATIVE DIODE amprobe off each lead Measure the exciter field as
PART 037210
shown in Section A low voltage If the alternator is
being operated in an overloaded condition and the voltage
regulator is operating at its maximum capacity to try and
maintain AC Voltage output the variations in the engines
speed in some cases the engine horsepower output can
no longer support the overload demands on the generator
as it goes through its power cycles will be observed as a
voltage variation with a regular and can be
very visible when lights are part of the load This type of
overload condition must be corrected otherwise genera
tor damage will result
2 A defective voltage regulator can also cause output volt
age to fluctuate This can be checked by replacing the
The single style three phase full wave Bridge Rectifier has
voltage regulator with a DC power source to excite the
been obsoleted by two separate and different low power recti
field 9 volts DC This DC voltage applied to the exciter
fiers in one assembly See ROTATING BRIDGE RECTIFIER
field generator plug 1 pin and the common ground
stud should produce 120 volts AC output from each
lead T1 and T4 under noload conditions Replacing the
voltage regulator board will accomplish the same
ROTATING FIELD
CONNECTION
2 STRAND WHITE 3 Voltage fluctuation can also be the result of loose electri
cal connections or electrical shorts A thorough check of
THIS ASSEMBLY REPLACES L WIRE all connections and component resistances can often find
THE EARLY MODEL SINGLE the cause of this problem once the possibility of a
tive voltage regulator is eliminated Voltage fluctuation
with engine rpm variations cycles and no overload con
dition can be the result of inadequate fuel delivery to the
engine clogged fuel filters air in the fuel system poor
fuel quality injectors misfiring or a faulty injection pump
High Voltage 130 Volts
1 This is most likely to be a voltage regulator related prob
NOTE Solder one of the auxiliary winding leads to each of lem If sensing voltage is not present at Pin 4 of the volt
the three separate interconnect wires between the three ter age regulator this senses AC voltage from Tl the
minals of the two rectifiers voltage regulator will attempt to bring up the voltage by
going into full power operation Consequently the line
Special for Low Voltage Problems voltage will increase without the voltage regulator sens
ing it Check the sensing circuit for an open and correct
1 Voltage drops under load but corrects when load is as needed
removed This symptom could be caused by an overload
condition check load with amprobe field saturation 2 If sensing voltage 120 volts AC is present at Pin 4 of
check shorts in generator components or electrical shorts the voltage regulator and this is the same as found on
in or to the load Check resistance of windings in genera output lead Tl the voltage regulator is most likely
tor components defective and should be replaced
As a precautionary step to prevent installing a new volt
2 Voltage drops under load and stays low when the load age regulator board into a environment it
is removed but normal voltage is restored when the is wise to check that the auxiliary circuit diodes found
generator is cool This symptom would indicate a high pressed in the generator housing are OK and that the aux
probability of a short Cold and hot resis iliary residual voltage 10 12 volts AC across these
tances should be checked for all components concentrat diodes is present when the generator is running with the
ing on the main rotor windings since these are susceptible voltage regulator unplugged
to heat damage from 3 Incorrectly isolating neutral from ground
fAiTl WESTERBEKE
I Engines Generators
ROTATING BRIDGE RECTIFIER
The Rotating Bridge Rectifier uses a tandem assembly of two
low power half wave components these components are
mounted 1800 apart on the rotor shaft as a field service kit the Rotating Bridge of two rectifiers that are mounted and prewired no
drilling or remilling is rotating bridge rectifier kit is a replacement for the
R6245 three phase full wave bridge rectifier used in all
1800 rpm Generators ROTATING BRIDGE Procedure
1 Disconnect either rotating field connection
RED DOT
2 With or without the exciter connected test each semi POSITIVE
conductor by measuring from the marked terminal to
the other three terminals on the same device
3 Polarity will be indicated as forward on one devise
reverse on the other RED DOT
1 ROTATING FIELD
BLACK DOT
fAT WESTERBEKE
I Engines Generators
WTA GENERATOR Regulator 2 LATE MODEL REGULATOR BOARD
The voltage regulator can be bench checked only for proper a HIGH OUTPUT Without elaborate equipment the actual detailed
1 Misadjusted Pl
defects possible in a voltage regulator cannot be accurately 2 No Connection to pin A simple GoNo Go tester schematic for func
3 Shorted Q2 Q3 Q4 Q5
tion testing follows 4 Any open component from T1 to ICl
lower part of circuit diagram
The easiest and most accurate method would be to check the
voltage regulator on an generator known to be operating h LOW OUTPUT Some possible defects and symptoms follow
1 Misadjusted Pl
1 EARLY MODEL REGULATOR BOARD 2 No connection to pins 12 or 3
3 Open Q2 Q3 Q4 Q5
a HIGH OUTPUT VOLTAGE can be caused by 4 Defective ICl
1 Misadjusted 5 Defective C5
2 Defective transformer TI
3 Shorted Q3 andor Q4 c FLUCTUATING VOLTAGE
4 Open RI R2 VRI R4 not due to generator saturation
5 Open QI Q2 1 CI defective
6 No connection pin 4 2 ICI defective
Check for line voltage at circuit board 3 QI defective
h LOW OUTPUT VOLTAGE can be caused by
1 Misadjusted 2 Shorted Q 1 Q2
3 Open Q3 Q4 DI R6
4 No Connection Pins 12 or 3 VOLTAGE ADJUSTMENT
FINE
1 4 3
i 9
VOLTAGE ADJ 0
CD COURSE
0 110 CURRENT REGULATOR BOARD
EARLY MODEL REGULATOR BOARD
tIfAT WESTERBEKE
I Engines Generators
WTA GENERATOR WIRING DIAGRAM
AND SCHEMATIC 24700
i 1
PREHeAT
0 I
I II r2VDC BATERY SATTERY RETURN
1 I TART SOL 5TARTER 0
I I
I I I
I I
LJ L J START I I I 0
PREHEAT
I i
I I
I I I r
I I
tjOIl
e B
120 A MP
PANEL
PREHEAT SOL
i I START SOt
I r
WI RI NG DI AGRAM IL
FuEL JOL
rr rp p
Hr
w SENDER
fUEL 500L
PREHAT SOL
PUR2
01 L V
Il WESTERBEKE
I Engines Generators ACuOT CONTROL PANEL i
WTA GENERATOR EARLY MODEL
RESISTANCE VALUES WTA GENERATORS
LATER MODEL
Single Phase Electrical Resistances for 15kW WTA Generators WTA GENERATOR
I NO WINDINGS WINDINGS VISIBLE
Model Main Stator Aux Coils ExcStator Main Main
WTA T1T2 T3T4 A1A2 A2A3 A1A3 FH3 F2F4 Rotor Rotor I
15 20 005 005 015 009 009 20 30 32 07
152025 004 004 014 008 008 23 34 30 08
Refer to GENERATOR SCHEMATIC
Values are in Ohms
NOTE These values represent measurements taken with leads
connected to the bridge rectifier Measurements for the main
rotor are taken from the red dot terminal on the rectifier to
the ground Exciter measurements can be taken from the ter
minal Refer to the preceding pages for rectifier testing
1 This chart is intended for reference use only as a ten per
