Westerbeke 71 B-FOUR User manual

SERVICE MA UAL
71 B·FOUR /71
DIESEL
and
6.0KW·50Hz
DIESEL TORS
SINGLE AND THREE PHASE
PUBU CATlON N O. 43317
2ND EDITION I MARCH 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 col-
orless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can Include:
-Dizziness
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- Vomiting
- WfIlIkness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
SET OUT INTO THE FRESH AIR IMMEDIATELY. " symptoms persist,
seek medical attention. Shut down the unit and do not restart
until It has been Inspected and repaired.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to foUow fundamental rules and precau-
tions. Know when dangerous conditions existand toke the
necessary precautions to protectyourself, yourpersonnel,
and your machinery.
The foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC elBCtrlcal CDIIIIBCIIons
while engine is IUnning
l Of
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.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Of
exhaust system components. A IUnnlng engine gets
very hot!
• Always check the engine coolantlevel at the coolant
recovery tank.
A WARNING: Steam can cause injury Of death!
• In case of an engine overheat, allow the engine to cool
before touching the engine
or checking the coolant.
i
PREVENT BURNS - FIRE
A WARNING: Fire can cause Injury Of 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 GuardApproved 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/gener-
ator 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 Of death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Checkbelow for fumes/vapor before run-
ning 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 offthe 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 orengine when servic-
ing. 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 shutoffvalve.
• 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.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause Injury
01 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 ofthe engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause Injury
01 death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in
the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection 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 ofexplosive 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
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid In battelles can cause
severe Injury 01 death!
• 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. If
it comes in contact with your skin, wash it offat 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 ofthe 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: ca, bon monoxide (CO) Is an Inlllsible
odorless gas. Inhalation ploduces Du-lIke symptoms,
nausea 01 death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
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 ofexhaust. 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 ofthe symp-
toms or signs ofcarbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause Injury
01 death!
• Do not service the engine while it is running. If a situation
arises in which it
is absolutely necessary to make operat-
ing adjustments, use extreme care
to avoid touching mov-
ing parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loosejackets, 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 legis can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do notrun engines for long periods with their enclosures
open.
A WARNING: Do not wotk on machinery when you alB
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 theAmerican Boat and Yacht Council's
(ABYC) standards. These standards are a combination
of
sources including the USCG and the NFPA.
Sections
of theABYC standards of particular interest are:
B-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).
iii
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 UNIVERSALengine
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
15 East 26th Street
New York,
NY 10010
NFPA (National Fire ProtectionAssociation)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Batterymarch Park
P.O. Box 9101
Quincy,
MA 02269-9101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
Washington, D.C. 20404

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is 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 minimum
of 18"
above the vessel's waterline. Failure to use a siphon-break when the exhaust
manifoldinjection port is at orbelow the load waterline will result in raw water
damage to the engine and possibleflooding of the boat.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
'A detailed 40 page Marine Installation Manual covering gasoline and diesel,
engines and generators, is available from your WESTERBEKE dealer.
Engines & Generators

