WESTERBEKE W-13 & W-18 Marine Diesel Engine Service Manual

SERVICE MANUAL 2&3·CYLINDER MARINE DIESEL ENGINES & GENERATORS 2-CYLINDER MODELS Engines Generators 60 Hz 50 Hz W-13 WMD 4.4 WMD 3.3 W-13A 4.4 BCD 3.3 BCD 3-CYLINDER MODELS Engines Generators 60 Hz 50 Hz W-18 WMD 6.0 WMD 4.5 W-18 6.0 BCD 4.5 BCD W-21 WMD 7.7 WMD 5.8 WMD 8.0 WMD 6.0 W-21A 8.0 BTD 6.0 BTD RD-60 35B THREE 10.0 BTD 7.5 BTD PUBLICATION NO. 43444 1st Edition / April 1999 J WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK AVON, MA 02322· TEL: (508) 588-7700. FAX: (508) 559-9323 WEBSITE: WWW.WESTERBEKE.COM ---- §.JI9 Member National Marine ManufacturersAssocation

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 cDntain CarbDn MDnDxide, an DdDrless an,d cDIDriess gas. CarbDn MDnDxide is pDisonDus and can cause uncDnsciDusness and death. SymptDms Df CarbDn MDnDxide expDsure can include: -Dizziness -Nausea -Headache - Weakness and Sleepiness - ThrDbbing in Temples - Muscular Twitching - Vomiting -Inability to Think CDherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. «symptoms persist, seek medical attentiDn. Shut dDwn the unit and dD nDt restart until it has been inspected and repaired.

SAFETY INSTRUCTIONS INTRODUCTION Read these safety instructions carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK A WARNING: Do not touch AC electrical connections while engine is running, or when connected to shore power. Lethal voltage is present at these connections! • Do not operate this machinery without electrical enclosures and covers in place. • Shut 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 with an insulated tool. PREVENT BURNS - HOT ENGINE A WARNING: Do not touch hot engine parts or exhaust system components. A running engine gets very hot! • Always check the engine coolant level at the coolant recovery tank. A WARNING: Steam can cause injury or death! • In case of an engine overheat, allow the engine to cool before touching the engine or checking the coolant. PREVENT BURNS - FIRE A WARNING: Fire can cause injury or death! • Prevent flash fires. Do not smoke or 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 burn. PREVENT BURNS - EXPLOSION A WARNING: Explosions from fuel vapors can cause 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 of leaks. • Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. Engines & Generators

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury Dr 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. BAmRY EXPLOSION A WARNING: Battery explosion can cause injury Dr 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 servicing the battery. BATTERY ACID A WARNING: Splphuric acid in batteries can cause severe injury Dr 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 manifold, 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 Dr death! • Do not use copper tubing in diesel exhaust systems. Diesel fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust/water leakage. • Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If the engine exhaust discharge outlet is near the 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 poison- ing are: Vomiting Dizziness Throbbing in temples Muscular twitching Intense headache Weakness and sleepiness AVOID MOVING PARTS A WARNING: Rotating parts can cause injury Dr death! • Do not service the engine while it is running. If a situation arises in which it is absolutely necessary to make operat- Engines & Generators ii

SAFETY INSTRUCTIONS ing adjustments, use extreme care to avoid touching moving parts and hot exhaust system components. • Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. • Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. • Do not check fluid levels or the drive belt's tension while the engine is operating. • Stay clear of the drive shaft and the transmission coupling when the engine is running; hair and clothing can easily be caught in these rotating parts. HAZARDOUS NOISE A WARNING: High noise levels can cause hearing loss! • Never operate 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: 00 not work on machinery when you are mentally or physically incapacitated by fatigue! OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures. 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 AIl installations must comply with the Federal Code of Regulations (FCR). ABYC, 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/generator. ABYC (American Boat and Yacht Council) "Safety Standards for Small Craft" Order From: ABYC 3069 Solomon's Island Road Edgewater, MD 21037 NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Craft" Order From: NFPA 11 Tracy Drive Avon Industrial Park Avon, MA 02322 USCG (United States Coast Guard) "USCG 33CFR183" Order From: U.S. Government Printing Office Washington, D.C. 20404 Engines & Generators iii