cent tolerance on these figures is cornmon Comparison
of ratios of actual readings to the above figures is often a
more accurate method of 2 If any abnormal variations cannot be isolated and symp
toms are still evident contact your WESTERBEKE dis SINGLE PHASE GENERATOR
tributor
T1 120240 V 120 V
3 Early model WTA generators can be distinguished from L1 T1
later model WTA generators when checking resistance
values by removing one of the screens from the generator T2
exhaust fan area and visually looking squarely into the
generator On early model WTA no windings will be visi
N T3
FRAME
FRAME
ble extending beyond the opening exposed when this
screen is removed Later model WTA generators will L2
have about 112 to 58 inches of windings visible in the
4 wire 3 phase alternator frameir N T1 T2 T3
opening as shown
factory connected for 120208
277480 or 346600 volts
N L1 L2 L3
GENERATOR CONNECTION DIAGRAM
r DIODES MOUNTED
1 HOUSING
1 I A2 r l
r Ifr
IS1 MAIN ROTOR
I 1 EXCITER ROTOR C I
MAGNET
T1 I I EB I I I I I Ii l l
I I
T2 1 1 I I GR0 UNO
I I I I I TO CASE
T3 I I I 1
IIII I III
I i BUTT CONNECTION
T4 1 I 1 I 1 I I F4 I
lei 1
L J LJ L J
I J I F2 I
MAIN STATOR TO ROTOR SHAFT L lj J
EXCITER STATOR
INTERNAL WIRING SCHEMATIC
1IfATI WESTERBEKE
I Engines Generators
WTA GENERATOR ELECTRICAL FAULT ANALYSIS
An understanding of the generators operation may be useful beginning of the WTA GENERATOR SECTION Also refer to
before attempting to analyze an electrical failure Refer to the ELECTRICAL DIAGRAMS and SCHEMATICS in ADJUSTMENT and
OPERATION in the manual
PROBLEM PROBABLE CAUSE Mechanical Noise 1 Defective
bearing 1 Replace bearing
2 Worn bearing 2 Replace bearing
3 Loose or rnisaligned coupling 3 Align andor tighten
4 Foreign objects within 4 Remove and check further for possible damage
No Output 1 Short or open circuits in any stator 1 Contact WESTERBEKE if repair is beyond local
facilities
rotor coil or associated leads Check grounding lead and terminal on shaft behind main
rotor coil
2 Defective bridge rectifier on shaft 2 Replace if faulty and check further for cause
3 Faulty voltage regulating circuit 3 Repair or replace if faulty and check further for cause
High Voltage Output 1 Misadjusted output voltage control 1 Set output voltage to desired value
CAUTION Some components carry live voltage and the use
of insulated tools is recommended
2 Wire T2 120240V T6 120208 2 Clean and remake this ground connection
or T12 120416 140240 ungrounded
3 Faulty voltage regulating circuit 3 Repair or replace if faulty and check further for cause
Low Output Voltage 1 Misadjusted output voltage control 1 Set the output voltage to the desired value
CAUTION Some components carry live voltage and the use
of insulated tools is recommended
2 High line loss if the voltage is low only at load 2 Increase the size of the wiring leading to the load as
required Load wires should not run hot at continuous full
load if properly sized Do not run a greater length of wire
than required as losses increase with distance If wire is cor
rectly sized and run is not too long check for poor connec
tions andor partly broken wires that may be indicated by hot
spots in the wire or at terminals of switches etc
3 Partially shorted main rotor field coil 3 Contact your WESTERBEKE Dealer if repair is beyond local
facilities
4 Electrical overload andor poor 4 The total load at the prescribed power fact see
power factor connected to alternator plate on generator should not be exceeded
5 Alternator shaft rpm too low 5 Check engine speed
6 Faulty voltage regulating circuit 6 Repair or replace if faulty and check further for cause
Unstable Output Voltage 1 Irregular engine speed 1 Check the engine and loads for transient operation
andor
overloads
2 Loose electrical connections 2 Tighten connections as required in load wiring and voltage
regulating connector
3 Faulty voltage regulating circuit or connector 3 Repair or replace if faulty and check further for cause
4 Higher than required engine speed 4 Check speed is 1800 rpm
Overheating 1 Airways blocked 1 Remove 2 High ambient
temperature 2 Do not permit ambient temperature to exceed 104F 40C
and operate in a well ventilated area
3 Electrical overload andor poor power factor 3 The total load at the prescribed power factorsee the
connected to the generator plate on the generator should not be exceeded
4 The engine exhaust is being drawn 4 Redirect the engine exhaust as necessary
into the generator air intake
Generator Housing Live 1 Static charge 1 Properly ground the frame of the generator
2 Open the circuit at the ground terminal in the control box 2 Ensure the generator neutral has continuity from the stator
to the ground
CAUTION Some components carry live voltage and the use
of insulated tools is Il WESTERBEKE
I Engines Generators
WTA GENERATOR INTERNAL WIRING SCHEMATICS
DIODES MOUNTED fMAIN STATOR
IN HOUSING
I EXCITER ROTOR
1vLJ I
f MAIN ROTOR
TI I l r
II I
I I I
T2 J r II I I
VR301
T3 0 II I I
1 II I I I I
T4 0 I II I I I I I
L J L 7 J I I 3 PHASE BRIDGEJ L J J L
J
RECTIFIER ITEM 20
USER TO INSURE THIS
EXCITER STATOR
GROUND CONNECTION IS MADE SINGLE PHASE ALL
f MAIN STATOR
o JII
a I I MAIN ROTOR V1JJ
VJgb VR301
UZ I Z
I I
10040 TI i rf I T4
I I I I I I USED
Ill 0 I I II 10G12
Olen I I 1I ONLY
Oen TS
ZJ I I I I I
T2 1PHASE iRDGEis1
RECTIFIER
I
L L J
ZOO ITEM 20
00 1 T3
I 120 V FROM
T3 OR TAP
O 1 USER TO ENSURE TH IS THREE PHASE TYPICAL 6 WIRE
Z GROUND CONNECTION IS MADE EXCEPT200 SERIES 60H SEE NOTE
STAOR
MAIN
I I
I
I MAIN XCITER ROTOR CMIOO
I ROTOR r
T4 1 I r
TIO 1
I Til
TB I TS
7
T2 USED
TI ON
ISG2
T6 120V FROM 81
r3
T9 OR TAP
L I
USER TO ENSURE THIS THREE PHASE TYPICAL 12 WIRE
GROUND CONNECTION IS NADE
Il WESTERBEKE
I Engines Generators
WTA GENERATOR CONNECTION SCHEMATICS
12 WlRE 1tREE PHASE 3 PHASE 3 PHASE SINGLE PHASE 3 PHASE
SINGLE PHASE
TI LI TI LI
T2 L2
T7 T7
N f fRAME
18 T8
120240Y 120 V
LI TI LI
T9 T9
N T3
fRAME
T FRAME
4Rf 3 PHASE ALTERNATOR
FACTORY CONNECTED FOR FRAME
tTl t tj
N LJ L2 L3
II WESTERBEKE
J Engines Generators
WTA GENERATOR PARTS VOLTAGE REGULATOR
EYE BOLT LIFT
EXHAUST AIR GROMMET
DRIP SHIELD
NEUTRAL GROUND TERMINAL
AIR SCREEN
DISC DRIVE
EXHAUST AIR
SCREEN
STATOR HOUSING
BELLVILLE WASHER RETAINING RING
MAIN STATOR
BEARING
INNER ROTOR
COVERS
CLAMPING RING
BEARING
ROTORSHAFT ASSEMBLY
STATOR HOUSING
EXCITER STATOR
VVI WESTERBEKE
I Engines Generators
BT GENERATOR SINGLETHREE PHASE
This generator is a fourpole brushless selfexcited generator A circuit breaker is installed on all WESTERBEKE genera
which requires only the driving force of the engine to pro tors This circuit breaker will automatically disconnect gener
duce AC output The copper and laminated iron in the exciter ator power in case of an electrical overload The are responsible for the
selfexciting feature of this gen breaker can be manually shut off when servicing the The magnetic field produced causes an AC voltage to
