Westerbeke 90A Four User manual

· SERVICE MANUAL
90AFOUR
MARINE DIESEL ENGINE
· and ·
32.0 KW-60 Hz BEDA
" .
25.0 KW-50 Hz BEDA .
MARINE DIESEL GENERATORS
SINGLE AND THREE PHASE
: . PUBLICATION NO. 43750
Revision 2 I February 2018
~rw 'WESTERBEKE :. ·.

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.
AwARNJNG
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. carbon Monoxide Is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness
•Nausea
•Headache
• Throbbing in Temples
•Muscular TWitching
•Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE S'(ltfPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. U symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends Installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

·TABLE OF CONTENTS
Introduction.........................................................................2
90AFour Propulsion Engine Specifications.......................4
90AFour Propulsion Engine Parts Identification...............5
Testing for Overhaul........................................................... 6
Engine Troubleshooting...................................................... 7
Engine Disassembly..........................................................
14
Engine Inspection and Repair........................................... 20
Engine Reassembly........................................................... 31
Exhaust Manifold..............................................................47
Engine Adjustments...........................................................48
Lubrication System........................................................... 51
Cooling System.................................................................54
Fuel System.......................................................................59
Starter Motor..................................................................... 64
Admiral Control Panel.......................................................78
Captain Control Panel........................................................79
Control Panel Troubleshooting......................................... 80
DC Electrical System..................... ~ .................................. 81
Alternator...........................................................................82
Dual OutputAlternators....................................................84
90AFour Propulsion Engine
Wiring
Diagram# 41343............................................. 86
90AFour Propulsion Engine
Wiring
Schematic# 41343.......................................... 87
Hurth HSW Transmissions............................................... 88
Hurth
HBW 250 Transmission......................................... 91
Borg Warner Velvet Drive Transmission.......................... 93
Transmission Troubleshooting..........................................
96
Standard Hardware I Sealants & Lubricants.....................98
90AFourTorque Specifications....................................... 99
32 KW BEDAGenerator Specifications.........................
100
1
32 KW BEDAGenerator Parts Identification................. 102
Generator Information............................. '.: ...................... 103
Generator Control Panel Switches.................................. 104
Control Panel Troubleshooting........................................105
The BE Generator, Single and Three Phase.................... 106
Generator AC Voltage Connections.................................107
Voltage RegulatorAdjustments....................................... 109
Internal Wiring Schematics............................................. 11 O
BE Troubleshooting.........................................................112
Electronic Governor.........................................................113
Troubleshooting the Electronic Governor........................114
Shore PowerTransfer Switch.......................................... 115
32 KW BEDA Generator Wiring Diagram #040425
· (Single Relay)............................................................. 116
32 KW BEDAGenerator Wrring Schematic #040425
(Single Relay).............................................................
.117
32 KW BEDA Generator Wiring Diagram #040425
(1\vo Relays)...............................................................118
32 KW BEDAGenerator Wiring Schematic #040425
(Two Relays)........................................................._......119
32
KW BEDA Gene~tor Wrring Diagram #44737
(Two Relays)(Plug;..in Remote Start/Stop Panel).......120
32 KW BEDA Generator Wrring Schematic #44737
(1\vo Relays)(Plug-in RemoteStart/StopPanel)....... 121
32 KW BEDA Generator Wrring Diagram #041128
(Single Relay) 24 VDC Special Spec.........................122
32 KW BEDA Generator Wiring Schematic #041128
(Single Relay) 24 VDC Special Spec.........................123
32
K;W BEDAGenerator Wiring Diagram #44806
(Two Relays) (Plug-in Remote Start/Stop Panel).......124
32 KW BEDAGenerator Wrring Schematic #44806
(1\vo Relays) (Plug-in Remote Start/Stop Panel).......125
Special Tools -Generator................................................126
Index................................................................................ 128
Metric Conversions....................,.................................... 130
Standard and Metric Conversion Data............................
131
REVISION 2006
Injection Pump
Removal and Installation ............................................63A
Setting the Timing.......................................................63A
Installation and Torques ..............................................63B

