WESTERBEKE Multi-port ELECTRONIC FUEL INJECTION Marine GASOLINE Generator Single Phase*Factory Service / Repair/ Workshop Manual

, , -(lRIJ " .., .,. l II' -t 'fer o q SERVICE MANUAL 44A-44B-44C"FOUR ' 35C-35D-35E- THREE MARINE DIESEL ENGINES 8.0KW • 60Hz " 6. OKW • 50Hz BTOA 10.0KW • 60Hz' , 7.5KW • 50Hz BTOA 11.SKW • 60Hz 9.2KW· 50Hz BTO,:(elec) 12.SKW • 60Hz' 9.4KW· 50HzBTOB 12.6KW • "6llHz 10.4KW· 50Hz BTO'(elec) '15.0J(W. 60Hz 12.0KW • 50Hz BTOC -" - --- "-- .. -.- ... _----- - ,' Single and Three Phase MARINE DIESEL GENERATORS , '.'of". . _. __ , , PUBLICATION NO.45100 REVISION 2 APRIL 2010

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 WARNING: Exhaust gasses contain carbon Monoxide, an odorless and colorless gas. Carbon Monoxide Is poisonous and can cause unconscltiusness and death. Symptoms of Carbon Monoxide exposure can Include: -Dizziness -Nausea -Headache - Throbbing In Temples - Muscular Jlltltchlng - Vomiting - Weakness and Sleepiness -InabIlIty to ThInk Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THt FRESH AIR IMMEDIATELY. If symptoms persist, seek medIcal attention. Shut down the. unit and do not restart until It has blfen Inspected and repaired. This WARNING DECAL Is provided by WESTERBEKE and should be flxed to a bulkhead near your engIne or genemtor. . WE$TERsEKEa!so recommends installing CARBON MONOXIDE DETECTORS In the IlvInll/Sleeplng quartem tif your vessel. T1Ieyare Inexpensive and easily obtainable at your local marine store.

SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and tak£ the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in complinnce with the Ameriean Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK A WARNING: Do not toullh AC electrillal Ilonnelltions while engine is running, or when Ilonnellted to shore power. Lethal voltage Is present at these connelltions! • Do not operate this machinery without electrical enclosures and covers in place. • Shut off electrical power before accessing electrical equipment. • Use insulated mats whenever working on electrical equipment. • Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment. • Remove wristwatch and all jewelry when working on electrical equipment. • Do not connect utility shore power to vessel's AC circuits, except through a ship-to-shore double throw transfer switch. Damage to vessel's AC generator may result if this procedure is not followed. • Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together. PREVENT BURNS - HOT ENGINE A WARNING: Do not toullh hot engine parts or exhaust system Ilomponents. A running engine gets very hot! • Always check the engine coolant level at the coolant recovery tank. A WARNING: Steam can cause injury or death! • In case of an engine overheat, allow the engine to cool before touching the engine or checking the coolant. PREVENT BURNS - FIRE A WARNING: Fire Ilan cause Injury or death! • Prevent flash fires. Do not smoke or permit flames or sparks to occur near the carburetor, fuel line, filter, fuel pump, or other potential sources of spilled fuel or fuel vapors. Use a suitable container to catch all fuel when removing the fuel line, carburetor, or fuel filters. • Do not operate with a Coast Guard Approved flame arrester removed. Backfire can cause severe injury or death. • Do not operate with the air cleaner/silencer removed. Backfire can cause severe injury or death. • Do not smoke or permit flames or sparks to occur near the fuel system. Keep the compartment and the engine/generator clean and free of debris to minimize the chances of fire. Wipe up all spilled fuel and engine oil. • Be aware - diesel fuel will bum. PREVENT BURNS - EXPLOSION A WARNING: Explosions from fuel vapors Ilan Ilau;e injury or death! • Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine. • All fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out of the reach of children. • Do not fill the fuel tank(s) while the engine is running. • Shut off the fuel service valve at the engine when servicing the fuel system. Take care in catching any fuel that might spill. DO NOT allow any smoking, open flames, or other sources of fire near the fuel system or engine when servicing. Ensure proper ventilation exists when servicing the fuel system. • Do not alter or modify the fuel system. • Be sure all fuel supplies have a positive shutoff valve. • Be certain fuel line fittings are adequately tightened and free ofleaks. • Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. WESTERBEKE Engines & Generators