tor to ensure no power is coming into the boat
be induced into the related exciter rotor windings during rota
NOTE This circuit breaker is available as a Diodes located in the exciter rotor rectify this voltage to
addon kit for earlier model generations contact your
DC and supply it to the windings of the rotating field This
WESTERBEKE an field which rotates through the
windings of the main stator inducing an AC voltage which is
supplied to a load A step down transformer is connected in
parallel to the AC output of the main stator An AC voltage is CIRCUIT in the auxiliary windings of the transformer
and the PART NUMBERS
main stator and is in turn supplied to a fullwave bridge rec 15 KW 42710
12 KW 42709
tifier The rectifier produces a DC voltage to further excite
the exciter stator windings enabling the generator to produce
a rated AC output An optional solidstate voltage regulator is
available to work in tandem with the transformer regulator to
produce a more stable AC output
SHIMS
POUND ELECTRONIC VOLTAGE
REGULATOR
FUSE HOLDER
BRIDGE RECTIFIER
TERMINAL BOARD
BT GENERATOR
SINGLE PHASE
AC TERMINAL BOARD
20A FUSE I
8AFUSE
BT GENERATOR
flf THREE PHASE
J WESTERBEKE
rEngines Generators
BT PHASE
r1 i
50 Hz TERMINL 60 Hz TERMINAL
I B iI
i I
I I Sr
r a I
I I
4 I 2
2 2
I I
b I I
I I
1 2 1 2 I
3 I
I I I
rr I I
NOTEStriped wires were used
to I I
J on early model generators
z The colors will however match
up to the current solid color
a r wires
RED YRlOWRED
RED AC RED
GREEN
FI GREEN
YElLOW
I YElLOW GREEN
J BLACK
BlACK
BLACK
IAVAI
BLACK
BLUE
BLUE
J 60cyc
50 eye
YELLOW I PLUG I
AVR FlEDWHITE
TO HERnNOLIS BAR
PLUG
BLUE WHITE
TO PIN UTERM
BLUEWHITE
TO HERT7VOLIS BAR YELLOW WHITE
TO SELECTOR SWITCH
BLACKWHITE
TO BRIDGE RECTRER
CIRCUIT BREAKER
42710150 KW
42709 120 KW
INTERNAL WIRING SCHEMATIC SIX STUD
WOPTIONAL VOLTAGE REGULATOR
A EXCITER STATOR WINDINGS 1 2 D COMPOUND TRANSFORMER
AI and A 2 Exciter Stator Windings 1 Compound Transformer Windings
Selector in COMP position 2 Compound Transformer Windings
3 Compound Transformer Auxiliary Windings
B EXCITER ROTOR and FIELD Resistance readings and voltage
checks can be accessed
1 Auxiliary Windings A B C easily for the components in the
exciter circuit A G C3 and
2 Diodes 6 D3 by locating the color coded wires
at the connection
3 Rotating Field Windings points shown on the above schematic
When checking
4 Posi Resistor winding resistance values be sure
to lift both of the
components electrical MAIN STATOR G BRIDGE
RECTIFIER
1 Main Stator Windings AYR
2 Main Stator Windings Optional Automatic Voltage
Regulator Plug 6 Prong
3 Main Stator Auxiliary Windings
IIVI WESTERBEKE
I Engines Generators
BT GENERATOR CHART
The following chart is designed to give These are hand tools an ampprobe and a quality into problems which may
be encountered with the BT meter capable of reading less than one ohm due to the generators operating on compound
transformer reg sion required in reading component winding Owing to the simplicity of the equipment and con
Before attempting any repairs get a clear an explanation of
trols is relatively easy once the relationship the problem as possible preferably from an individual wit
between cause and effect is understood Most potential prob nessing the problem In some cases this may bring to light a
lems are covered in the text of this manual problem which is related to the method of operation rather
Keep in mind that a basic fundamental knowledge of electric than equipment fault Bring basic repair tools with you on
ity is required for this and always remember initial trip to the problem equipment such as diodes and
that lethal voltages are present in the circuitry therefore bridge rectifier so that if the problem should be found in
extreme caution is essential when a generator of these easily replaceable parts the problem can be reme
Only a few basic tools are necessary for diagnosis and repair died early and Problem
Probable Cause Low voltage 70 volts at NIL with 1 Selector switch in wrong
position 1 Place selector switch in COMP position
and loss of voltage as load is applied
No loss of engine speed and hertz
High voltage 125 135 volts at NIL with 1 Generators engine speed rpm high at NIL 1 Check NIL speed and adjust NIL voltage
correct voltage when loaded
115 120 volts
High voltage at NIL and FL 1 Generators engine speed rpm high 1 Check NIL rpm and adjust NIL voltage
2 Short in compound transformer auxiliary 2 Check continuity and connections of 03 windings
windings 03
Low voltage 0 5 volts at NIL with 1 Main stator windings shorted C1 C2 1 Check continuity and resistance values of C1 C2 windings
growling noise from generator and loss of and connections
engine speed when load is applied 2 Compound transformer windings shorted 2 Check continuity and resistance values of 01 02
windings
0102
Generator does not excite voltage is 1 Generators engine speed is slow 1 Adjust the engines speed and adjust NIL voltage
is 0 volts at NIL
2 Short in the main stator windings or 2 Check the diodes as shown in this manual
transformer
Low voltage 10 20 volts at NIL when 1 Diodess in rotating exciter 82 shorted 1 Check B1 and B2 in the rotating exciter as explained in
load is applied voltage drops this section
2 Bridge rectifier defective 2 Follow test procedure for the bridge rectifier
3 Auxiliary windings B1 shorted 3 Check the continuity and resistance values
4 Auxiliary windings 03 andor C3 open 4 Check the continuity and resistance values of windings and
connections
Low voltage at NIL and FL 50 70 volts 1 Exciter stator windings A are open 1 Check the continuity and resistance values of the
windings
2 Generators engine speed rpm is too low 2 Check the NIL rpm and adjust the NIL voltage Check and adjust
the engines rpm
Voltage correct at NIL but not at FIL with 1 Generator overload 1 Monitor the load
loss of engine rpm hertz
2 Rotating diode failing 2 Check the diode
3 Generators engine speed is low 3 Check the electroniC govemor operation
4 Low power load factor 4 Check the type of load applied Consider use of optional
regulator board
Voltage correct at NIL and 1 Diode in exciter rotor B2 shorted 1 Check the diodes in the exciter rotor
loss of voltage at FIL
High voltage at NIL with no adjustment 1 Regulator board defective 1 Replace the regulator board Adjust NIL voltage
with
from regulator transformer then switch to ELEC and adjust with
AVR
continued
ll WESTERBEKE
I Engines Generators
BT GENERATOR CHART
Problem Probable Cause voltage at NIL and FL No 1 Regulator board
defective 1 Replace the regulator board Adjust NIL voltage from regulator
transformer then switch to ELEC and adjust with
AVR 2 Exciter stator winding A1 open 2 Check resistance values of C3 and D3 windings and
their voltage at NIL and voltage drops 1 Diodes in exciter rotor shorted B2 1 Check the diodes in the exciter as a load is applied
2 Auxiliary windings in exciter 2 Check the resistance values and continuity to ground