INTRODUCTION
ENGINE OVERHAUL
This service manual contains detailed information relating to
the overhaul
of the 90A Four Diesel Engine and the 32.0
KW/25.0
KW BEDA Diesel Generators. For the major
engine overhaul procedure, refer to the ENG,NE DISASSEM-
BLY, ENGINE INSPECTIONAND REPAIR, and ENGINE
REASSEMBLYsections. Additional service information for
the generators and
o~er specific components and systems
may
be found by referring to the TABLE OF CONTENTS and
the
INDEX. Refer also to your WESTERBEKE Parts
Catalog.
These service procedures are intended for the guidance
of
suitably equipped and staffed marine engine service and
rebuilding facilities, and should only be undertaken
by such-
facilities and their personnel.
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 CANNOTBERESPONSIBLE FOR THE
CONTENTOFSUCH
SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BEUABLE
FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING
OR USE OFSUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings
of WESTERBEKE product soft-
ware and the unavoidable existence
of earlierWESTER-
BEKE manuals. Product software provided with
WESTERBEKE products, whether from WESTERBEKE
or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense
but is imperative that appropriate
representatives
of WESTERBEKE or the supplier in question
be' consulted to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTION AND WARNINGS
As this manual takes you through the service procedures and
troubleshooting
of your marine engine, critical information
will
be highlighted by NOTES, CAUTIONS, and WARNINGS.
Anexplanation follows.
NOTE: An operating procedure essential to note.
A CAUTl'ON: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly fol-
lowed, can result in personal injury or loss of life.
2
CUSTOMER IDENTIFICATION CARD
tw/WESTERBEKE
I
Customer Identification
MR. ENGINE OWNER
MAIN STREET
HOMETOWN, USA
Model 90A FOUR
Expires 8/2/00
Ser.#UOOOO-D906
The WESTERBEKE engine serial number is an alphanu-
meric number that can assist
in determining the date of man-
ufacture
of your WESTERBEKE engine. The manufacturer's
date code is placed
at the end of the engine serial number and
consists
of a characterfollowed by three numbers. The char-
acter indicates the decade (A=1960s, B=1970s, C=1980s,
D=1990s, E=2000s), the first number represents the year in
the decade, and the second and third numbers represent the
month
of manufacture.
ORDERING PARTS/SERIAL NUMBER LOCATION
Whenever replacement parts are needed, always provide the
engine model number and engine serial number as they
appear
on the silver and black identification nameplate locat-
ed on the side of the engine's exhaustmanifold. The engine
serial number can also
be found stamped into the engine
block just above the injection pump, and on generators, on
the decal locl;lted
on the side of the generator. You must pro-
vide
us with this information so we may properly identify
your engine.
In addition, include a complete part description
and part number for each part needed (see the separately fur-
nished Parts List). Also insist upon WESTERBEKE pack-
aged 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 asfollows: 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. ·

INTRODUCTION
Owners may find it convenient to fill in the data on the decal or identification
nameplate shown belowto 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/PHASE----
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE----
BAITERY ------
C.1.0. ----------
50 HZ.
GENERATOR DECAL
60 HZ.
I
- ENGINE.lllENTlfl!:ATIOJf. N~EPLATE
3