Engines & Generators

TABLE OF CONTENTS Introduction .......................................................................................... 3 Engine Adjustments .......................................................................... .39 Product Software ............................................................................3 Tightening the Cylinder Head ......................................................39 Engine/Generator Model Designations ..........................................3 Adjusting Valve Clearance ...........................................................39 Notes, Cautions and Warnings........................................................ 3 Adjusting Fuel Injection Timing ................................................. .40 Ordering Parts/Serial Number Location .........................................3 Adjusting No-Load Engine Speeds ............................................. .40 Engine/Generator Specifications ....................................................... .5 Lubrication System Service .............................................................. .42 Testing for Overhaul ............................................................................. 6 Description ................................................................................... .42 How to Judge Engine Overhaul Period .......................................... 6 Disassembly ................................................................................. .42 Cause of Low Compression ...................................................... 6 Oil Filter and Oil Pump ......................................................... .42 Measuring Compression Pressure ............................................. 6 Inspection ..................................................................................... .43 Overhaul Conditions ....................................................................... 6 Oil Pump .................................................................................43 Disassembly .............................................................................. 7 Reassembly .................................................................................. .43 Reassembly ............................................................................... 7 Testing the Oil Pressure ............................................................... .43 Service Standards ................................................................................ 8 Oil Pressure Switch ..................................................................... .44 Technical Data .................................................................................... ]] Tightening Torque ......................................................................... 11 Engine Troubleshooting ..................................................................... ]2 Engine Parts Identification ................................................................ 16 2-Cylinder Models ........................................................................ 16 3-Cylinder Models ........................................................................ 17 Cylinder Head ..................................................................................... 18 Construction .................................................................................. 18 Cylinder Head Service ........................................................................ 20 Disassembly .................................................................................. 20 Inspection ..................................................................................... .20 Cylinder Head ......................................................................... 20 Valve Guide ............................................................................. 20 Valve Seat ............................................................................... .20 Valve ....................................................................................... . 21 Valve Spring ............................................................................ 21 Rocker Arm and Rocker Shaft ................................................ 21 Reassembly .................................................................................. .22 Partial Reassembly ................................................................. .22 Installation of Cylinder Head Assembly .................................22 Valve Clearance Adjustment .................................................. .22 Cylinder Block .................................................................................... 23 Construction .................................................................................. 23 Cylinder Block Service ....................................................................... 25 Disassembly ..................................................................................25 A Models ................................................................................ .25 B, C and D Models ............................................................... .25 Removing Piston Pin .............................................................. 26 Inspection ...................................................................................... 26 Cylinder Block ........................................................................26 Piston, Piston Pin and Piston Rings ........................................ 27 Connecting Rod ......................................................................27 Crankshaft ............................................................................... 28 Main Bearings and Connecting Rod Bearings ....................... 28 Gearcase .................................................................................. 29 Timing Gears and Lube Oil Pump Gear .................................29 Camshaft ................................................................................ .29 Fuel Injection Pump Camshaft ............................................... 29 Ball Bearings ........................................................................... 29 Tappets ................................................................................... .29 Push Rods ................................................................................ 29 Reassembly - A Models ............................................................. 30 Reassembly - B, C and D Models ............................................ .33 Governor ............................................................................................. 37 Description .................................................................................... 37 Disassembly .................................................................................. 37 Inspection ..................................................................................... .37 Governor Lever ....................................................................... 37 Generators .............................................................................. .44 Propulsion Engines ................................................................. 44 Fuel System ........................................................................................ 45 Description ................................................................................... .45 Fuel System Service .......................................................................... .47 Disassembly ................................................................................. .47 Fuel Filter ............................................................................... .47 Fuel Lift Pump ....................................................................... .47 Fuel Injection Pump .............................................. ,................ .47 Injector ................................................................................... .48 Inspection ..................................................................................... .48 Fuel Filter ............................................................................... .48 Fuel Lift Pump ...................................................................... .48 Fuel Injection Pump ............................................................... .48 Nozzle .................................................................................... .48 Reassembly .................................................................................. .48 Fuel Filter ............................................................................... .48 Fuel Lift Pump ....................................................................... .48 Injection Pump ........................................................................ 48 Installation and Adjustment of Fuel Injection Pump ............. .49 Injector .................................................................................... 50 Adjustment and Installation of Nozzle Holder Assembly ..... .50 Raw Water Cooling Circuit... ............................................................. .52 Description ................................................................................... .52 Raw Water Pump Service ................................................................... 53 Pump Overhaul - Raw Water Pump PN 33636 .........................53 Disassembly ........................................................................... .53 Inspection ................................................................................53 Reassembly .............................................................................53 Pump Overhaul - Raw Water Pump PN 32610 ......................... 54 Disassembly ............................................................................ 54 Inspection ................................................................................ 54 Reassembly ............................................................................ .54 Pump Overhaul - Raw Water Pump PN 24143 ........................ .55 Disassembly ........................................................................... .55 Inspection ................................................................................55 Reassembly ............................................................................ .55 Fresh Water Cooling Circuit .............................................................. 56 Description .................................................................................... 56 Fresh Water Cooling Service ............................................................ .57 Disassembly ................................................................................. .57 Inspection ...................................................................................... 57 Water Pump ............................................................................. 57 Thermostat ............................................................................. .57 Reassembly .................................................................................. .57 Drive Belt Adjustment ............................................................ 57 Admiral Control Panel ....................................................................... .58 Description ................................................................................... .58 Governor Spring ...................................................................... 37 Needle Bearing ........................................................................ 37 Reassembly and Adjustment. ....................................................... .37 Captain Control Panel ....................................................................... .59 Description ................................................................................... .59 Control Panel Troubleshooting .......................................................... 60 Engine Shutoff .................................................................................... 38 Engine with Manual Stop (Standard) .......................................... .38 Optional Key Switch Shutoff (D Models only) ........................... 38 Installing and Adjusting the Key Switch Shutoff Solenoid ................................................................. 38 TachometerlHourmeter ................................................................. 60 Hourmeter Inoperative ............................................................ 60 Tachometer Inoperative ........................................................... 60 Tachometer Sticking ............................................................... 60 Tachometer Inaccurate ............................................................ 60 Key-Stop Solenoid System Operation Checking Procedure ............................................................ 38 Manual Starter Disconnect (Toggle Switches) ............................ 61 Troubleshooting Water Temperature and Oil Pressure Gauges ................................................................ 61 (continued) Engines & Generators 1