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury or death! • Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect it last. • Make certain all personnel are clear of the engine before starting. • Make certain all covers, guards, and hatches are re- installed before starting the engine. BAnERY EXPLOSIDN A WARNING: Battery explosion can cause injury or death! • Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing dur- ing servicing. • Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Sparks could ignite battery gases Or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb the battery charger connections while the battery is being charged. • Avoid contacting the terminals with tools, etc., to prevent bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery. • Always tum the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery. BAnERYACID A WARNING: Sulfuric acid in batteries can cause severe Injury or death! • When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which is destructive. If it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps. TOXIC EXHAUST GASES A WARNING: Carbon monoxide (CO) is a deadly gas! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close attention to the martifold, water injection elbow, and exhaust pipe nipple. • Be sure the unit and its surroundings are well ventilated. • In addition to routine inspection of the exhaust system, install a carbon monoxide detector. Consult your boat builder or dealer for installation of approved detectors. • For additional information refer to ABYC T-22 (educa- tional information on Carbon Monoxide). A WARNING: Carbon monoxide (CO) is an invisible odorless gas. Inhalation produces flu-like symptoms, nausea or death! • Do not use copper tubing in diesel exhaust systems. Diesel fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust/water leakage. • Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. lithe engine exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Avoid overloading the craft. • Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some of the symptoms or signs of carbon monoxide inhalation or poisoning are: Vomiting Muscular twitching Dizziness Intense headache Throbbing in temples Weakness and sleepiness AVOID MOVING PARTS A WARNING: Rotating parts can cause injury or death! • Do not service the engine while it is running. 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 components. -...v: WESTERBEKE Engines & Generators ii

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. • Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. • Do not check fluid levels or the dtive belt's tension while the engine is operating. • Stay clear of the dtive shaft and the transruission coupling when the engine is running; hair and clothing can easily be caught in these rotating parts. HAZARDOUS NOISE A WARNING: High noise levels can cause hearing loss! • Never operate an engine without its muffler installed. • Do not run an engine with the air intake (silencer) removed. • Do not run engines for long periods with their enclosures open, A WARNING: Do not wOlk on machinery when you ale mentally 01 physically Incapacitated by fatigue! OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures. ENGINE INSTALLATIONS Preparations to install an engine should begin with a thor- ough examination of the American Boat and Yacht Council's (ABYC) standards. These standards are a combination of sources including the USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-l Exhaust systems P-4 Inboard engines E-9 DC Electrical systems All installations must comply with the Federal Code of Regulations (FCR). ABVC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommenda- tions when installing your engine. ABYC (American Boat and Yacht Council) "Safety Standards for Small Craft" . Order from: ABYC 3069 Solomon'S Island Rd. Edgewater, MD 21037 NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Oaft" Order from: NFPA 11 Tracy Drive Avon Industrial Park Avon, MA 02322 USCG (United States Coast Guard) "USCG 33CFR183" Order from: U.S. Government Printing Office Washington, D.C. 20404 Engines & Generators iii