90A.FOUR PROPULSION ENGINE:SPECIFICATIONS
Engine Type
Aspiration
Governor
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque
(at 3600 rpm)
SPECIFICATIONS ..
Diesel, four-cycle, four-cylinder, fresh water-
cooled, vertical in-line overhead valve
mechanism, (90 hp at 3600 rpm maximum).
Naturally aspirated.
Integral with the injection pump; mechanical
flyweight type.
3.94 x4.33 inches (100.0x110.0 mm)
210.8 cubic inches (3.5 liters)
1-3-4-2
Clockwise, when viewed from the front
168 lb-ft (23 kg-m)
Compression Ratio 18:1
Dimensions
Weight
Height: 36.0 inches. (91.4 cm)·
Width: 23.0 inches (58.4 cm)
Length: 39.3 inches (99.8 cm)•
790 lbs (358.3 kgs)
TUNE-:UP SPECIFICATIONS .....
Compression Pressure
(Limit of difference
between cylinders)
Valve Timing
Engine Timing
Injector Pressure
Valve Seat Angle
Valve Clearance
(engine cold).
Engine Speed
427 psi (30 kg/cm
2)
at 200 rpm
47.6 psi (3.0kg/cm2)
Intake Opens 19° BTDC
Intake Closes 47° ABDC
Exhaust Opens 52" BBDC
Exhaust Closes 14° ATOC
Static timed - drop valve method
0.180 :1: 0.005 inches BTDC.
2450 :1: 35 psi (172.2 :1: 2.5 kg/cm
2
).
Intake 45°
Exhaust30°
Intake 0.012 inches (0.3 mm)
Exhaust 0.014 inches (0.35 mm)
Idle: 700 - 900 rpm
Cruise: 2500 - 3000 rpm
·Max: 3500-3600 rpm
. COOLING SYSTEM .
General
Operating Temperature
Coolant Pump
Raw Water Pump
Raw Water Flow,
at3600rpm
Coolant (fresh water)
System Capacity
Exhaust Elbow
Exhaust Hose Size
Fresh water-cooled block, thermostatically-
controlled with heat exchanger.
170-190"F (n-88° G)
Centrifugal type, metal impeller, belt-:driven.
Positive displacement, rubber impeller;
belt-driven.
20.0 US gpm (75.5 lpm) (measured
before discharging into exhaust elbow).
8.5 US qts (8.04 liters)
EXHAUST SYSTEM
70°elbow
3" l.D. hose
General
Fuel
Fuel Injection Pump
Fuel Injection Timing
Nozzle
Fuel filter (on engine)
Air Intake Silencer
Air Flow
(engine combustion)
Fuel consumption
i
FUEL SYSTEM
Closed SYStem with ble~ points.
#2-D (Cetane of#45 orhigher. SAEJ313.
Diesel grade according to ASTM D975.
ZEXEL Model PE (In-Line).
12° BTDC
Orifice type.
Full flow replaceable, spin-on element. . ·
Metal screen type - cleanable. Tuned intake
(no filter).
220 cfm (6.2 cmm)
2.0 U.S. gph (7.5 lph) at 2500 rpm
LUBRICATION SYSTEM
General
Oil pump
on filter
Oil cooler
Sump Capacity
(not including filter)
Operating Oil Pressure
(engine hot)
:on Grade
Pressure fed system.
Trochoid type.
Full flow, paper element, spin-on type.
Water cooled.
6.3 U.S. qtS (6.0 liters)
plus filter/cooler assembly.
50 - 55 psi (3.5 - 3.9 kg/cm
2)
API Category: CF,CG-4,CH-4,CI-4 or CJ-4
SAE 1@'::10 or lSW-40
ELECTRICAL SYSTEM
Starting Battery
Battery Capacily
DC Charging Alternator
Starting Aid
Starter
DC No-Load Current
,,
DC Cranking Current
12 Volt, (-) negatiVe ground
· 800 - 900 Cold Cranking Amps (CCA)
51 amp rated, belt-driven
Air intake heater
12Volt,3KW
:1: 2% of rated amps
250 - 300 amps (engine ci>ld)
ENGINE AIR REQUIREMENTS
Combustion Air
Engine Cooling
220 cfrn (6.2 cmm)
100 cfrn (2.8 cmm)
Note: The pressure differential between the outside of the engine compart-
ment versus the inside ofthe engine compartment should not exceed 2 inches
of water (51 mm) at full open throttle (measured with a manometer).
General
Gear ratio (standard)
Propeller Shaft
: Propeller
. Recommendations
' (using standard
transmission
2.74: 1 reduction)
Lubricating Fluid
Transmission Sump
Capacity
TRANSMISSION
·.--
(Hurth Standard Transmission) Case-
hardened helical gears, with a servo-operated
m1..1ltiple disc clutch.
2.74: 1 (HBW250-3R)
Riaht handed - .standard transmission
24Dx·12 P-2 blade or 22 Dx 14 P-3,.
blade propeller should allow the engine
to reach its full rated rpm (3600 + 000 ..
-100) at'ftill open throttle while under
way in forward gear.
ATF - type A or Oextron -II or Ill
0.79 U.S. qts (0.75 liters) approximate
Engines & Generators
4

90A FOUR PROPULSION :ENGINE:PARTS IDENTIFICATION
INSTRUMENT PANEL
CONNECTIONS
TRANSMISSION•
FILTER ·
TRANSMISSION
OUTPUT FLANGE
COOLANT
TEMPERATURE
SWITCH
COOLANT
TEMPERATURE
SENDER
FUEL
PRIMER
OIL PRESSURE
SENDER
IDENTIFICATION
PLATE
REAR
FRONT
RIGHT SIDE
LEFT SIDE
STARTER
WITH SOLENOID
ENGINE OIL
FILTER
REAR
FRONT
Engines &Generators
5
TOP ENGINE
OIL FILL
DC CHARGING
ALTERNATOR
LUBE OIL
DIPSTICK
RAW WATER
PUMP
LUBE OIL
DRAIN HOSE
TRANSMISSION
SHIFT LEVER

TESTING FOR OVERHAUL
HOW TO DETERMINE WHEN
TO OVERHAUL THE ENGINE
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 ofdiesel 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, there-
fore, 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 ofmonitoring
engine internal
wear. When caused by worn cylinders or pis-
ton rings, the following symptoms will occur:
• Low engine power output
• Increased fuel consumption
• Increased oil consumption
• Hard engine starting
• Noisy engine operation
These symptoms often appear
together. Increased fuel con-
sumption and hard engine starting can also result from exces-
sive
fuel injection, improper injection timing, and wear ofthe
injection pump
and nozzles. They are also caused by defec-
tive electrical components such as the battery, alternator,
starter
and air intake heater. Therefore itis desirable to judge
the optimum engine overhaul time
by the lowered compres-
sion 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 com-
pression 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.
Measuring Compression Pressure
To check the compression pressure, see ENGINE COMPRES-
SION TESTunder ENGINEADJUSTMENTS.
NOTE: Do not guess the conditions of other cylinders from a
result
of testing one cylinder. Be sure to measure the com-
pression pressurefor each
cylinder. Lookfor cylinders with
dramatically (at least 20%) lower compression than the aver-
age of the other cylinders. If the weak cylinder is flanked by
healthy cylinders, the problem
is either valve- or head-gasket
related. Very low compression in an adjacent cylinder indi-
cates gasketfailure. Abnormally high readings on all cylin-
ders indicate heavy carbon accumulations, a condition that
might be accompanied by high pressures and
noise.
NOTE: In case of severe vibrations and detonation noise,
have the injectors overhauled by an authorizedfuel injection
service
center. Poorfuel quality, contaminants, and loss of
positivefuel pressure to the injection pump will result in
injectorfaults.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until the piston rings and valve seats have been bro-
ken in. Thereafter, it decreases gradually with the progressive
wear
of these parts.
When the decrease ofcompression pressure reaches its limit
(see SERVICE STANDARDS), the engine must be over-
hauled. The engine also requires an overhaul when oil con-
sumption is high, when blowby is evident, and when
compression values are at a minimum or below.
NOTE: Refer to the SERVICE STANDARDS chart during an
engine overhaul. It gives the measurements and values for
the r,epair or. replacement of the engine components.
NOTE: The ENGINE TROUBLESHOOTING section may be
helpful
in determining the needfor an engine overhaul.
Engines & Generators
6

ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems
relating
to engine service, the probable causes ofthese prob-
lems, and
the recommendations to overcome these problems.
NOTE: The engine's electrical system is protected by a 20
ampere manual reset circuit breakerlocated on a bracket.
The preheat solenoid is mountedon the same bracket.
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
HARD STARTING LOW CRANKING SPEED
-
1. Engine oil viscosity too high. 1. Replace engine oil with less viscous oil.
2. Run-down battery.
2. Recharge battery.
3. Worn battery.
3. Replace battery.
4. Battery terminals loosely connected. 4. Clean terminals and tighten cables.
5. Defective starter.
5. Repair or replace starter.
DEFECTIVE FUEL INJECTION SYSTEM
1. No fuel at injectors.
1. Check a. through e.
a. No fuel in fuel tank and/or fuel shutoff.
a. Fill fuel tank. Open shutoff and bleed system.
b. Fuel filtertwater separator clogged.
b. Replace filter and bleed.
c. Injection pump fuel filter clogged.
c. Bleed injection pump. Check fittings for
suction leak on fuel supply.
d. Fuel shutoff solenoid not working.
d. Check solenoid.
e. Injection pump faulty.
e. Inspect pump. Repair or replace pump as
needed.
2. Fuel injectors faulty; inadequate spray.
2. Remove and test nozzles. Repair nozzles as
needed.
3. Low injection pressure.
3. Adjust injection pressure.
4. Injection timing incorrect.
4. Check and adjust timing.
5. Poor quality fuel.
5. Drain and replace with proper fuel.
6. Water and/or air in fuel system.
6. Remove water and/or bleed air from fuel system.
Check fuel system for leaks and fuel tank for
water contamination.
•,.
MAIN ENGINE TROUBLES
' .
1. Low compression.
1. Check a. through k.
a.
Leaking compression from fuel injector gasket.
a. Tighten fuel injector or replace gasket.
b.
Incorrect valve clearance.
b. Adjust valve clearance.
c. Inadequate contact of valve seat. c. Lap valve.
d.
Valve stem seized.
d. Replace valve and valve guide.
e. Weak or broken valve spring.
e. Replace valve spring.
f.
Bent push rod.
f. Replace push rod.
g. Compression leaks through cylinder head gasket.
g.
Replace gasket.
h. Cracked or worn piston.
h.
Replace piston.
i.
Piston ring seized.
i. Replace piston and piston ring.
j.
Worn piston ring or cylinder liner.
j. Replace piston ring or cylinder liner.
k.
Cracked or distorted cylinder head.
k.
Replace cylinder head.
2. Carbon accumulation in combustion chamber.
2. Clean.
3. Faulty air intake heater.
3. Check terminal connections; replace heater.
(continued)
EtJg/nes & Generators
7

