Westerbeke WMD12.5 Manuel de service

-( I. It Ii " ~ . ~ ~ ~ 1ft ~ ..,. o q ~LD"" SERVICE MANUAL FOR THE 82B FOUR MARINE DIESEL ENGINE AND THE 25KW-60Hz BED /20KW-50Hz BE

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY LOW OUTPUT (cont.) OVERHEATING 1. Low coolant level. 1. Add coolant. 2. Loose V-belt

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY SMOKY EXHAUST (coni.) WHITISH OR PURPLISH (coni.) d. Worn valve stem and valve guide

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1. Main engine troubles. a. Overheated cyl

TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Generally, the time at which an engine should be overhauled is d

ENGINE/GENERATOR DISASSEMBLY PROPULSION ENGINE Unplug the instrument panel wiring harness. Drain the trans-mission fluid and the transmission oil cool

ENGINE DISASSEMBLY DISASSEMBLING THE MAIN ENGINE With the transmission/or generator separated from the engine, begin the following step by step proced

ENGINE DISASSEMBLY 16. Remove the fuel injectors, dust seals and sealing washers from the cylinder head using a 27mm deep socket. 17. Remove the glow

ENGINE DISASSEMBLY Engine Block Disassembly Disassemble the engine in the following order: 21. Remove the cylinder head rocker cover and gasket. ~j ,

ENGINE DISASSEMBLY CRANKSHAFT PULLEY 27. Remove the crankshaft pulley bolt with the aid of a 38 mm socket and draw the pulley off the front crankshaft

ENGINE DISASSEMBLY REMOVING THE TIMING GEAR CASE REAR OIL SEAL b. Remove the wrist pin snap rings. c. Using a nylon drift, drive the wrist pin from th

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defec

ENGINE INSPECTION INSPECTING .THE CYLINDER HEAD 1. Visual Inspection. Check the cylinder head for cracks or any other damage and, if necessary, repai

ENGINE INSPECTION NOTE: Measure the fitting pressure after compressing the spring several times. Spring Fitting Pressure Inner Fitting Length 1.49 in

ENGINE INSPECTION '/:,.,-.. _ SEAT INSERT d. Check for contact between the valve and valve seat by applying a thin coat of Prussian Blue (or Red

ENGINE INSPECTION ROCKER ARM CYLINDER BLOCK 1. Visual Inspection. Check each component part of the 1. VISUal Inspection. Check the cylinder block for

ENGINE INSPECTION 2. Cylinder Liner Replacement. Hydraulic press or similar device is needed. a. Attach the cylinder liner puller and installer to the

ENGINE INSPECTION CONNECTING ROD 1. Visual Inspection. Check the connecting rod for cracks or other damage and, if necessary, replace it. CONNECTING R

ENGINE INSPECTION 6. Inspecting connecting rod bearing. Check the connect-ing rod bearing for peeling and thennal damage. If it is severe, replace th

ENGINE INSPECTION 4. Inspecting crankshaft end play. Check the end play of the crankshaft and, if the end play exceeds the limit, replace the thrust w

ENGINE INSPECTION CHECKING . CLEARANCE BETWEEN TUI: I\\f.oi ~l(\\~'t\ BUSHING AND SPINDLE CHECKING THE GEARS 1. Visual Inspection. Check each ge

ENGINE INSPECTION TIMING GEAR COVER OIL SEAL 1. Inspecting timing gear cover oil seal. Check the timing gear cover and the lip of the oil seal for any

SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused byfailure to follow fundamental rules and precau-tions.

ENGINE ASSEMBLY Reassembly Precautions • Be careful not to mix bolts and nuts. Metric and S.A.E. bolts are used on various engine assemblies. • Duri

ENGINE ASSEMBLY 4. Main Bearings and Bearing Caps. NOTE: Do not apply oil to the backsides of the main bearing shells. a. Fit the main bearings on the

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 t

ENGINE ASSEMBLY 19. Assemble the new gasket set (lower block). a. Position the gasket ends A on the gaskets B and C. b. Apply a silicon sealing agent

ENGINE ASSEMBLY 31. Adjust the valve clearance. Adjust the No.1, 2,3, and 6 . valves when the No. 1 piston is on Top Dead Center (IDC) or the compres

ENGINE ASSEMBLY 43. Install the fuel injection nozzles and return lines. Use new sealing washers throughout, in the same order as were the old washers