TABLE OF CONTENTS
Introduction ............................................................... .2
DC Wiring Diagram (engine) .................................... .48
Testing for Overhaul ..... .............................................. 3
DC Wiring Schematic (engine) ................................ .49
Engine Troubleshooting ............................................. .4 Generator Information .............................................. 50
Engine Disassembly ............... ..................................... 8 BE Generator ............................................................ . 51
Engine Inspection .................................................... . 13 Generator AC Voltage Connections .. ....................... 52
Engine Reassembly ................................................... 23 Voltage Regulator Adjustments .............................. .54
Exhaust Manifold ..................................................... .29 Internal Wiring Schematics ...................................... 55
Heat Exchanger ........................................................ .29 BE Troubleshooting ................................................... 56
Fuel Injection Pump ................................................. 30 Electronic Governor ................................................. . 57
Fuel Lift Pump ......................................................... . 31 Electronic Governor Troubleshooting ...................... 58
Fuel Injectors .. ................................................ - .......... 32 Shore Power Transfer Switch ................................... 59
Glow Plugs . ............................................................... 34 DC Wiring Diagram (generator) ................................ 60
Engine Adjustments .................................................. 35 DC Wiring Schematic (generator) ............................ 61
Coolant Circulating Pump ........................................ 37 Generator Specifications ......................................... .62
Lubricating Oil Pump ............................................... .38
Service Data/Tolerances & Limits ............................ 64
Oil Pressure Switch .................................................. 39
Torque Specifications ............................................... 68
Oil Pressure .............................................................. 39
Engine Specifications ............................................... 69
Raw Water Pump ...................................................... .40 Standard Hardware Torques ..................................... 70
Starter Motor ........................................................... .41
Metric Conversions .................................................. 71
Tachometer .............................................................. .45
Index .......................................................................... 72
Alternator Testing .................................................... .46
Engines & Generators
1

INTRODUCTION
PRODUCT SOFTWARE
Product software (tech 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
CONTENTOFSUCHSOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPlETENESS THEREOF AND WILL INNO EVENT
BE UABLE FOR ANY TYPE OFDAMAGE OR INJURY
INCURRED IN CONNECTION WITH
OR ARISING OUT
OF THE FURNISHING OR USE OFSUCHSOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings
of WESTERBEKE product
software and the unavoidable existence
of earlier
WESTERBEKE manuals. Product software provided with
WESTERBEKE products, whether from WESTERBEKE
or other suppliers, must not and cannot be relied upon
exclusively as the definitive authority
on the respective
product. It not only makes good sense but is imperative
that appropriate representatives
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 disassembly, inspection
and assembly procedure
of your 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
obselVt1d, can result in the damage or destruct/on of
your engine/generator.
A WARNING: Procedures, whIch if not properly
followed, can result in personal injury or loss of life.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear
on the silver and black
name-plate located on the generator end. 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 upon
WESTERBEKE packaged parts because will
fit or generic
parts are frequently not made to the same specifications
as original equipment.
CUSTOMER IDENTIFICATION CARD
/..-v-IWES I ERBEKE
I .
Customer Identification
WESTERBEKE
OWNER
MAIN STREET
HOMETOWN,
USA
Model71C
Expires 4/4/98 Ser. #UOOOO-D702
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date
of
manufacture of your WESTERBEKE engine/generator. The
first character indicates the decade (A=1960s, B=1970s,
C=1980s, 0=1990s), the second character represents the year
in the decade, and the fourth and fifth number represents the
month
of manufacture.
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal
on the generator housing.
The engine serial number can also
be found stamped into the
engine block
just above the injection pump. The generator
serial number is stamped into the generator housing
on the
flat surface on the left side
of the generator ..
An identification plate on the engine manifold also displays
the engine model and serial number.
ENGINE
SERIAL
NUMBER
GENERATOR
10 DECAL
The following sections contain detailed information
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 undertaken only by such facilities.
Additional detailed information and specifications are
provided in other sections
of this manual, covering the
generator, alternator, starter motor, engine adjustments,
cooling pumps, etc.
Engines & Generators
2