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
--
ENGINE IDLING
1. Idle speed too low.
1. Adjust idle stop as needed.
TOO LOW
2. Fuel filter clogged.
2. Replace filter and bleed fuel system.
3. Incorrect injection pump timing.
3. Check timing and adjust as needed.
4. High pressure injection line leaking.
4. Slacken attaching nut and retighten.
5. Fuel injector leaking at sealing gasket in head.
5. Retighten injector and/or replace sealing washer.
6. Injection nozzle not operating properly.
6. Check nozzle and adjust as needed.
7. Engine air intake obstructed.
7. Check air intake silencer and air flow into
engine compartment.
ROUGH IDLING MALFUNCTION OF ENGINE-llELATED COMPONENTS
1. Improper valve clearance.
1. Adjust clearance.
2. Poor valve to valve seat contact.
2. Repair or replace valve.
3. Failure of cylinder head gasket.
3. Replace gasket.
FUEL INJECTION SYSTEM PROBLEM
1. Faulty idling speed.
1. Adjust idling speed.
2. Faulty injection timing.
2. Adjust injection timing.
3. Clogged fuel line or fuel filter.
3. Clean fuel line or replace fuel filter.
4. Leak in fuel line or fuel filter.
4. Repair fuel line or replace fuel filter.
5. Air in injector, fuel line, injection pump, fuel filter
or fuel filter/water separator.
5. Bleed air.
6. Seized or leaky delivery valve.
6. Clean or replace delivery valve.
7. Faulty injection starting pressure.
7. Adjust starting pressure.
8. Injection nozzle malfunction.
8. Clean or replace injection nozzle.
9. Feed pump malfunction.
9. Clean or replace feed pump.
10. Injection pump timer malfunction.
_ 10. Replace timer.
11. Injection pump malfunction.
11. Take to a fuel injection pump service facility,
or replace the pu_mp.
ENGINE SLOWS 1. Fuel lift pump failure.
1. Check fuel pump operation.
AND STOPS
2. Switches and/or wiring loose or disconnected.
2. Inspect wiring for short circuits and loose
connections. Inspect switches for proper
operation.
3. Fuel starvation.
3. Check fuel supply, fuel valves, fuel lift pump.
4. 20 amp circuit breaker tripping.
4. Check for high DC amperage draw during
operation. Ensure breaker is not overly sensi-
tive to heat which would cause tripping.
5. Exhaust system is restricted.
5. Check for blockage, collapsed hose, carbon
buildup at exhaust elbow.
6. Water in fuel.
6. Pump water from fuel tank(s); change filters
and bleed fuel system.
(continued)
Engines & Generators
8

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATIONJREMEDY
LOW OUTPUT
LOW COMPRESSION
See Low Compression under 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. Bleed and check for source.
2. Clogged filter.
2. Clean or replace filter element.
3. Contaminated or inferior fuel. 3. Purge fuel system and replace with quality
fuel.
4. Contaminated fuel tank.
4. Clean fuel tank.
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. 4. Add engine oil.
OTHER
1. Insufficient intake air. 1. Increase engine compartment air supply.
KNOCKING
ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
1. Check a. and b.
a. Overheated cylinder.
c,
a. See ENGINE OVERHEATS/SHUTS
DOWN; LOW OUTPUT.
b. Carbon deposits in cylinder.
'·
b. Clean.
.
2. Injection timing too early.
2. Correct the timing.
3. Injection pressure too high. 3. Correct the pressure.
4. Improper fuel.
4. Replace with proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
1. See Low Compression under HARD
STARTING.
2. Injection pump malfunctioning.
2. Adjust/Repair.
3. Nozzle malfunctioning.
3. Check a. through d.
a. Poor spray.
a. Clean or replace nozzle.
b. Chattering.
b. Repair or replace nozzle.
c. After-injection drip.
c. Repair or replace nozzle.
d. Nozzle needle valve seized.
d. Replace needle valve.
ABNORMAL SOUND
CRANKSHAFT AND MAIN BEARING
OR NOISE
1. Badly worn main bearing.
1. Replace bearing and grind crankshaft.
2. Badly worn crankshaft. 2. Grind crankshaft.
3. Melted bearing. 3. Replace bearing and check lubrication system.
4. Excessive crankshaft end play. 4. Repair or replace crankshaft.
(continued)
Engines & Generators
9

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
ABNORMAL SOUND CONNECTING ROD AND CONNECTING ROD BEARING
OR NOISE (Cont'd)
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.
4. Excessive connecting rod bearing oil clearance.
4. Repair or replace bearing.
5. Connecting rod bearing seized or heat-damaged. 5. Replace bearing.
PISTON, PISTON PIN, PISTON RING, CYLINDER LINER
1. Worn cylinder liner.
1. Repair or replace liner.
2. Worn piston or piston pin: 2. Replace piston.
3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or·damaged.
4. Replace piston and rings.
VALVES OR TIMING-RELATED PARTS
1. Worn camshaft. 1. Replace camshaft.
2. Excessive valve clearance. 2. Adjust valve clearance.
3. Worn timing gear. 3. Replace timing gear.
4. Broken valve spring.
4. Replace valve spring.
5. Excessive clearance between rocker arm and
bushing.
5. Replace bushing.
6. Excessive clearance between idler gear bushing and 6. Replace bushing.
spindle.
FUEL SYSTEM
1. Poor quality and/or incorrect fuel.
1. Use No. 2 diesel fuel.
2. Incorrect injection timing. Timing too advanced. · 2. Check and correct injection timing.
'
3. Fuel injector stuck open. 3. Locate and remove faulty injector. Rebuild or
'·
replace.
.
OTHER
1. Coolant pump bearing worn or seized.
1. See Coolant Pump under COOLING SYSTEM.
2. Improper drive-belt tension. 2. Adjust.
3. Malfunction of alternator bearing. 3. See Alternator Troubleshooting under
DC ELECTRICAL SYSTEM.
4. Exhaust gas leakage. 4. Repair.
ROUGH OPERATION
INJECTION PUMP
(HUNTING)
1. Uneven injection. 1. Adjust injection or replace parts.
2. Inadequate injection nozzle spray. 2. Replace injection nozzle.
GOVERNING SYSTEM
1. Governor lever malfunctioning. 1. Check governor shaft and adjust.
2. Fatigued governor spring. 2. Replace spring.
(continued)
Engines & Generators
10