INSTALLATION When installing WESTERBEKE engines arid generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment. SIPHON-BREAK For installations where the exhaust manifold/water injected exhaust elbow is close to ' or will be below the vessel's waterline, provisions must be made to install a siphon- break in the raw water supply hose to the exhaust elbow. This hose must be looped a ntinimum of 20" above the vessel's waterline. Failure to use a siphon-break when the exhaust manifold injection port is at or below the load waterline will resuf1 in raw water damage to the engine and possible flooding of the boat. If you have any doubt about the position of the water-injected exhaust elbow relative to the vessel's waterline under the vessel's various operating conditions, instaU a siphon-break. NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper operation. Failure to properly maintain a siphon-break can result in catastrophic engine damage. Consult the siphon-break manufacturer for proper maintenance. EXHAUST SYSTEM The exhaust hose must be certified fur marine use. The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of the vessels hull. A detailed Marine Installation Manual covering gasoline and diesel engines and generators is supplied with every unit sold. This manual is also available in pdllormat on our website to download Website: www.westerbeke.com Engines & Generators iv AVAILABLE FROM YOUR WESTERBEKE DEALER

TABLE OF CONTENTS Parts Identification/Engines ............................................... 2 Wiring Schematic - Engines .............................................. 59 Parts Identification/Generators .......................................... 3 Specifications - 44-Four Models ...................................... 60 Introduction ........................................................................ .4 Specifications - 35-Three Models .................................... 61 Engine Troubleshooting ....................................................... 5 DC Electrical System (Alternator) .................................... 62 Testing for Overhaul... ......................................................... 9 Mando Alternator Service ................................................. 64 Engine Disassembly ...... .................................................... 10 Wiring Diagram - Generators ............................................ 71 Inspection .......................................................................... 16 Wiring Schematic - Generators ....................................... 71a Assembly ............................................................................ 27 Remote Panel Schematic .................................................. 72 Exhaust ManifoldlHeat Exchanger ................................... .35 Specifications - Generators ............................................... 73 Fuel Injection Pump .......................................................... 36 BT Generator Single/fhree Phase .................................... 76 Governor ........................................................................... 38 12 Stod Internal Wiring Schernatic................................ 77 Fuel Injection Timing ....................................................... .39 Glow Plug Testing ............................................................. .41 Starter Motor ..................................................................... 42 Raw Water Pumps #33636 ........................................................................... .46 #48080........................................................................... .47 Component Resistance Values ....................................... 77 Internal Wiring Schematic 6 Stod.................................. 78 BT Generator Troubleshooting (Chart) ................... •.......... 79 BT Generator Troubleshooting .......................................... 80 , BT Generator Troubleshooting (Single Phase) ................. 81 AC Terminal Board (12 Stud) ...•••.................... ••...•.•........... 85 #48080 Parts List .......................................................... .48 BT Internal Wiring (Three Phase) ...................................... 86 Engine Adjustments .......................................................... 49 BT Troubleshooting (Three Phase) .............................. • ..... 87 Valve Clearance Adjustment. ........................................ .49 BT Voltage Regulator Adjustments (Three Phase) ........... 88 ( Testing Engine Compression ......................................... 50 Generator Frequency Adjustment .................................. 51 Fuel Run Solenoid ......................................................... 51 Oil Pressure ........................ ........................................... 52 Drive Belt Adjustment ................................................... 53 Adjusting Idle Speed...................................................... 53 Service Data-Standards and Limits ................................. .54 Wiring Diagram - Generator (Electronic Governor) ........... 89 Wiring Schematic- Generator (Electronic Governor) ....... 90 Electronic Governor (Optional) .......................................... 91 Electronic Governor (Adjustments) .............................. • .... 92 Linear Actuator Troubleshooting ...................................... 93 Special Tools - Generator ................................................. 94 Special Tools - Engines ..................................................... 56 Standard Hardware ............................................................ 95 Torque Specifications ....................................................... 57 MetriC Conversion Data .................................................... 96 Wiring Diagram - Engines ................................................. 58 Index .................................................................................. 98 ".yo WEBTERBEKE Engines & Generators 1

PARTS IDENTIFICATION/PROPULSION WATER INJECTED EXHAUST 20ACIRCUIT REAR FRONT DC ALTERNATOR RAW WATER UNIHD, OIL ,coo LAN I PRESSURE CAP RIGHT SIDE DRAIN HOSE COOLER I INTAKE/AIR FILTER THERMOSTAT FRONT . OIL FILL l@L ___ PRE'HEAT SOLENOIO FILTER REAR HEAT EXCliANGiER LEFT SIDE ... WESTERBEKE Engines & Generators 2 \ J