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output,
in the case
of diesel engines, is not necessarily due to trouble
with the engine itself, but is sometimes caused by injector
nozzle wear
or injection pump wear. It is most reasonable to
judge by a decrease in compression pressure. The decrease
in compression pressure is caused by many factors. It is,
therefore, necessary to determine a cause or causes on the
basis
of data produced by periodic inspection and
maintenance. Oil analysis on a seasonal basis is a good
means
of monitoring engine internal wear. When caused
by worn cylinders or piston rings, the following symptoms
will occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased oil consumption
4
Hard engine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms (2) and
(4) can result also from excessive fuel injection, improper
injection timing, and wear
of plugs and nozzles. They are
caused also by defective electrical devices such as the battery,
alternator, starter and glow plugs. Therefore it is desirable
to judge the optimum engine overhaul time by the lowered
compression pressure caused
by worn cylinders and pistons
plus increased oil consumption. In diesel engines,
satisfactory combustion is obtained only under sufficient
compression pressure.
If an engine lacks compression
pressure, incomplete combustion
of fuel will take place even
if other parts of the engine are operating properly. To
determine the period of engine overhaul, it is important to
measure the engine compression pressure regularly.
At the
same time, the engine speed at which the measurement
of
compression pressure is made should be checked because the
compression pressure varies with engine rpm. The engine
rpm can be measured at the front end of the crankshaft.
NOTE: To test engine compression see the
ENGINE ADJUSTMENT section of this manual.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress
of wear
of these parts.
When decrease
of compressiOll pressure reaches the repair
limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blowby evident, and compression valves are at minimum or
below. Engine compression should be
30 kg/cm2,
427 psi at 200 rpm.
Precautions for Disassembly and Reassembly
When servicing an engine, keep in mind the following
precautions.
Disassembly
1. Before disassembly and cleaning, carefully check for
defects which cannot be found after disassembly and
cleaning.
2. Drain water, fuel and oil before disassembly.
3. Clean or wash the engine exterior.
4. Do not remove
or disassemble the parts that require no
disassembly.
5. Perform disassembly in a proper order using proper tools.
Keep disassembled parts
in order. Apply oil when neces-
sary. Take special care to keep the fuel system parts from
intrusion
of dust and dirt.
Reassembly
1. Clean or wash the parts. Apply oil on surfaces where
needed or specified.
2. Carefully check gaskets, packings and oil seals even
if checking is not specified. Replace with new ones
if defective.
3. Be sure to install components in proper directions and
positions. (pay attention to dowel pins, mating marks and
specified directions.) Where tightening torque is not
specified, tighten evenly to an ordinary torque. Apply
sealant where specified.
4. After completion of reassembly, recheck for any
abnormalities. Prepare for starting the engine, and idle
the engine sufficiently for a test run.
ENGINE TROUBLESHOOTING
The following ENGINE TROUBLESHOOTING section may
be
of assistance in determining the need for planning and
engine overhaul.
SERVICE MANUAL
The engine block of the 7lC-FOUR differs from it's
predecessor, the 71B-FOUR, with variations in service data
(tolerances, limits and torques). In this service manual 71B
or 71C designates this service data and a small 718 or 71C
will identify the artwork. Components that are common to
both engines such as the Raw Water Pump will have no
designation.
The 71B-FOUR engine powers the 20.0KW BED generator.
The 7lC-FOUR engine powers the 20.0KW BEDAgenerator.
NOTE: Make certain the engine model has been correctly
identified, see SERIAL NUMBER LOCATION.
Engines & Generators
3

ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain
problems relating
to engine service, the probable causes of
these problems,
and the recommendations to overcome
these problems.
PROBLEM PROBABLE CAUSE
HARD STARTING LOW CRANKING SPEED
1. Engine oil viscosity too high.
2. Run-down battery.
3. Worn battery.
4. Battery terminals loosely connected.
5. Defective starter.
6.Defective main drive section.
DEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
2. Clogged fuel filter.
3. Low injection pressure.
4. Inadequate spray.
5. Injection pump delivering insufficient fuel.
6. Injection too early.
MAIN ENGINE TROUBLES
1. Low compression.
a. Incorrect valve clearance.
b. Inadequate contact of valve seat.
c. Valve stem seized.
d. Broken valve spring.
Note: The engineselectrical system is protected by a 20-
ampere manual reset circuit breaker. The preheat solenoid is
mounted on the same bracket.
VERIFICATION/REMEDY
1. Replace engine oil with less viscous oil.
2. Recharge battery.
3. Replace battery.
4. Clean terminals and correct cables.
5. Repair or replace starter.
6. Check clutch for disengagement.
1. Bleed air from fuel system.
2. Clean or replace filter.
3. Adjust injection pressure.
4. Clean or replace nozzle.
5. Repair or replace injection pump.
6. Adjust injection timing.
a. Adjust valve clearance.
b. Lap valve.
c. Replace valve and valve guide.
d. Replace valve spring.
e. Compression leaks through cylinder head gasket. e. Replace gasket.
f. Piston ring seized.
f. 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 fo 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.
(continued)
Engines & Generators
4