PROBLEM
SMOKY EXHAUST
EXCESSIVE
EXHAUST SMOKE
ENGINE TROUBLESHOOTING
PROBABLE CAUSE
WHITISH DR PURPLISH
1. Engine is running cold.
2. Excessive engine oil.
3. Excessive rise of oil into combustion chamber.
a. Poor piston contact.
b. Seized piston ring.
c. Excessive piston-to-cylinder clearance.
d. Worn valve stem and valve guide.
e. Low engine oil viscosity.
f. Excessive oil pressure:
4. Injection timing is too late.
5. Insufficient compression.
BLUE
1. Incorrect grade of engine oil.
2. Crankcase is overfilled with engine oil {oil is blow-
ing out through the exhaust).
BLACKISH DR DARK GRAYISH
1. Poor compression.
2. Improper valve clearance.
3. Improper injection timing.
4. Improper fuel.
5. High back-pressure In exhaust.
6. Insufficient intake air.
7. Overload.
BLACK, LARGE AMOUNT
1. Clogged fuel filter.
2. Restricted air intake.
3. Engine overloaded.
4. Injection timing.
5. Fuel injectors not operating properly.
1. Faulty injection timing.
VERIFICATION/REMEDY
;:__,
1. Warm-up engine.
2. Correct oil level.
3. Check a. through f.
a. Check.
b. Clean or replace.
c. Correct or replace.
d. Replace valve stem and guide.
e. Replace engine oil.
f. Inspect the lubrication system. See
LUBRICATION SYSTEM.
4. Adjust timing.
5. See Low Compression under HARD STARTING.
1. Use the correct grade of oil; see LUBRICATION
SYSTEM under 90A FOUR ENGINE
SPECIFICATIONS.
2. Decrease oil level.
1. See Low Compression under HARD STARTING.
2. Adjust valve clearance.
3. Adjust injection timing.
4. Replace with proper fuel.
5. Check for restrictions in exhaust system.
6. lncrea~e engine cpmpartment air supply.
7. Reduce load.
1. Replace fuel filter and bleed system.
2. Remove air obstruction.
3. Check engine propeller size and engine
performance no-load through fully loaded.
4. Check the injection pump timing and adjust as
needed.
5. Check nozzle spray pressure setting.
1. Adjust timing.
2. Water in injection pump, fuel filter or fuel filter/water 2. Drain fuel system.
separator.
3. Faulty injection starting pressure. 3. Adjust starting pressure.
4. Injection pump malfunctioning. 4. Replace injection pump.
(continued)
11

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
INTERMITIENT
EXHAUST SOUND
1. Fuel filter clogged. 1. Clean or replace filter.
2. Fuel line sucks air.
2. Retighten fuel line joints or replace fuel line.
3. Water mixed in fuel.
3. Replace fuel.
EXCESSIVE FUEL
ENGINE PROBLEMS
CONSUMPTION
1. Noisy knocking. 1. See KNOCKING.
2. Smoky exhaust.
2. See SMOKY EXHAUSr
3. Moving parts nearly seized or excessively worn.
3. Repair or replace.
4. Poor compression. 4. See low Compression under HARD STARTING.
5. Improper valve timing. 5. Adjust timing.
6. Improper valve clearance. 6. Adjust clearance.
INSUFFICIENT INTAKE AIR
1. Air intake obstructed. 1. Remove obstruction.
FUEL INJECTION PROBLEMS
1. Injection timing incorrect. 1. Adjust timing.
2. Faulty injection starting pressure. 2. Adjust starting pressure.
3. Seized nozzle. 3. Replace nozzle.
4. Worn nozzle. 4. Replace nozzle.
5. Nozzle leaking.
5. Tighten nozzle or replace sealing gasket.
6. Injector not operating properly. 6. Adjust nozzle spray pressure.
7. Clogged fuel filter.
7. Replace filter.
8. High idling speed.
. 8. Adjust idling speed.
FUEL PROBLEMS
1. Improper fuel. 1. Replace with proper fuel.
2. Fuel leaks. 2. Find fuel leaks.
ENGINE OVERLOADED
1. Propeller size. 1. Check propeller size and engine performance
at rated rpm.
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 line connector. 5. Retighten oil line connections.
6. Broken rocker cover gasket. 6. Replace gasket.
7. Loose rocker cover attaching bolts. 7. Retighten attaching bolts.
(continued)
lw/WESTERBEKE
· {Engines & Generators
12