rotor shorted OK at NIL and low at FIL 1 Auxiliary windings in the exciter rotor 1 Check the resistance values and continuity to ground
2 Exciter stator compound winding 2 Check the continuity and the connection of the winding
A2 is open
3 Auxiliary windings D3 or C3 open 3 Check the continuity and the connection of the unstable 1 Defective regulator
board 1 Check the stability of DC voltage from the regulator to the
exciter stator windings Operate the unit on CaMP Replace the
regulator board
2 Engine is hunting Engines rpm fluctuating 2 Check the engine operation and the fuel system
3 Electrical connections 3 Check for clean and secure connections
See ENGINE
IMTI WESTERBEKE
I Engines Generators
BT GENERATOR Testing Residual Voltage 3 The absence of any voltage from the generator indicates a
fault with the main stator windings Cl and C2 andor
1 The amount of noload voltage produced by the
the compound transformer windings Dl and D2
generator can be an indicator of where in the generator
Apply l vol DC excitation to the exciter stator windings
the problemfault may lie
as explamed m paragraph 2 A fault in the main stator
Residual Voltage 1014 volts AC
andor compound transformer windings such as a short
This voltage is the AC voltage produced by the generator will cause the generator engine to load down and the
from magnetism in the exciter stator field This voltage is shorted windings to eventually produce smoke as the
measured between the AC Neutral and Hot leges with excitation is continued
noload on the generator running at 60 hertz
4 Voltage output greater than residual and less than rated
The presence of residual voltage is an indication that the
output 25 100 volts indicates a fault in the exciter
following generator components are OK Refer to
rotorfield B1 B2 or B3 Excitation of the generator as
INTERNAL WIRING SCHEMATICS
explained in paragraph 2 should produce a partial rise in
a Exciter Rotor B1 a b c B2 voltage output and when removed the voltage will return
b Rotating Field B3 to the original low output
c Main Stator C1 C2 and
d Compound Transformer D1 D2 BRIDGE RECTIFIER
The fault lies in one or more of the following components e ridg rectifier is supplied AC voltage from the auxiliary
in the exciter circuit wmdings mthe generator stator C3 and the compound
transformer D3 The AC voltage measured across the AC
a Exciter Stator A1 A2 terminals of the rectifier during engine operation is as fol
b Bridge Rectifier G lows
c Selector Switch F 120 Volts 120240
d Main Stator Auxiliary Windings C3 NILFIL NILFIL
11 20 volts AC 11 20 volts AC
e Compound Transformer Auxiliary Winding D3
Diodes in the rectifier convert this AC voltage to DC and
2 Twelve 12 volt DC excitation of the exciter stator wind
supply it to the windings of the exciter stator to induce a field
ings should cause the generator to produce between 140
through which the exciter rotor revolves The DC voltage
150 volts AC between each hot lead and the neutral 12
measured across the and terminals of the bridge recti
volts DC is applied between the lifted and leads of
fier during engine operation is as follows
the bridge rectifier to and to
Correct voltage produced with twelve volts DC excitation 120 Volts 120240
indicates the fault is in one or more of the above listed NIL FIL NIL FIL
components b d or e 8 15 volts AC 8 15 volts AC
If the generator does not produce 140 150 volts AC Failure of the bridge rectifier will result in a weak field being
then include a and c produced by the exciter stator windings A weak field is pre
sent due to the magnetism in the exciter stator which will
cause the generator to produce residual voltage
Testing the Bridge Rectifier
for Faults with an Ohmmeter
Meter used Simpson 260 at 70F 21C
1 Set the ohmmeter scale on RXl DC and set the
needle to zero
2 Connec the positive lead from the ohmmeter to point
4 Taking the ohmmeters negative lead momentarily
contact points 1 2 3 and 5 The ohmmeter should
register no deflection for any of the points touched
3 Remove the positive lead from point 4 and connect
the negative lead to point 4 and with the positive
lead momentarily touch points 1 2 and 3 The ohm
meters needle should deflect when each point is touched
TESTING THE showing a passage of meter voltage through the diodes in
BRIDGE RECTIFIER the rectifier
NOTE Current BT Generators use a bridge rectifier that is
configured differently connections are the same
fATl WESTERBEKE
I Engines Generators
BT GENERATOR PHASE
CURRENT RECTIFIERS
ARE CONFIGURED SLIGHTLY E AC Tenninal Board F Selector Switch
DIFFERENTLY BUT TEST
POINTS ARE THE SAME H Optional AVR
G Bridge Rectifier early models
The model code number is found stamped in the generator
housing on a flat surface above the rear generator carrier
bearing
NOTE These two model BT generators are used on models
rated lower than the capabilities of the generator However
TESTING THE the generator is rated according to the capabilities of the
BRIDGE RECTIFIER drive engine since horsepower produces kilowatts
4 Leaving the negative ohmmeter lead on point 4
touch point 5 with the positive lead No deflection of COMPONENT RESISTANCE CHECKS
the needle should occur Exciter Stator Windings
5 Place the positive lead of the ohmmeter on point 1 1 Windings AI andA2
and the negative lead on point 3 The ohmmeter Resistance readings for exciter windings AI and A2
should not register any deflection of the needle no with the selector switch in the COMP position are taken
deflection indicates infinite resistance Reverse these between the positive and negative leads lifted off
connections and the ohmmeter should again register no the bridge rectifier G Neither of these two leads should
deflection have the continuity to the generator caseground
If the rectifier fails any of the previous tests 1 4 it is 2 WindingAl
defective and should be replaced Resistance readings for exciter windings AI with the
NOTE Different stylemodel meters may produce opposite selector switch in the ELEC position is taken between the
results from the above tests yellow wire and the black at the AYR plug G
3 Winding A2
Component Resistance Values Resistance readings for exciter winding A2 with the
A Exciter Stator B Excitor RotorlField selector switch in the ELEC position is taken between the
AI A2 115 ohm B1 105 ohm green wire lifted off the negative terminal of the bridge
rectifier G and the red wires lifted off the positive
AI 494 ohm B2 89 ohm terminal of the bridge rectifier G
A2 129 ohm
NOTE The white striped wiring on earlier model generators
C Main Stator D Compound Transformer has been changed to solid colors on current generators the
Cl 0089 ohm Dl 0007 ohm colors however remain the same
C2 0089 ohm D2 0007 ohm
Auxiliary Windings Auxiliary Windings
C3 085 ohm D3 502 ohm
r1 r
C
i 0
e2 5
I I I n I
I j 3 I RED WHITE
TO HEFlTZNOLTS BAR AVR
i I I I I
i 3 J L J
BlUE WHITE BLACK IWHITE
TO PIN 8TERM TO SELECTOR SWITCH
BlUE WHITE