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
LOW OUTPUT (cDnt.)
OVERHEATING
1. Low coolant level.
1. Add coolant.
2. Loose V-belt.
2. Adjust or replace V-belt.
3. Incorrect injection timing.
3. Adjust injection timing.
4. Low engine oil level.
6. Add engine oil.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION
1. Defective oil seals.
1. Replace oil seals.
2. Broken gear case gasket.
2. Replace gasket.
3. Loose gear case attaching bolts.
3. Retighten bolts.
4. Loose 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.
4. Replace a valve and valve guide.
EXCESSIVE FUEL ENGINE BODY TROUBLES
CONSUMPTION 1. Noisy knocking. 1. See KNOCKING.
2. Smoky exhaust.
2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn. 3. Repair or replace.
4. Poor compression.
4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing.
5. Adjust.
6. Improper valve clearance. 6. Adjust.
INSUFFICIENT INTAKE AIR
1. Air intake obstructed. 1. Remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle. 1. Replace.
2. Worn nozzle. 2. Replace.
IMPROPER FUEL
Replace with proper fuel.
FUEL LEAKS Find fuel leaks.
SMOKY EXHAUST WHITISH OR PURPLISH
1. Excessive engine oil. 1. Correct oil level.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact. a. Check.
b. Seized piston ring ..
b. Replace or clean.
c. Excessive piston-to-cylinder clearance. c. Replace or correct.
(continued)
Engines & Generators
5

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
SMOKY EXHAUST (cont.)
WHITISH OR PURPLISH (cont.)
d. Worn valve stem and valve guide. d. Replace.
e. Low engine oil viscosity. e. Replace.
f. Excessive oil pressure.
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 fuel.
ABNORMAL 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 wom or damaged.
4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft.
1. Replace.
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear.
3. Replace.
4. Worn fan pulley bearing.
4. Replace.
ROUGH OPERATION
INJECTION PUMP SYSTEM
1. Uneven injection.
1. Adjust injection or replace parts.
2. Control rack malfunctioning.
2. Disassemble, check and correct injection pump.
3. Worn delivery valve.
3. Replace.
4. Inadequate injection nozzle spray.
4. Replace injection nozzle.
GOVERNING SYSTEM
1. Governor lever malfunctioning.
1. Check governor shaft and correct operation.
2. Fatigued governor spring.
2. Replace.
(continued)
Engines & Generators
6

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a. Overheated cylinder. a. See OVERHEATING; LOW OUTPUT.
h. Carbon deposits in cylinder. h. 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 malfunctioning.
a. Worn plunger.
a. Replace.
h. Pinion is not in mesh with control rack. h. Correct.
c. Broken delivery valve spring. c. Replace.
d. Worn delivery valve seat. d. Replace.
3. Improper nozzle.
a. Poor spray.
a. Clean or replace nozzle.
h. Poor chattering. h. Repair or replace nozzle.
c. After-injection drip. c. Repair or replace nozzle.
d. Nozzle needle valve seized. d. Replace.
INTERMITTENT
1. Fuel filter clogged. 1. Clean or replace.
EXHAUST SOUND
2. Fuel pipe sucks air. 2. Retighten pipe jOints or replace pipe.
3. Water mixed in fuel 3. Replace fuel.
OVERHEATING
1. V-belt 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.
Engines & Generators
7