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
...
EXCESSIVE OIL OIL
LEVEL RISING
CONSUMPTION
1. Incorrectly positioned piston ring gaps. 1. Correct ring gap positions.
(cont'd)
2. Displaced or twisted connecting rod. 2. Replace connecting rod.
3. Worn piston ring, or piston ring groove. 3. Replace ring or piston.
4. Worn piston or cylinder liner. 4. Repair or replace.
OIL LEVEL FALLING
1. Defective stem seal. 1. Replace stem seal.
2. Worn valve and valve guide. 2. Replace valve and valve guide.
LOW OIL PRESSURE
1. Worn main or connecting rod bearings. 1. Replace bearings.
2. Relief valve malfunction.
2. Overhaul oil pump.
3. Clogged oil cooler. 3. Clean.
4. Diesel fuel is diluting the oil. 4. Injection pump repair.
ENGINE OVERHEATS/
1. V-belt slackening or slippery with oil. 1. Adjust, replace or clean belt.
SHUTS DOWN
2. Low oil level or poor oil quality.
2. Add or change oil.
3. Knocking.
3. See KNOCKING.
4. Moving parts seized or damaged.
4. Replace.
5. Lack of coolant.
5. Add coolant.
6. Raw water not circulating. 6. Check a. and b.
a. Raw water pump failure. Check impeller;
replace if necessary.
b. Obstruction at raw water intake or raw water
filter.
7. Coolant not circulating.
· 7. Check a. through d.
a. Thermostat - remove and test in hot water.
Replace thermostat.
b. Loss of coolant - check hoses, hose clamps,
drain plug, etc. for leaks.
c. Broken or loose belts - tighten/replace.
d. Air leak in system; run engine and open the
pressure cap to bleed air. Add coolant as
needed.
Engines & Generators
13

ENGINE DISASSEMBLY
GENERAL DISASSEMBLY PROCEDURE
NOTE: Before disassembly and cleaning, carefally check
for defects which cannot be found after disassembly and
cleaning.
• All disassembled parts should be carefully arranged in
the order
of reassembly. Mark or label the parts as
needed to insure proper mating and reassembly in the
proper directions and positions.
• If the disassembly procedure is complex requiring many
parts to be disassembled, the parts should be disassem-
bled in a way that will allow them to be efficiently
reassembled without any change in the engine's external
appearance or its performance.
• Do not remove or disassemble parts that require no
disassembly.
• Carefully inspect each part after removal for damage,
deformation, and other problems.
• Carefully check gaskets, packings and oil seals, even if
checking is not specified. Replace with new ones, if
defective.
• Be careful not to damage the disassembled parts. Keep
the parts clean.
• Use the proper tools. Apply oil when necessary. Take
special care to keep the fuel system parts free from the
intrusion
of dust and dirt.
TRANSMISSION REMOVAL
1. Unplug the instrument panel wiring harness.
2. Drain the transmission fluid and the transmission oil
cooler hoses.
3. Detach the oil cooler hoses.
4. Unbolt the transmission from the engine.
NOTE: For transmission service and maintenance, refer to
your transmission owner '.s manual. To rebuild a transmis-
sion, contact your WESTERBEKE dealer or a qualified
marine transmission servicefacility.
If the transmission is not being rebuilt, it should be visually
inspected. Flush out and pressure-test the oil cooler, and
replace the coolant hoses. Inspect and lubricate the gear shift
linkage and the propeller shaft coupling. Clean and repaint
the transmission and change the transmission fluid. Refer to
the TRANSMISSIONS section in this manual.
GENERATOR REMOVAL
1. Disconnect the AC wiring and unplug the engine's DC
wiring harness at the generator control panel.
2. Disconnect the battery cable connections and the
engine ground cables.
3. Separate the exhaust hose at the water injected elbow.
4. Disconnect the fuel supply and return lines.
NOTE: Label any lines, hoses or cables as you separ-
ate them.
14
5. Drain the engine oil and the coolant from the engine.
6. Carefully support and then unbolt the
"generator back
end from the engine. See SPECIAL TOOLS-
GENERATOR in this manual.
For generator maintenance and service, refer to the
GENERATOR section of this manual.
STARTER MOTOR
& SOLENOID
BACK ENO
GENERATOR REMOVAL
ENGINE DISASSEMBLY
With the transmission or generator separated from the
engine, begin the following step-by-step procedure
of the
engine disassembly.
1. Clean the exterior
of the engine of any deposits of dirt
and oil.
2. Mount the engine on a suitable engine stand for
disassembly.