G TO HERTZNOLTS BAR YELLON WHITE
TO SELECTOR SWITCH
RED YEllOW RED
RED RED
GREEN TO BRIDGE RECTIFIER
GREEN
YELLOW
BT GENERATOR
BlACK INTERNAL WIRING
BLUE SCHEMATIC
BLUE
50 eye WOPTIONAL AVR
NOTEStriped wires were used on early
tl WESTERBEKE model generators The colors will however
matchup to the current solid color wires
I Engines Generators
BT GENERATOR PHASE
Main Stator Windings 3 Transformer Auxiliary Windings Resistance is
measured between the yellow wire lifted off the AC ter
1 Group 1 The resistance value is measured between the
minal block of the bridge rectifier G with the selector
lifted lead 4 from the insulated terminal below the trans
switch in the ELEC position and the 1 red lead lifted off
former and lead 6 lifted from the AC terminal block
the VoltagelHertz connection bar Off this same bar lift
Lead 5 should be lifted from the terminal block in order
the 2 and 3 red leads that come from the auxiliary
to totally isolate the stator windings of group 1
windings to totally isolate these windings There should
2 Group 2 The resistance value is measured between the be no continuity found from either of these connections
lifted lead 1 from the insulated terminal below the trans to the caseground or to either of the transformer groups
former and lead 3 lifted from the AC terminal block In
order to totally isolate the stator windings of group 2 Selector Switch
lead 2 should be lifted from the terminal block This switch is is normally set in the COMP position If an
NOTE No continuity should be found between any of the optional AVR is installed the switch is toggled to the ELEC
lifted stator leads and the case ground or between the position
connections of the two groups NOTE With the selector switch in ELEC position the exciter
Main Stator Windings 20 22 Ohms stator windings are divided one group is excited through the
3 Main Stator Auxiliary Windings The resistane values bridge rectifier and the other group through the A YR
for these windings are measured between the black
double lead connection lifted off the AC terminal of the Bridge Rectifier Wiring
bridge rectifier G and the red 3 lead lifted off the The illustration below shows the color coded wires at the two
VoltageHertz connection bar AC terminals and the color coded wires at the and DC
terminals
NOTE No continuity should be found between either of
these winding groups or to the generator case NOTE When removing or reinstalling connections maintain
Main Stator Auxiliary Windings 15 18 Ohms correct polarity connection on the and DC Group 1 Resistance value
is measured between lifted
lead 4 from the red insulated terminal stud below the
transformer and lead 8 lifted off the AC terminal block
2 Group 2 Resistance value is measured between lifted
lead 1 from the red insulated terminal stud below the
transformer and lead 7 lifted off the AC terminal block
NOTE No continuity should be found between either of
these lifted leads or to the generator BLUE
BLUE BLUE VOLTAGEHERn
CONNECTION BAR
GREEN
AVR PLUG
NOTEStriped wires were used on early YELLOW
model generators The colors will however
RED matchup to the current solid color wires
TO HERTZ BAR BLACK
BLACK
BLACK
TO SELECTOR SWITCH
YELLOW
TO SELECTOR SWITCH
1VV1 WESTERBEKE
r Engines Generators
SELECTOR SWITCH
BT GENERATOR Exciter RotorField RESISTANCE
VALUE
11 OHMS THROUGH THE DIODE
1 Auxiliary windings group a b aJld c Locate the three
1 1 OHMS
terminal points on the exciter rotor for these auxiliary
INFINITE 1
winding groups Position the exciter rotor as shown in the
illustration and count off the porcelain knobs from the 12
BLOCKING 1
oclock point either left or right to locate terminal points INFINITE
a b and c Measure the resistance value between the pairs
of terminal points A B B C and C A There is no NOTE Attempting to check diodes in place with an ohm
need to unsolder these connections unless a faulty reading meter will give erroneous readings on the diodes due to
appears If this occurs unsolder and verify the winding the auxiliary windings connections
fault There should be no continuity found between any 4 When leads are put across the diode as illustrated volt
of the three terminal points and the rotor shaftcase age passes through the diode allowing the headlight to
ground glow brightly
Auxiliary Windings 10 12 Ohms
High beam 12V bulb
REDJWHITE RED glows bright
1211 5 Reverse the leads across the diode The diode should
block voltage passing through it and the headlight should
not glow or it may glow faintly
a Should the bulb not glow with leads connected in both
directions the diode is open internally
b Should the bulb glow with leads connected in both
directions the diode is shorted internally
In both a and b above the diode should be replaced
Check the resistance values of the rotating field windings
and the integrity of the resistors connected between the
2 Rotating Field Windings Refer to the illustration above field windings
of the exciter rotor The field winding connections are
noted as the and connections of the red white
striped wires Measure the resistance value with your
olunmeter between these two connection points These
connections need not be unsoldered unless a faulty read
ing appears If this occurs unsolder the connection and 12VBATTERY
verify the resistance reading With these connections
lifted there should be no continuity to the rotor shaft
This would indicate a short to ground with these field
windings
3 Diodes Six diodes are mounted on the exciter rotor they
rectify the AC voltage produced by the three groups of 6 Rotating Field Windings 7080 ohm Readings taken
auxiliary windings toDC voltages and supply this DC between the two red white wires connected to the
voltage to the rotating field windings and terminals of the exciter rotor as shown
The diodes can be easily checked in place with the use of 7 Infinite readings between both yellow leads
a common automotive 12volt high beam headlight bulb lifted from the and terminals on the exciter rotor
some jumper leads and the generators 12 volt starting A short in the posiresistor will cause a loss of the rotat
battery ing field AC output voltage will drop to zero
A short or an open in a diode can easily be found with
the above without having to unsolder and isolate each
diode to check it with an ohmmeter
VVI WESTERBEKE
I Engines Generators
BT GENERATOR PHASE
NoLoad Voltage Adjustment 115V 50Hz 230V50Hz 120V 60Hz 120240V 60Hz
Voltage adjustment is made with the generator regulation
being governed by the compound The selector switch must be in the COMP position
2 To confirm noload voltage start the generator and apply
a momentary moderate load to excite the transformer 1
The voltage produced by the generator after the momen
tary load is removed is noload voltage Note the voltage
output from the generators 120 volt leges 230 volt 50
hertz The noload voltage should be between 121124
volts at 61562 hertz 232 236 volts at 51552 hertz