\
ENGINE DISASSEMBLY
GENERATOR
Disconnect the AC wiring, unplug the DC wiring harness
at the control panel and remove the speed sensor from the
bellhousing. Carefully support and then unbolt the generator
back end from the engine.
For generator maintenance and service, refer to the
GENERATOR SECTION of this manual.
PROPULSION ENGINE
Unplug the instrument panel wiring harness. Drain the trans-
mission fluid and the transmission oil cooler hoses, Detach
the oil cooler hoses and unbolt the transmission from the
engine.
For transmission service and maintenance refer to your
transmission owners manual.
To rebuild a transmission contact yourWESTERBEKE
dealer
or your local marine transmission shop.
With the transmission or generator separated from the
engine, begin the following step by step procedure
of engine
disassembly.
ENGINE DISASSEMBLY
Take the following precautions:
•. Clean the exterior of the engine of any deposits
of dirt and oil.
• Be careful not to damage the disassembled parts.
• Mount the engine on suitable engine stand for
disassembly.
~
1. Drain the engine oil and coolant from the engine
and heat exchangers.
2. Remove engine wiring harness
in its entirety. Label
terminal connections to insure proper reattachment.
C
o ~~: ~~
iBIO~
~·t~
, DAMPER PLATE
,BOLTS
3. Remove engine heat exchanger and engine cooler. If pos-
sible, leave one
end of each hose connection attached to
the part being
removed.'
4. Remove starter motor.
S. Remove engine bellhousing. ONE BOLTDEVIATES S'
6. Remove transmission damper plate. . FROM THE 6(], S-.€T UP ."
7. Remove flywheel.
WHEN REMOVING
THE MOUNTING
BOLTS -- ____ I4...~-IJ
LOCK THE FLYWHEEL
WITHA RING
GEAR
BREAK TOOL
GENERATOR
STARTER/SOLENOID f· .
{PROPULSION ENGINE
9. Unbolt elbows at head and remove the exhaust manifold
in its entirety.
10. Remove the engine alternator and raw water pump.
11. Remove the engine mounted fuel filter and fuelline to
injection pump. (Note the arrangement
of sealing wash-
ers
on banjo bolts at fuel filter and injection pump.)
\
DAMPER
PLATE
00
Engines & Generators
8

\\
r
12. Remove the thennostat housing and the thennostat.
Leave temperature sending unit in place.
13. Remove the coolant circulating pump.
14. Remove the air intake silencer.
15. Remove all the high pressure injector lines from the
injection pump to the injectors. Leave the two upper line
clamps
in place.
NOTE: Cap the ends of the lines and the connections at the
injection
pump and at the injectors to prevententry of
foreign material.
16. Remove the intake manifold.
17. Remove the fuel return line from the top of the injectors
and from the fuel injection pump. (Note the washer
arrangement on fuel return line banjo bolts. Cap all the
openings on the fuel return line, injectors and injection
pump.)
a.
Remove the fuel injectors, dust seals and sealing
washers from the cylinder head.
b. Remove the glow plugs.
18. Remove the crankcase breather hose and rocker
arm cover. .
""",.... \ \
', . ....:J.--l ROCKER ARM
~i \\ COVER
.;
\"
ROCKER ARM, 'J
ASSEMBLY ,
a. Remove the rocker arm assembly.
b. Remove the valve stem caps so as not to lose them
when removing the cylinder head.
Label each cap as
top which valve it belongs.
c. Remove the push rods. Label each rod as to
which valve
it belongs.
d. Lift the cylinder head offthe engine.
INTAKE MANIFOLD:
jASSEMBLyL ,.
19. Remove the cylinder head.
NOTE: Loosen the cylinder headbolts equally and gradually
in
the' ordershown in ~he dia~r~
,.' i I :" .
! 14;1 10 1.6 23;7
i13 9
I
14 18 /12
.J
;.
i /
, ,~~ @I@..
i 20. RelIlove the ~~. ~ter~assembl~
I
Engines & Generators
9