ENGINE DISASSEMBLY
3. Drain the coolant from the engine and engine hoses, and
from the heatexchanger. Drain the fuel, and drain'or
pump out the engine oil.
4. Remove the engine wiring harness in its entirety. Label
the terminal connections to insure proper reattachment.
LABEL THE TERMINAL
CONNECTIONS
5. Remove the engine heat exchanger and the engine oil
cooler/oil filter assembly.
If possible, leave one end of
each hose connection attached to the part being removed.
6. Remove the starter motor.
7. Remove the engine bellhousing (propulsion engines only}.
ENGINE DISASSEMBLY
TRANSMISSION
DAMPER PLATE
(PROPULSION
ENGINES ONLY)
8. Remove the transmission damper plate (propulsion
engines only).
TRANSMISSION
DAMPER PLATE
(PROPULSION
ENGINES ONLY)
9. Remove the flywheel and flywheel washer.
WHEN REMOVING
.THE MOUNTING BOLTS,
LOCK THE FLYWHEEL
WITH A RING GEAR
BREAK TOOL
REMOVING THE FLYWHEEL
10. Remove the engine back plate.
11. Remove the exhaust manifolel.
12. Remove the alternator and alternator adjusting strap.
13. Remove the raw water pump.
14. Remove all the high pressure injector lines from the
injection pump to the injectors. Leave the upper line
clamps in place.
NOTE: Cap the ends of the lines, and the connections at
the injection pump and at the injectors, to prevent entry
of foreign material.
15. Remove the oil level dipstick.
16. Remove the injection pump oil line.
17. Remove the fuel line to the injection pump. (Note the
arrangement
of the sealing washers on the banjo bolts
at the fuel filter and the injection pump.)
18. Remove the fuel return lines from the top
of the injectors
and from the fuel injection pump. (Note the washer ar-
rangement on the fuel return line banjo bolts. Cap all
openings on the fuel return line, injectors and injection
pump~)
19. Remove the engine-mounted fuel filter and fuel filter
bracket.
Engines & Generators
15

ENGINE DISASSEMBLY
20. Remove the thermostat housing, gasket, and the thermo-
stat. Leave
the temperature sending unit in place.
THERMOSTAT
HOUSING
THERMOSTAT
ASSEMBLY
21. Remove the air intake silencer.
22. Remove the
two front lifting eyes and the rear lifting eye.
23. Remove the intake manifold.
24. Remove the alternator bracket.
25. Remove the crankcase breather
hose.
26. Remove the rocker covers and gaskets.
27. Remove the
fuel injectors, 0-rings and gaskets from the
cylinder head.
ROCKER
COVER
COVER
ROCKER
COVER
28. Loosen the cylinder head bolts gradually in the numbered
sequence shown in the illustration.
3 7 11 15 18 14 10 6
4 8 12
16 ' 17 13 9 5 1
LOOSENING THE CYLINDER HEAD BOLTS
29. Remove the rocker arm and shaft assembly.
30. Remove the push rods. Label each rod as to which valve
it belongs.
l
~
VALVE-!
.,.., ROCKER . ~ I
·~·"i I
ROCKER ARM ASSEMBLY
31. Remove the cylinder head by tapping it from below
with a plastic hammer. __
32. Remove the cylinder head gasket.
INNER
SPRING
LOWER
SEAT
Engines & Generators
16

ENGINE DISASSEMBLY
33. Valves Disassembly
a. Mark the valves with their cylinder numbers, then
remove the valves, stem caps, cotters, spring seats and
springs from the cylinder head using the
valve spring
lifter (Mazda #49 0636
lOOA) and pivot {Mazda #49
0107 222A) or an appropriate valve spring compres-
sion tool.
NOTE: Valve guides are only to be removed, ifneces-
sary, after completing the procedure described under
Valves and Valve Guides in the ENGINE INSPECTION
AND REPAIR section.
34. Timing Mechanism Disassembly
Remove the following components that
are related to the timing mechanism:
a. Coolant pump
b. Crankshaft pulley
c. Timing gear cover and gasket
d. Fuel injection pump
NOTE: See Fuel Injection Pump Removal
under FUEL SYSTEM
for detailed instructions
on removing the fuel injection pump.
e. Camshaft gear lock plate
f. Camshaft friction gear
g. Camshaft gear
h. Idler gear plate
i. Idler gear
j. Idler gear hub
k. Crankshaft slinger
l. Crankshaft friction gear spring ~
n. Crankshaft gear and key ..,
m. Crankshaft friction gear ia·.·. , "'
o. Timing gear case and gasket . ,
@
b~~~
~~~
~
f
b. Remove the valve oil seals (intake only) by grasping
them with pliers and working them out.
c. When removing the valves, make sure each valve
is
marked so it can be returned to its original position,
if reused.
TIMING MECHANISM
DISASSEMBLY
0
0
Engines & Generators
17

ENGINE DISASSEMBLY
35. Lubrication System Disassembly
Remove the following lubrication system components:
a. Oil filter housing
b. Lube oil cooler and gasket
c. Oil filter housing gasket
d. Sump stiffeners
e. Lube oil sump and gasket
f. Lube oil pump assembly
WBRICATION SYSTEM
DISASSEMBLY
g. Lower block
h. Block to lower block left and right gaskets
L Block to lower block front and rear gaskets
j. Oiljets
k. Oil pressure sender
L Oil pressure switch
Engines & Generators
18