ENGINE ASSEMBLY MARINE ENGINEJTRANSMISSION 59. Assemble the damper plate to the flywheel. Damper Plate Torque 14·20 ft·lb (1.7 -2.7 m-kg) 60. Reinstal

EXHAUST MANIFOLD I HEAT EXCHANGER EXHAUST MANIFOLD The exhaust manifold, which was disassembled from the cylinder head, should be inspected before rea

FUEL INJECTION PUMP TESTING INJECTION TIMING 1. Remove the air intake/silencer assembly. 2. Remove the four high pressure injector lines that connec

FUEL INJECTION PUMP I FUEL LIFT PUMP CHECKING CAM LIFT 1. Turn the crankshaft in the direction of normal engine rotation and read the maximum value

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury or death! • Disconnect the battery cables before servicing th

FUEL INJECTORS REMOVING THE INJECTORS NOTE: Injector must be serviced in a "clean room" environ-ment. 1. Disconnect the high pressure line

FUEL INJECTORS INSPECTING SPRAY PAnERN 1. Operate the hand lever of the nozzle tester at intervals of one stroke per second to check if the fuel is in

FUEL SYSTEM TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY Engine hard to start or fails to start 1. No fuel at injectors. 1. Check causes

FUEL SYSTEM TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY Engine output and performance poor. 1. Contaminated or inferior fuel. 1. Purge

GLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid. When PREHEAT is pressed at the control panel this solenoid should "

ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT 1. Warm the engine to nonnal operating temperature. 2. Pull off the air breather pipe from the rocker

ENGINE ADJUSTMENTS Abnonnally high readings on all cylinders indicates heavy carbon accumulations, a condition that might be accompanied by high press

COOLANT CIRCULATING PUMP REMOVING THE PUMP Remove in the following order: coolant (drain as needed); V-belt; water hoses; water pump attaching nuts; a

LUBRICATING OIL PUMP REMOVING THE OIL PUMP Remove from the engine in the following order: 1. Oil Pan; 2. Oil Pump Set Screw; 3. Oil Pipe Attaching B

LUBRICATING OIL PUMP 6. Measure the free length of the plunger spring. Check the relief valve for worn plunger and fatigued spring. PLUNGER . PLUNGE,\

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sle

RAW WATER PUMP PUMP OVERHAUL NOTE: Since completely rebuilding a damaged or worn pump from individually purchased parts would almost match the price o

STARTER MOTOR DESCRIPTION The starter can be roughly divided into the following sections: • A motor section which generates a drive power. • An over

STARTER MOTOR 3. Holding test. With a battery connected to the solenoid terminal S (+) and to the starter body, manually pull out the pinion fully.

STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between terminals S and body. No continuit

STARTER MOTOR Field Coil Inspection 1. Check for insulation between one end (brush) of the coil and yoke. 2. Check for continuity between both ends (

TACHOMETER TACHOMETER/HOUR METER The tachometerlhour meter used in propulsion engine instru-ment panels contains two separate electrical circuits with

ALTERNATOR TESTING DESCRIPTION The charging system consists of an alternator with a voltage regulator, an engine DC wiring harness, a mounted DC cir-c

ALTERNATOR TESTING e. Now check the voltage between the alternator output tenninal (B+) and ground. If the circuit is good, the voltage at the alterna

I ,-------,:~: ,~ I +~ ~~ ll..illl.U NOTE .: An on-off switch should be installed in this circuit to disconnect the starter from the battery in an eme

828 FOUR MARINE ENGINE + II YDe WIRING SCHEMATIC #039144 START SOL. STAun +---______ ~r-i-I~'+_------~{M}_--------------~ ------1 r---~~---------

INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND R

SPECIFICATIONS -828 FOUR MARINE ENGINE ENGINE SPECIFICATIONS Engine Type Aspiration Govemor Combustion Chamber Bore & Stroke Piston Displacement F

SERVICE DATA I STANDARDS AND LIMITS -828 FOUR MARINE ENGINE Component Specified Value I Standard Repair Limit inches{mm) inches{mm) COMPRESSION I TIMI

SERVICE DATA I STANDARDS AND LIMITS • 828 FOUR MARINE ENGINE Component CONNECTING ROD Small End Bore Piston Pin and Specified Value / Standard Repair

TORQUE SPECIFICATIONS -828 FOUR MARINE ENGINE COMPONENT FHB (M-KG) COMPONENT FHB (M-KG) Alternator Bracket ... 27 -38 (3.8 -5.3