21. Remove the injection pump, Scribe the mating marks
on the pump hody flange and the timing gear case
before removing.
a. Remove the cover and the lock nuts.
INJECTION
PUMP
b. Loosen the two injection pump hold down nuts. Do
not 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.
c. Remove the nut and lockwasher from the injection
pump shaft,
NOTE: Take care not to drop the nut and the washer into
timing gear case.
d. Place the keyway on the injection pump shaft in
the 12:00 position with the aid
of the front crankshaft
pulley bolt before attempting
to remove the
injection pump.
e. With the use of extractor #49 SE 01 157 apply
sufficient pressure to loosen the pump from the keyed
gear. The loose hold down nuts will prevent the
pump.
from falling from the engine.
EXTRACTOR HOLES
NOTE: If an extractor is not available, replace the nut on the
injection
pump shaftloosely and with a nylon drift and
hammer gently tap the injection pump shaft to dislodge it
from the keyed drive gear. '
f. Once loosened. remove the hold down nuts and
washers 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.
EXTRACTOR TOOL *49 SE 01157
REMOVING THE
CRANKSHAFT
PULLEY
NOTE: Remove the pulley bolt with the aid of a
38
mm socket and draw the pulley off thefront crankshaft,
22. Remove the timing gear cover.
23. Remove the injection pump gear and the oil baffle plate,
24. Remove the central idler gear and idler gear spindle,
25. With a suitable puller remove the crankshaft gear
and key.
26. Remove the camshaft gear using a suitable puller.
, INJECTION PUMP
. GEAR AND BAFFLE PLATE'
TIMING GEAR COVER
@~
~>::.
IDLER
SPINDLE~
\8.»
'"
PUMP GEAR
TIMING GEARS· 71 B
, I
,

ENGINE 'DISASSEMBLY
~
llOLER GEAR
'J TIMING ~EARS
REMOVING THE INJECTION PUMP GEAR
'INJECTION
27. Thrn the engine over and remove the oil pan.
28. Loosen the set screw,
then remove the oil pump assembly.
29. Remove the
camshaft carefully. Insure that all the
pushrod tappets
are seatedinto the engine block prior to
attempting to
remove the camshaft from the block.
30. Remove the
timing gear ~~ from the front ofthe engine
block. Discard
the old gasket.
/
! OIL PAN:
\.'.~ •• 0
.. ~~ .. : .... . " ,Jfi!J
'~~
REMOVING THE OIL PAN. '..~ G
.~ ~ ~
. - .. - -... .,'
REMOVING THE TIMING GEAR CASE
Engines & Generators
11

ENGINE DISASSEMBLY
31. Remove the rear oil seal.
32. Remove the connecting rod bearing caps.
33. Remove the piston and connecting rod assemblies from
the top ofthe cylinder block.
34. Remove the main bearing caps.
NOTE: Mark the bearing caps to insure properr~~sembly.
35. Remove the crankshaft.
CRANKSHAFT
\ ASSEMBLY .
REMOVING THE
VALVES
36. Remove each valve from the cylinder head assembly.
Use an appropriate valve spring compressor to aid: in
disassembly. Arrange or label valves so as to replace
them in the cylinder and the guide from which they
were removed.
37. Disassemble the rocker arm assembly.
38. Disassemble the piston assembly.
a. Using the piston ring remover, remove the
piston rings.
b. Remove the wrist pin snap rings.
'c. Using a nylon drift, drive the wrist pin from the piston
and rod.
\ PISTON
I;IST~N RING:
"
~~
I
(
I
I
I,
i
I
1'-
[lARGE END
'._- .'.--~\
\
/ "\
L PISTON ASSEMBLY . \
\
d. Protecting your eyes with safety glasses, disengage
and withdraw the snap rings. Although mechanics
generally press out (and sometimes hammer out)
pistons pins, these practices should be discouraged.
Instead, take the 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 itenters the
\ far boss.
\ NOTE: The number stamped on the rod shankandcap should
1\ correspond to the cylindernumber. Sometimes these numbers
are scrambled
or missing, and the mechanic must supply
lthem. Stamp the correct numbers on the padsprovided and,
l,tO prevent confusion, deface the originals.
I
Engines &Generators
12