TABLE OF CONTENTS Control Panel- Early Models ............................................................ 62 Replacement of Field Coil(s) ....................................................... 91 Activation by Key Switch ............................................................ 62 Low Voltage Output ...................................................................... 91 Starter/Solenoid Service .................................................................... 64 High Voltage Output ..................................................................... 92 Description .................................................................................... 64 Adjustment and Repair ................................................................. 64 Solenoid with Throttle Linkage .................................................... 92 WMD Generator AC Internal Wiring Diagrams .................................. 93 Pinion Gap Inspection ............................................................. 64 WMD Generator DC Electrical System .............................................. 94 No-Load Test ........................................................................... 64 WMD Generator Wiring Diagram #24700 ................................... 94 Solenoid ........................................................................................ 65 WMD Generator Wiring Schematic #24700 ................................ 95 Starter Disassembly ...................................................................... 65 8.0 BTD Generator .............................................................................. 96 Starter Inspection .......................................................................... 66 Solenoid .................................................................................. 66 Inspecting the Armature .......................................................... 66 Brush and Brush Holder Inspection ........................................ 66 Field Coil Inspection ............................................................... 67 Starter Adjustment and Reassembly ............................................. 67 DC Electrical System ......................................................................... 68 Description .................................................................................... 68 Description .................................................................................... 96 8.0 BTD Generator Troubleshooting .................................................. 97 8.0 BID Internal Wiring Schematic ............................................. 97 8.0 BID Internal Wiring Schematic with Voltage Regulator Circuit Removed .................................................... 98 Bridge Rectifier .......................................................................... 100 Testing the Bridge Rectifier for Faults with an Ohmmeter ............................................................ 100 Engine 12-Volt Control Circuit... ............................................ 68 Charging System ........................................................................... 68 Exciter Stator Windings .............................................................. 101 Exciter Rotor ............................................................................... 102 Alternator Troubleshooting........................................................... 68 Checking for Proper Voltage ................................................... 68 Battery Maintenance ..................................................................... 69 Main Stator Windings ................................................................. 103 Compound Transformer .............................................................. 103 Selector Switch ........................................................................... 104 Glow Plugs ................................................................................... 69 AlternatorJRegulator Service ............................................................. 70 Bridge Rectifier Wiring .............................................................. 104 No-Load Voltage Adjustment ..................................................... 105 Description .................................................................................... 70 Optional Voltage Regulator ........................................................ 106 Alternator Troubleshooting ........................................................... 70 Installation ............................................................................. 1 06 Testing the Charging Voltage .................................................. 70 Generator Frequency .................................................................. 1 07 Output Test .............................................................................. 71 Manual Check ....................................................................... 107 Disassembly .................................................................................. 71 Electrical Check .................................................................... 107 Inspection ...................................................................................... 72 Winding Connections ................................................................. 108 Diode ....................................................................................... 72 10.0 BTD Generator .......................................................................... 109 Checking for Short Circui!... ................................................... 72 Checking for Open Circui!... ................................................... 72 Checking Diode Trio ............................................................... 72 Stator ....................................................................................... 73 Field Coil (Rotor) .................................................................... 73 Checking Brush and Brush Spring ......................................... 73 Checking the Slip Ring ........................................................... 73 Description .................................................................................. 109 10.0 BTD Generator Troubleshooting .............................................. 