STANDARD HARDWARE BOLT HEAD MARKINGS Bolt strength classes are embossed on the head of each bolt. Customary (inch) bolts are identifed by markings two

GENERATOR INFORMATION USE OF ELECTRIC MOTORS The power required to start an electric motor is considerably more than is required to keep it running af

GENERATOR CONTROL PANEL SWITCHES DESCRIPTION This manually controlled series ofWESTERBEKE marine diesel generators is equipped with toggle switches on

CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine control system is protected by a 20 amp manual reset circui

THE BE GENERATOR SINGLE AND THREE PHASE DESCRIPTION This generator is a four-pole, brushless, self-excited generator which requires only the driving f

GENERATOR AC VOLTAGE CONNECTIONS DESCRIPTION The regulator is equipped with seven numbered terminals (0 to 6) and their related brass jumpers. The ill

TABLE OF CONTENTS Introduction ... 2 Engine Torque Specifications ...

GENERATOR AC VOLTAGE CONNECTIONS AC VOLTAGE CONNECTIONS NOlE The frame ground wire (white/green) must be prop-erly positioned when changing the AC out

VOLTAGE REGULATOR ADJUSTMENTS Description The voltage regulator is an advanced design which ensures optimum AC alternator performance. It is equipped

INTERNAL WIRING SCHEMATICS SINGLE PHASE r------------, L_ 3 o ... ... ... >-EXCITER STATOR RED RED EXCITER ROTOR 1---- ---1 I STATOR I + 1 I RE

INTERNAL WIRING SCHEMATICS 3 PHASE TWELVE WIRE RECONNECT ABLE r-------., I I EXCITER STATOR r - - - + - - - - - - - , II II EXCITER II ROTOR FIELD I

BE TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH ENGINE OPERATING AT 60 HER1Z. PROBLEM PROBABLE CAUSE No AC voltage output

ELECTRONIC GOVERNOR Electronic Governor System The system is composed of three basic components: 1. Controller. Mounted in the instrument panel. 2. Se

TROUBLESHOOTING THE ELECTRONIC GOVERNOR Problem Probable Cause VerificationJRemedy System appears dead 1. Low battery voltage at controller. 1. Check

SHORE POWER TRANSFER SWITCH SHORE POWER CONNECTIONS (60 HERTZ) Generator r N G1 4G2 • l , =-NOTE: Diagram shows connections for a two-wir •• 120&quo

BED GENERATOR WIRING SCHEMATIC #039422 + 12VDC r -, J : BATTERY START : : SWITCH , -, SOL. STARTER I-----------+-r--I---I--... '------i M l--

BED GENERATOR WIRING DIAGRAM #039422 AL T""RNATOR _ 51 A liFT PUMP [1,----", PO"---+--. ~ NOTE 2: An on-off switch should be insta

INTRODUCTION PRODUCT SOFTWARE Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE a

BED GENERATOR WIRING SCHEMATIC #039422 (WITH DUAL RELAYS) : BATTERY ! SWITCH 120 AMP ICIRCUIT jBREAKER 1 EMERGENCY I STOP r ! SWITCH I r I I ~~?b L

BED GENERATOR WIRING DIAGRAM #039422 (WITH DUAL RELAYS) L ,~ -... ----'ltlf) OR.N ~ r> 114 PUR "4 PUR .14 PUR ((=f) ~) 114 PUR WATER NrrN

SPECIFICATIONS WESTERBEKE 25 KW BED GENERATOR ENGINE SPECIFICATIONS Engine Type Aspiration Govemor Combustion Chamber Bore & Stroke Piston Displac

SPECIFICATIONS WESTERBEKE 25 KW BED GENERATOR ELECTRICAL SYSTEM AC GENERATOR (THREE PHASE) Starting Battery Battery Capacity DC Charging A1temator Sta

SPECIAL TOOLS • GENERATOR FIELD FABRICATED TOOLS These drawings provide a means by which simple tools can be made to assist in the removal of the gene

METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches mm Inches mm mm Inches mm Inches 1 25.40 15 381.00 1 0.0394 15 0.5906 2 50

INDEX AC Voltage Connections ... 53, 63 Raw Water Pump ... 44 Alternator Testing ... 50 Rear

INDEX Wiring Diagram ... 73 Tappets ... 22 Wiring Schematic ... 72 Testing fo

ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problem

~r"9Y" rWESTERBEKE WESTERBEKECORPORATION ~ MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 1008 WMDW 12/98