ENGINE INSPECTION
CYLINDER HEAD
1. Visual Inspection. Check the cylinder head for cracks
or any other damage and,
if necessary, repair or replace it.
2. Distortion Inspection. Measure the cylinder head
surface distortion
with a straight edge and the thickness
gauge. Take 6 measuring positions as shown in the diagram.
IT the distortion exceeds permissible limit, replace the
cylinder head. (The
head has no allowance for planing and
must be replaced,
not renewed.)
Cylinder
Head Distortion Limit
71 ani C Positions: 1, 2 0.10 mm (0.004 in)
3,4,5, 6 0.25 mm (0.010 in)
FEELER GAUGE ~
2·
!-~~~-&::"""~-e~~~~~~~~5
6
1.
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 injection nozzle hole, then tap the drift
with a hammer. To install, setthe insert in position and insert
the welch washer into the insert guide hole. Secure the welch
washer by tapping the raised center of the welch washer.
REMOVING THE.
I INSERT
a Use a new welch washer.
h. Insert the welch
washer so that its convex surface
is toward the
cylinder head gasket.
c. After installation, check to see if the insert is
completely fixed
in place.
i WELCH WASHER"'-..
VALVE SEAT
NOTE: Valve seat inserts cannot befitted to this engine.
1. Valve SeatAngle. Valve seat angle is 45° and 30°
respectively for intake and exhaust sides. The standard
contact width of the valve seat is 2.0 mm (0.08 in) for both
intake and exhaust sides.
If the valve margin is less than the
pennissible limit, replace
the valve.
Mllve margin limit
71 ani C 1.35 mm (0.053 in)
12mm(.08 in)
Engines &Generators
13
"I 3{7 mm (1.25 in)
EXHAUST

ENGINE INSPECTION
2. Dimension L. Check the protruding length of the valve
stem,
if it exceeds the specification, correct it as follows:
Dimension L Standard
71 Bn1 C 48.0 mm (1.890 in)
/
a. When dimension L becomes large 0 -0.5 mm (0-
0.0202 in) from the standard, it is possible to use both
the valve and the cylinder head.
I
I
DIMENSION L
b. When dimension L becomes to large 0.5 -1.5 mm
(0.20 -0.059 in) from the standard, adjust the
dimension L to the standard by adding some washers
(inner diameter 12.8
mm (0.504 in ), outer diameter 39
mm (1.535 in) between the lower spring seat and the
cylinder head.
c.
When dimension L becomes to large ( more than 1.5
mm, 0.059 in) from the standards, install the valve with
a
new one, and recheck dimension L.
d. When dimension L becomes 1Q large 0 - 0.5 mm
(0 -0.0202 from the standard, replace the valve.
e. When dimension L becomes to large 0.5 -1.5
111m
(0.020 -0.059 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 1.5
mm (0.059 in) from the standard, replace both the
valve
and the cylinder head.
,
l ..
\. \
I
,
'LOWER
SPRING
SEAT
! WASHER
g. Check for contact between the valve and valve seatby
applying a thin
coat of Prussion Blue (or Redlead) on
the valve seat contact face, then insert the valve into
the valve guide
and press fit the valve on the valve
seat.
NOTE: Do not rotate the valve!
CONTACT FACE
h. Check if the valve seat contact face contacts the
center position
of the valve contact face. If the contact
position is not
centered, repair the valve and the
valve seat.
..
2. Stem Wear Inspection. If the valve stem is bent orits
diameter is less than
the limit, replace the valve.
Stem diameter limit
71B Intake
Exhaust
71C Intake
Exhaust
8.884 mm (0.350 in)
8.864
mm (0.349 in)
7.880 mm (0.3102 in)
7.867
mm (0.3097 in)
i CHECKiNG VALVE STEM WEAR ....
Engines & Generators
14