110 10.0 BID Internal Wiring Schematic ......................................... ll0 Residual Voltage Check .............................................................. 112 Bridge Rectifier .......................................................................... 112 Testing the Bridge Rectifier for Faults with an Ohmmeter ............................................................. 113 Regulator ....................................................................................... 73 Reassembly ................................................................................... 74 Transmissions ..................................................................................... 75 DC Electrical System ......................................................................... 76 Internal Wiring Diagram ............................................................. 113 Component Resistance Values .................................................... 114 Component Resistance Checks ................................................... 114 Exciter Stator Windings ........................................................ 114 Engine Wiring Diagram #24666 Key Switch ............................... 76 Exciter RotorlField ..................................................................... 115 Engine Wiring Schematic #24666 Key Switch ............................ 77 Main Stator Windings ................................................................. 116 Engine Wiring Diagram #33685 Key Switch & Compound Transformer .............................................................. 116 Two Pushbuttons ..................................................................... 78 Selector Switch ........................................................................... 116 Engine Wiring Schematic #33685 Key Switch & Bridge Rectifier Wiring .............................................................. 116 Two Pushbuttons .....................................................................79 No-Load Voltage Adjustment ..................................................... 117 Engine Wiring Diagram #36844 Admiral Panel .......................... 80 Voltage!Hertz Connection Bar .................................................... 117 Engine Wiring Schematic #36844 Admiral Panel ........................81 Generator Frequency ................................................................... 118 Engine Wiring Diagram #36467 Captain Panel ........................... 82 Wiring Connections .................................................................... 119 Engine Wiring Schematic #36467 Captain Panel ........................ 83 Engine Wiring Diagram #39144 Admiral & Captain Panels ......................................................................... 84 Engine Wiring Schematic #39144 Admiral & Captain Panels .........................................................................85 Standard Hardware ............................................................................. 86 BT Generator DC Electrical System ................................................. l20 BT Generator (Early Models) Wiring Diagram #34651 ............ 120 8.0 BID & 10.0 BID Generators Wiring Diagram #36412 .................................................................... 122 8.0 BID & 10.0 BID Generators Wiring Schematic #36412 ................................................................. 123 Sealants & Lubricants ....................................................................... 86 BC Generator .................................................................................... 124 Metric Conversions ............................................................................ 87 Description .................................................................................. 124 Generator Information ........................................................................ 88 Troubleshooting Guide ............................................................... 124 Use of Electric Motors ................................................................. 88 BC Generator Troubleshooting ......................................................... 125 Required Operating Speed ............................................................ 88 Internal Wiring Schematic With Battery Charging Circuit ........ 125 Generator Frequency Adjustment ................................................. 88 Rotating Field/Auxiliary Windings and Diodes ......................... 126 Generator Maintenance ................................................................. 88 Main Stator Windings ................................................................. 127 Generator Troubleshooting ........................................................... 88 Exciter Windings and Capacitors ............................................... 127 WMD Generator .................................................................................. 89 Battery Charging Circuit ............................................................ 129 Description .................................................................................... 89 Disassembly .................................................................................. 89 Inspection ...................................................................................... 89 Reassembly ................................................................................... 89 WMD Generator Troubleshooting ....................................................... 90 No Electrical Output ..................................................................... 90 Flash Field Coils ...........................................................................90 Generator Frequency (Hertz) Adjustment .................................. 130 50 Hertz - 60 Hertz Adjustment ........................................... 130 Engine Speed/Generator Hertz Adjustment... ....................... 130 No-Load Voltage Adjustment... ............................................. 131 BC Generator DC Electrical System ............................................... .132 4.4 BC & 6.0 BC Generator Wiring Diagram #35951 ............... 132 4.4 BC & 6.0 BC Generator Wiring Schematic #35951 ........... .133 Engines & Generators 2