3 To raise or lower the voltag shims of varying thickness BT Generator Six Stud AC Voltage Connections
material are placed or removed from NOTE The frame ground wire must be moved when changing
under the steel laminated bar on top of the compound from 110 volts and 1101220 volts 50 hertz to 230 volts 50
transformer The material used for shimming should not hertz For output leads from the AC terminal block use
soften at temperatures in the 1760 F 80 0 C range A terminal ends for 114 inch studs that will accept multistrand
small reduction in noload voltage 1 to 3 volts can some copper wire sized for the amperage rating from the hot lead
times be accomplished by gently tapping the top of the connection The frame ground wire connects between the
laminated steel bar to reduce the gap between the exist neutral stud and the generator frame
ing shims and the transformer core
Generator CONNECTION BAR
1 Frequency is a direct result of speed
If there is no automatic voltage relator AVR installed 1800 rpm 60 hertz
do not change the wiring on the VoltagelHertz Connection 1500 rpm 50 hertz
Bar Sim2Jy reconfigre the AC voltage connections at the
AC terminal for the hertz chang 2 To change generator frequency follow the steps below
The blue or bluewhite lead should be connected to the a Connect the AC output leads to the AC terminal block
Hertz terminal that the generator will be set to produce following the correct diagram above
The order of the numbered connections on some h If an AVR is installed reposition the blue or Connection Bars may
be reversed as in the lead to correspond to the hertz selected on the
diagrams below To ensure a proper connection follow the VoltagelHertz Connection or blue lead to the AC terminal block it
should c Start the engine monitor voltage and adjust engine no
connect to the correct terminal stud 6Vl for 50 Hz 5rvY2 load speed Adjust diesel units by the linkage between
for 60 Hz See the BT WIRING SCHEMATIC the throttle arm and fuel solenoid or the throttle lever
on the injection pump
NOTE When the optional voltage regulator is installed 60 hertz noload speed 615620 hertz
and if the BlueWhite Blue lead is not correctly positioned 50 hertz noload speed 515520 hertz
to correspond to the Hertz the unit is operating at the regu
lator will sense incorrect voltage and cause the generator to d After the noload hertz adjustment is made the noload
produce abnormally high output voltage voltage may need to be readjusted In most cases if the
generator was producing the correct noload voltage at
the previous hertz setting it would be correct at the
CURRENT MODELS VOLTAGEHERTZ CONNECTION BAR changed hertz setting
REPOSITION THIS WiRE In the event it needs adjustment adjust the shim thick
FOR 50Hz EARLY MODELS ness under the laminated steel bar of the transformer
TO 60Hz 60 hertz noload voltage 121124 volts
TERMINAL BLUEWHITE 50 hertz noload voltage 232236 volts
e Load the generator to the rated amperage output
corresponding to the hertz speed of the generator
Rated Loaded Speed
60 hertz loaded speed 585590 hertz
50 hertz loaded speed 485490 hertz
The lowest acceptable voltage at full rated output
amps
60 hertz 108110 volts
50 hertz 205210 volts
fATl WESTERBEKE
I Engines Generators
BT GENERATOR f Should the voltage drop below the proper rate loaded
excitation can be increased to raise this voltage by
repositioning connections on the VoltagelHertz N L1115V 50Hz
Connection Bar Repositioning the two leads redwhite
and yellowwhite from 1 to 2 or 3 terminals will 6
increase the loaded voltage out progressively in that
order
NOTE Noload voltage may be effected needing read
justment with the compound transformer Do not use
these adjustments to compensate for overload condi
5 8
L1 230V 50Hz
tions being placed on the inductive
motor type loads Loss of generator hemspeed the
result of overload will cause a drqp in voltage output
BLUE
TO PIN 18 TERMINAl BLOCK J7
6 5
LRED
TO SELECTOR SWITCH TO HERTZ BAR
L2 240V 60Hz
NOTEStriped wires were used on early
model generators The colors will however Terminal Block Wiring Connections
matchup to the current solid color wires
Wiring connections needed to obtain proper voltage and fre
A VH Plug and Connections quency are illustrated in the diagrams above
NOTE Connections 1 and 4 are located on two red terminals
below the compound fATJ WESTERBEKE
I Engines Generators
BT GENERATOR VOLTAGE REGULATOR AmpHertz
The voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the two
optimum AC generator perfonnance It is equipped with protection circuits in the voltage regulator that are protection circuitry to
guard against operating by the illumination of colored LED that could be detrimental to the AC generator 1 Delayed
overload protection yellow LED
2 Low speed protection red LED
Both systems have an intervention threshold which can be
adjusted using the respective Each of the two
circuits are able to cause an adequate reduction in excitor
voltage to safeguard the excitor windings and prevent their
overheating
The overload protection system has a delay which pennits
temporary overloading of the generator during times such as
motor startup or other similar load surge demands The regu
lator also has a third LED green that glows during genera
tor operation to indicate correct operation of the regulator
with the potentiometer is used to adjust output voltage At proper Setting the Overload operating speed the output voltage should be held
at In order to set the AMP overload protection the generator
1 from a noload condition to a full rated generator output must be loaded to its full output rating
and from power factor 10 08 with engine drive speed 1 Load the generator to its rating then decrease the speed of
variations up to 6 Prior to starting the engine turn the the engine by 1010 54 Hertz on 60 hertz units 45
VOLT and STAB trimmers using a mini phillips screw hertz on 50 hertz fully in a counter clockwise Minimum direction
2 Rotate the AMP adjustment until it hits
until you feel them hit their stops Turn the AMP and
its stop Wait about 1520 seconds after which the AC out
HERlZ trimmers completely clockwise Maximum in the
put of the generator should drop and the yellow LED light
same manner With the generator running at noload at
should come on
nonnal speed and with VOLT adjust at minimum it is
possible that output voltage will oscillate Slowly rotate the 3 Slowly rotate the AMP adjustment clockwise until the
VOLT adjust clockwise The voltage output will increase and output voltage increases to approximately 97 of the Increase the voltage
to the desired value In this age output at the start of the adjustment At this point only the green LED will stay lit
yellow LED light should come on
4 Return to nominal speed the yellow LED will turn off
Stability and the generator voltage will rise to its nonnal value
This potentiometer permits variation of the regulators Should this not happen repeat the to generator load changes so as to limit