( ( ( PARTS IDENTIFICATION/GENERATORS LEFT SIDE OIL RAW WATER ru .. r--:-__ HEAT PANEL BACK-ENO. 20 CIRCUIT BREAKER FRONT PREHEAT BREAKER OIL REAR MOUNT OIL RIGHT SIDE OIL PRESSURE GENERATOR EMERGENCY STOP SWITCH CONNECTION TO BREAK '0t<>ct-t---E'XHAUSTELBOW __ --'I-IL_-!iTART SOLENOID REAR '!'O(iLANTJ PRESSURE CAP C .FILL FRONT FILL THERMOSTAT ASSEMBLY AIR INTAKE SILENCER & FILTER PUMP OIL FILL FILTER Engines & Generators 3"

INTRODUCTION PRODUCT SOFTWARE Product software, (technical data, parts lists, manuals, brochures and catalogs), provided from sources other than . WESTERBEKE are not within WESTERBEKE'S control. WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOF1WARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMEUNESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OF SUCH SOF1WARE. WESTERBEKE customers should keep in mind the time span between printings ofWESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE product software. The product software provided with WESTERBEKE products, whether from WESTERBEKE or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product. It not ouly makes good sense bnt is imperative that appropriate representatives ofWESTERBEKE or the supplier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer. NOTES, CAUTIONS AND WARNINGS As this manual takes you through the operating procedures, maintenance schedules, and troubleshooting of your marine engine, critical infonnation will be highlighted by NOTES, CAUTIONS, and WARNINGS. An explanation follows: NOTE: An operating procedure essential to note. A CAUTION: Procedures which, if not strictly observed, can result in the damage or destruction of your engine. A WARNING: Procedures which, if not properly followed, can result in pelSonal injury or loss of life. ORDERING PARTS Whenever replacement parts are needed, always provide the engine model number and serial number as they appear on the silver and black nameplate located on the manifold. You must provide us with this infonnation so we may properly identify your engine. In addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). Insist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment. Customer Identification Card ·/"Mf'IWESTERBEKE I Customer Identification MR. GENERATOR OWNER MAIN STREET HOMETOWN, USA Modelll.5 EDT Ser. #UOOOO-ESll Expires: 8/5/2013 The WESTERBEKE engine serial number was an alphanumeric number that can assist one in detennining the date of manufacture. A manufactoring date code is placed at the end of the engine serial number. It consisted of a character followed by three numbers. Today it consists of two characters. Previous date code. The character indicated the decade E=2000s. The first number represented the year in the decade, and the second and third, the month of that year. Beginning in May 200S, the two characters HE. H represented 2008 and the E the month of May and so on HF 2008 July, HG 200S July. SERIAL NUMBER LOCATION The engine's serial number can be found stamped into the engine block just above the injection pump. An identification plate on the engine manifold also displays the engine model and serial number. The gene.rator serial number is stamped on the left side of the generator housing and on the flat surface above the rotary . ENDI.NE SERIAL NUMBER ENGINE OVERHAUL The following sections contain information GENERATOR 10 DECAL relating to the proper operation characteristics of the major components and systems of the engine. Included are disassembly, inspection and reassembly instructions for the guidance of suitable equipped and staffed marine engine service and rebuilding facilities. The necessary procedures should be taken ouly by such facilities. Additional detailed iufonnation and specifications are provided in other sections of this manual, covering the generator, alternator, starter motor, engine adjustruents, cooling pumps, etc. WESTERBEKE Engines & Generators 4

WESTERBEKE Multi-port ELECTRONIC FUEL INJECTION Marine GASOLINE Generator Single Phase*Factory Service / Repair/ Workshop Manual

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