INTRODUCTION This service manual contains detailed information relating to the proper operation of the major components and systems of the engine or generator. Included are disassembly, inspection, service, and reassembly instructions for the guidance of suit- ably equipped and staffed marine engine service and rebuild- ing facilities. The necessary procedures should be undertaken only by such facilities and their personnel. Refer also to your Westerbeke parts catalog when performing an engine overhaul. PRODUCT SOFTWARE Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTER- BEKE are not within WESTERBEKE'S control. WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE, MAKES NO WAR- RANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCUR4CY, TIMELINESS 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 SOFTWARE. WESTERBEKE customers should also keep in mind the time span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTER- BEKE manuals. In summation, product software provided with WESTERBEKE products, whether from WESTER- BEKE or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product. It not only makes good sense but is imperative that appropriate representatives of WESTERBEKE or the sup- plier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer. ENGINE/GENERATOR MODEL DESIGNATIONS This manual contains certain descriptions, procedures and specifications that vary depending on the engine/generator model. Where references to specific models are necessary, four basic model group designations are used: A Models, B Models, C Models and D Models. A MODELS B MODELS (2-CYLINDER) (3-CYLINDER) ENGINES GENERATORS ENGINES GENERATORS 60 Hz 50 Hz 60 Hz 50 Hz W-13 WMD 4.4 WMD 3.3 W-18 WMD 6.0 WMD 4.5 W-13A 4.4 BCD 3.3 BCD W-18 6.0 BCD 4.5 BCD C MODELS D MODELS (3-CYLINDER) (3-CYLINDER) ENGINES GENERATORS ENGINES GENERATORS 60 Hz 50 Hz 60 Hz 50 Hz W-21 WMD 7.7 WMD 5.8 35B Three 10.0 BTD 7.5 BTD WMD 8.0 WMD 6.0 W-21A 8.0 BTD 6.0 BTD RD-60 Differences between 2-cylinder and 3-cylinder engine models are described in the disassembly, inspection and reassembly procedures throughout the Engine section of this manual. NOTES, CAUTIONS AND WARNINGS As this manual takes you through the service procedures, maintenance schedules, and troubleshooting of your marine engine/generator, critical information 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/generator. A WARNING: Procedures, which if not properly followed, can result in personal injury or loss of life. ORDERING PARTS/SERIAL NUMBER LOCATION Whenever replacement parts are needed for engines, always provide the engine model number and engine serial number as they appear on the silver and black identification nameplate located on the manifold. For generators, provide the complete generator model number, engine serial number, and generator serial number as they appear on the silver and black decal located on the generator end. The engine serial number can also be found stamped into the engine block just outboard of the injection pump. The generator serial number is stamped into the generator housing on the side or above the rear carrier bearing. You must provide us with this information so we may properly identify your engine/generator. In addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). Also insist ijpon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment. NOTE: Component locations in this manual are referenced from the front of the engine which is the pulley/drive belt end. Left and right sides are determined as follows: imagine straddling the engine, facing in the same direction as the front of the engine: the left side is at your left, the right side is at your right. Engines & Generators 3

INTRODUCTION Owners may find it convenient to fill in the data on the decal or identification nameplate shown below to provide a quick reference when using this service manual. SPECIFICATION MODEL _______ _ RPM __________ _ KW ___________ _ KVA __________ _ VOLTS ________ _ AMPS ________ _ ENG. HP ______ _ ENG. SER. NO. GEN. SER. NO. PF IPHASE ___ _ WIRES ________ _ RATING _______ _ INSUL CLASS __ TEMP. RISE ___ _ BAITERY _____ _ C.'.O. _________ _ 50 HZ. GENERATOR DECAL 60 HZ. I PROPULSION ENGINE IDENnFICATION NAMEPLATE Engines & Generators 4

WESTERBEKE W-13 & W-18 Marine Diesel Engine Service Manual

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