and obtain a minimum recovery time to the nonnal
NOTE When changing from 60 hertz to 50 hertz operation
remove the 60 hertz jumper bar from the regulator output
In order to adjust the regulator stability the generator must be Setting the Underspeed at noload and the output must be the STAB adjust
slowly clockwise until the voltage NOTE If the unit is operating at 60 Hertz ensure that the
starts to fluctuate At this point rotate the STAB adjust coun jumper strap is in place on the regulator board between until the voltage is
stable within 1 or 2 tenths of two 60 Hertz terminals In order to adjust the underspeed
a volt setting the generator should be running at noload
1 To adjust the underspeed low frequency protection circuit
lower the engine speed at 90 of its normal running speed
54 hertz on 60 hertz units 45 hertz on 50 hertz units
ffi green L
2 Rotate the Hertz adjustment slowly until
the generators AC output voltage starts to decrease and at
yellow L
the same time the red LED light comes on
3 Increase the engine speed to its nonnal speed frequency
Stab The red LED light will go out and the AC voltage out
Volt put will return to nonnal
With the above adjustments made the regulator should func
tion nonnally
VOLTAGE REGULATOR DIAGRAM
I WESTERBEKE
r Engines Generators
BT GENERATOR INTERNAL WIRING
3 PHASE TWELVE WIRE I
A EXCITER STATOR
1 1
I I I DSTATOR 1
I r I 1 1
I 10 I 9
I B
EXCITER
ROTOR FIELD
I a I
I 2 11 t r o
I I I
I DIODES I I
L
E VOLTAGE REGULATOR CI
c F
fUSE
63 AMP
GREEN
ji Hertz REO
g Slab
BLUE
iil Voll
YELLOW
Resistance Values
A EXCITER STATOR 179 ohm D MAIN 005 OHM
AUXILIARY WINDING 12 OHM
B EXCITER ROTOR WINDINGS abc 06 ohm
E VOLTAGE REGULATOR
C ROTATING FIELD 249 OHM
F AUXILIARY CIRCUIT FUSE
tftATl WESIERBEKE
r Engines Generators
BT GENERATOR PHASE
NOTE AC GENERATOR MUST
BE PERFORMED WITH ENGINE OPERATING AT 60 HER1Z
FAULT PROBABLE CAUSE
No AC voltage output at no load 1 Short or open in the 4 Short or open in
exciter
main stator winding stator winding
2 Shorted poziresistor 5 Short or open in rotating
on exciter rotor field winding
3 Four or more shorted or
open diodes on exciter voltage produced at no load 1 Blown 6 AMP buse fuse 3
Shorted or open main
15 20 volts AC auxiliary circuit feed to AVR stator auxiliary
winding
2 Faulty voltage AC voltage output at no load 1 Open or shorted diodes in 3 Faulty
voltage regulator
60 100 VAC exciter rotor 1 to 3 diodes
2 Open or shorted exciter
rotor AC output voltage 1 Faulty voltage VAC or voltage output
1 STB pod on regulator 2 Faulty voltage regulator
needs voltage drop under load 1 Diodes on exciter rotor
60 100 volts AC breaking down when load is
applied inductive 13 diodes
A EXCITER STATOR
I 12
I DSTATOR i
r I 11
I I I
I 10
I I
I B I C I I
ROTORFIELO
I EXCITER I I a I 7
I I I 6
I I
I I I
I I 2 1
I I 4 3
I I
I DIODES I
L
w w
a F
FUSE
63 AMP
green L
yellow
GREEN
r1Z RED
io Amp
c Slab
g Voll BLUE
YELLOW
rJ WESTERBEKE
rEngines Generators
BT GENERATOR
WIRING DIAGRAM 039422
WITH ELECTRONIC GOVERNOR
100RN
LlFTPUMP
4 PUR
FUEL SOlENOII
WATER TEMP SENDER
SPEED ACTUATOR D
GlOWPlUGS
IfiIiI Ir4REO PUR z
Oil PRJRE SW
SA TT SWITCH 10 RED
1f14BlU
O to PURREO
LtV PREHEAT Oil PRESS
STARER
OjIII D
BATTERY lOA CB
12 VDC REO
GROUND TO BLOCK
r4TAN
4 BlU
EXHAUST SW
U 14 BRN
i14PURwHT
4 REO
t12 Rln
J
REMOVE THIS
JUMPER WHEN
f0 20 CONNECTING A
50
JlJFUK
J4RED
REMOTE PANEL
0 07
it 04
J jjjj I
GOVERNOR
CONTROL
140RN
STANDARD
INSTRUMENT
IJ WESTERBEKE
I Engines Generators
BTGENERATOR
WIRING SCHEMATIC 039422
WITH ELECTRONIC GOVERNOR
BATTERY
SWITCH START
L SOL STARTER
L I
PREHEAT
SOL GLOWPLUGS
L l
ALTERNATOR
TB23
STARLJ
1 EMERGENCY g
STOP L J
L JSWITCH
i PREHEAT
L SWITCH K
L 87
LIFT PUMP
ESTOP
J SWITCH OP ET WT
Sw Sw SW FUEL SOL
OP WT
SNDR NOTE An onoff switch should be installed in this circuit
to disconnect the starter from the battery in an emergency
and when leaving the boat Twelve volt diesel engine starters
typically draw 200 to 300 amps when cranking A switch
with a continuous rating of 175 amps at 12 VDC will nor
mally serve this junction but a switch must never be used to
make the starter circuit
IVVI WESTERBEKE
I Engines Generators
BT GENERATOR WIRING DIAGRAM
36411 WOUT ELECTRONIC REGULATION
t14 PUR
o 0
IOORN
XC ALTERNATOR
LIFT PUMI
14 PUR 14 PUR
REG T Jt
WATER
1i1 TEMP SW
o
i
WATER TEf1P z
FUEL
R r
SDLENOi
IIii ii
GlOWPLUGS
OIL PjE LP SW
0 ORN
01 L PRESSURE
PREHEAT
r SENDER
flO RED
2 RED
I S I CIRCUIT
I r BREAKEP
I RCUD CIRCUIT
I TOBlOCK STARTER
12RED
t4TAN
14 BLUE
EXHAUST TE1f
SvlTCH
14 N
t 14 PURWHT EMERGENCY
STOP
SITCH
12 YELRED
TO ENGINE
BLOCK 0
F 14 REO
T8 f
r
7 I
2 EMOVE THIS
JUPER WHEN
CONIECTIIG A Ie 3
REMOTE PAEL r
14 GRN
fJ 1 eR1J
108lK
14 RI 10 RED
1 14 YEl lovHT
14PUP
I i
01 14 GRN J
rtt I
PREHEAT
SW ITCH
iSTANDARD
START
I INSTRUMENT
SWITCH I PANEL
srop II
I I
SWITCH I
I
II WESTERBEKE
I Engines Generators
BT GENERATOR WIRING SCHEMATIC
36411 WOUT ELECTRONIC REGULATION
r2VOC
JE 2 START SOL ENOl 0 TARTEIt
PREHEAT
SOLENQlb
STPT sw
rB23
r EMERGENCY
j STOP 5W
I IPREHEAT sw LIFT PUMP
I
r 1
L J P
I
lSTOP SW
FUEL SOLNOIO
NOTE An onoff switch should be installed in this circuit
to disconnect the starter from the battery in an emergency
and when leaving the boat Twelve volt diesel engine starters
typically draw 200 to 300 amps when cranking A switch
with a continuous rating of 175 amps at 12 VDC will nor
mally serve this junction but a switch must never be used to
make the starter circuit
REMOTE STARTSTOP PANEL
i 5A SURGE
22A START
3A RUN
Current Models
wITwo Relays
Models wI
Terminal Blocks
Models wout
Terminal Blocks
I RED
TO TB1l TBl2
10 TB11 10 Slop
I r I Switch
STOP T
1 I
1114 BLACK rJ BLACK
4J U TB1GroundIo Panel Ground
SWITCH I
1122 I
BLACK I
1122 RED G I
1 1DHT5 10 TB21lo Preheat Swilch
1110 RED I 4APURPLE I I I
10 TB22lo Preheat Switch
SWITCH SWITCH 3A RUN
I RED
14 RED 1114 RED
14 RED
Yl
I I
TB13 10 TB12 10 Preheal Switch
r TB15
I I
T to T814 to Start I
REMOTE PANEL REAR VIEW
fiATl WESTERBEKE
I Engines Generators
GENERATOR AC GENERATOR Single Phase AC GENERATOR 3 Phase
Single Phase Brushless fourpole revolving field Three Phase Brushless sixpole revolving field Sealed
design 150 Kw 60 Hertz lubricated design 12 Lead
singlephase transformer 120 Kw 50 Hertz reconnectable for low voltage WYE high
regulation optional solidstate voltage voltage Delta Solid state voltage regulator with
regulation protection 120 or 120240 Volts 60 Hertz
Voltage 3 phase 50 Hertz Low Voltage WYE 208 Volts
230 Volts 50 Hertz High Voltage WYE 480 Volts
DELTA 240 Volts
Voltage regulation 5 no load to full load
Voltage 3 Phase 50 Hertz High Voltage WYE 380 regulation 3 Hertz 5 no load to full load
DELTA 230 Volts
Electronic Govemered
Amperage Low Voltage WYE 52 Amps
NonElectric 3 Hertz 3 phase 60 Hertz High Voltage WYE 22 Amps
Rating Volts AC 60 Hertz 1800 rpm 120 Volts 125 Amps DELTA 45 Amps
120240 Volts 125625 Amps Amperage High Voltage WYE 22 Amps
50 Hertz 1500 rpm 230 Volts 60 Amps 3 phase 50 Hertz DELTA 39 Cooling 225 250 cfm 637 708
cmm Generator Compartment 104F 40C maximum
Air Requirements Ambient Hertz at 1800 rpm NOTE Increase air supply 15 for 50 Hertz
NOTE Forced ventilation should be provided to
operation 1500 rpm maintain generator compartment Combustion 70 cfm 189 cmm
below 104F 40C
Air Hertz at 1800 rpm
Generator Compartment 104F 40C NOTE Forced ventilation should be provided to
maintain generator compartment temperatures
below 104F 40C
For WTA Generator Resistance Values see page 86 For WMF Generator Resistance Values see page 70
Il WESTERBEKE
I Engines Generators
SPECIAL TOOLS GENERATOR
FIELD FABRICATED TOOLS Lifting Eye Tool
These drawings provide a means by which simple tools can This tool allows a mechanic to safely remove the generator
be made to assist in the removal of the generator end from end from the engine by attaching this Generator End Lifting
the engine and in the replacement of the generator end on the Eye to the four screw holes located under the control panel
engine A local machine shop should be able to fabricate these To use this Lifting Eye remove the generators control panel
tools at a modest price but first check with your local WEST and screw the Lifting Eye to the generator end
ERBEKE dealer to see if these tools are on hand for loan
Housing Puller Tool 159 mm
This tool allows the bearing in the generator housing to be
gently pushed straight off the housing without any twisting
If a nut of the same as that of the tapped hole
in the pilot tool were to be welded on the end of the eye bolt
this tool would be able to pull the bearing back into place
without any twisting Please refer to these drawings before
1 212
635 mm
the generator end is removed
4 HOLES
1213 UNC Storebought 6mm
eye bolt with tapered tip
UuER tOOL
fEl
I I
I
4 I
45 Center lifting eye on
1016mm
1 aper I baseplate and weld 85 mm
I Disk Alignment Tool
Dia BC This tool allows a mechanic to safely remove and install the
r 1 generator drive disks by aligning the disks with the Drive
J 0 Plate Guide Pin The Pin screws into the flywheel and acts as
a guide Also the pin helps to support some of the rotor and
the drive plates weight while removing or replacing these
Weld a 1213 UNC Hex Nut parts
one side of this center hole
nWWW1HUJm 5
12 127 mm Dia
Drill Typ 4 holes Material Coldrolled Steel Material One M8 bolt with the hex head machined off and a
screwdriver slot cut in the machined end
Pilot Tool
The tool below helps keep the rotor from damaging the
windings in the generator housing to be removed straight off
the engine or to be placed straight on the engine Refer to the
removal and replacement diagram at the bottom of the page
I 203 mm I ROUND TIP
I fP1
155 mm Drill
I I
114 3175 mm Deep Approx
M18 x 15 Pitch
Tap 1 254 mm Deep
PROPER USE OF HOUSING PULLER
Material Aluminum
lfATl WESTERBEKE
I Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEEn
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO Liters Gallons Liters Liters Gallons Liters Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 OF
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
ll WESTERBEKE
I Engines Generators
Testing 50 Lubricating Oil Pump 42
BT Bridge Rectifier 95 96 Main Bearing 21
BT Generator 91 Oil Pan 27
BT Chart 94 104 Oil Pressure 43
BT AC Connections 100 Oil Pressure SwitchSender 43
BT No Load Adjustment 100 Piston and Piston Ring 18
BT Voltage Regulator Adjustment 101 Push Rod 22
Camshaft 21 Raw Water Pump 39 Rear Oil Seal 23
Connecting Rod 19 Reassembly 24
Control Panel 63 Rocker Arm 17
Coolant Circulating pump 41 54
Crankshaft 20 Standards and Limits 52
Cylinder Block 17 Starter Motor 45
Cylinder Head Bolt Pattern 27 35 Stop Solenoid 40
Cylinder Liner 17 Tappets 22
Electronic Governor Thermostat 28
Electronic Governor Kit 65 Timing Gears Cover 23
Electronic Governor 67 Timing Gears 12 22
Engine Testing for Overhaul Adjustments 39 Torque 54
Assembly 3
Block 11 Valve Clearance 2839
Camshaft 21 Valve Guide 15
Checking gears 22 Valve Seat 16
Coolant Pump 41 Valve Spring 14
Compression 39 Wiring 56 57 58 59
Connecting Rod 19 Exhaust Manifold 31
Crankshaft 20 Frequency Adjustment BT 99
Cylinder Block 17 Fuel Injection Pump 32
Cylinder Head Bolt Pattern 27 Fuel Injectors 34
Cylinder Head Inspection 14 17 Fuel Lift Pump 33
Cy linder Liner 17 Fuel System 36
Disassembly 8 Generator
Exhaust Manifold 31 Circuit Breaker BT 91
Fuel Injection Pump 32 Control Panel Switches 62
Fuel Injectors 34 Control Panel 63
Fuel Lift Pump 33 Disassembly 8
Glow Plugs Testing 38 Electronic Governor 646566
Heat Exchanger 31 Electronic Governor 67
Idler Gear 21 Electronic Regulation WMF 69
Idle Speed Adjustment 40 Field Flashing WTA 79
Injection Pump 9 32 Flashing the Field WMF 71
Injection Timing 32 Frequency Adjustment BT 99
Injectors 34 Information 61
Inspection 14 Maintenance 61
Low Oil Pressure 43 Output Voltage Adjustment WTA IVVI WESTERBEKE
I Engines Generators
INDEX
Overload Protection Setting 101 Remote StartStop Panel diagram 62 107 BT Generator 93103
Rotating Bridge Rectifer 83 WMF Generator 68
Shore Power Transfer Switch WTA Generator Special Tools 109 Control Panel 83
108 Electronic Governor 66
Voltage Regulator WTA 84 Engine 3
Voltage Regulator 3 Phase 101 Fuel Lift Pump 33
Glow Plugs Testing 38 Fuel System 36
Heat Exchanger 31 Valve Clearance 28 39
Injection Pump 9 10 Valve Guide 15
Injection Timing 32 Valve Seat 16
Injectors 34 Valve Spring 14
L Dimension 15 Voltage Regulator BT Oil Pump 42 Wiring Diagrams Conversion Chart 11 0 BT Generator Terminal
Block Conn 100
NoLoad 100 BT Generator Single 92
Oil Pump BT Generator 3 102 103
Oil Pressure 43 BT Generator 39422 Schematic 105
Oil Pressure Testing 43 BT Generator 39422 Diagram 104
Pumps BT Generator 36411 Schematic 1 07
Coolant Circulating 41 BT Generator 36411 Diagram 106
Fuel Lift 33 BT Wiring 96
Injection 32 Remote StopStart Panel 1 07
Raw Water Overhaul 44 Rotating Bridge Rectifier 83
Raw Water Pump 44 W52 Engine 33685 Diagram 56
Rear Oil Seal 23 W52 Engine 33685 Schematic 57
Remote StartStop Panel 63 108 WMF Generator Internal Schematic 72
Sealants 55 WMF Generator 40438 73
Service Data 52 WTA Schematic 78
Special Tools Generator 109 WTA Series Schematic Engines 60 WTA Generator 24700 Generators 108 WTA Schematic
Standards and Limits 52 WTA Generator Connections Schematic 89
Starter Motor 45 63B63C Engine 039144 Diagram 58
Starter Motor Adjustment and Repair 45 63B63C Engine 039144 Schematic 59
Tachometer 49 WMF Generator 68
Tappets 22 WMF Resistanve Values 70
Testing for Overhaul WMF Gear Cover 23 WMF Gear 12 WTA Generator 74
Torques WTA Regulator Boards 84
Standard Hardware 55 WTA Resistance Values 86
Westerbeke Components 54 WTA Electrical Fault Chart Oil Coolers 30 WTA Parts 8
IVtTI WESTERBEKE
I Engines Generators
IJ WESTERBEKE
I Engines Generators

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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.