Westerbeke 22.0 KW EDE-60Hz User manual

D
SERVICE MANUAL
D-NET DIESEL GENERATORS
22.0KW EDE 17.0KW EDE
-- - -
17.0KW EDE 13.5KW EDE
at 60 Hertz at 50 Hertz :
SINGLE AND THREE "PHASE
FIRST EDITION
JULY 2008
~ WESTERBEKE
----
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK
ROAD' TAUNTON MA 02780-7319' TEL. [phone]
FAX [phone]' WEBSITE: WWWWESTERBEKE.COM
NAII'A Member National Marine Manufacturers Association
... WO.

A WARNING
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:
-Dip/ness
-Nausea
-Headache
- Throbbing in Temples
• Muscu/ar Twitching
• Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
/F YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
6ET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
:WARNING
Generatoffi Pnx1UC6!CARBON MONOXIDE
Regular Maintenanca Required
A 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/s/eeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
'----~.....-:::::.--~-.:...,' .------' CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gaSOline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

TABLE OF CONTENTS
Testing for Overhaul ......................................................... 2
Engine Troubleshooting ................................................... 3
Disassembly Procedures ................................................. 5
Assembly Procedures ...................................................... 6
Assembly Instructions ..................................................... 7
Disassembly/Assembly .................................................... 8
Servicing .......................................................................... 21
Wiring Diagrams ............................................................. 34
Engine Adjustments ...................................................... .36
Glow Plugs................................................................. 36
Drive Belt Adjustment ............................................... 36
Fuel Injectors..............................................................37
Valve Clearance..........................................................38
Testing Engine Compression......................................39
Testing Oil Pressure ...................................................39
Oil Pressure Sensor....................................................39
Testing Magnetic Pick-up Coil ..................................40
Air Intake Silencer.....................................................40
Specifications ................................................................. 43
Raw Water Pump ........................................................... .45
Starter Motor .................................................................. .46
Alternator Testing ......................................................... .52
SpeCial Tools .......................... , ........................................ 59
Service/Standards and Limits ...................................... 61
Torque Specifications .................................................... 67
Generator Information ................................................... 68
Electronic Regulation.................................................69
Exciter Rotor Troubleshooting...................................71
Terminal Board Connections
......................................72
Hertz Voltage Change.................................................73
Internal Schematic......................................................
74
Wiring Diagrams ........................................................75
Generator Assembly...................................................76
BE Troubleshooting ...................................................78
Metric Charts .................................................................. 79
Hardware Torques ........................................................... 81
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side of the engine's manifold.
The engine's serial number can also
be found stamped into
the engine block on the flat surface
of the blockjust above
and inboard
of the injection pump.
SPECIACATION
MODEL~. _____ _
RPM __________ _
KW ___________ _
KVA _______ • __ _
VOLTS ________ _
AMPS • _______ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ___ _
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE ___ _
BAlTERY _____ _
C.1.0. _________ _
50 HZ.
60 HZ.
I
An identification plate on the top of the engine air intake also
displays the engine model and serial number.
NOTE: Use the two name plates above to write in the data
from your engine while it is accessable. In years to come it
will always be available in your manual.
Engines &Generators
1

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 ofmonitoring 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 ofplugs 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
ifother parts
of the engine are operating properly. To
determine the period ofengine 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
ADJUSTMENTsection 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 ofcompression 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 512 to 583 psi/36 to 41
kgflcm2 @290 rpm (difference between cylinders must
not exceed 10%).
Precautions for Disassembly and Reassembly
When servicing an engine,keep in mind the fonowing
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 parts that do not require
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. Carefully check gaskets, packings and oil seals even
ifchecking is not specified. Replace with new ones
if defective. ~
2. 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.
3. After completion ofreassembly, recheck for any
abnormalities. Prepare for starting the engine, and idle
the engine sufficiently for a test run.
PRECAUTIONS
• Be careful not to mix bolts and nuts. Metric and SAE.
bolts are used on various engine assemblies.
• During assembly, recheck clearances and insure that pints
are being assembled in their proper order and facing in
the correct direction in relation to the engine block, such
as, pistons, piston rings, bearings and bearing caps.
• Apply lublicating oil to moving parts during assembly.
Insure that moving parts, when assembled on the engine,
fQtate Of slide and are not subject to binding or excessive
tension.
• If there are mating marks scribed during disassembly, ref-
erence them cOlTectly for assembly ..
• Use new gaskets, lockwashers, o-rings, etc.
• Tighten the bolts and nuts on important parts ofengine to
specified torques using a reliable torque wrench.
• Use liquid sealants when required on nuts, bolts and gas-
kets. Refrain from using tape sealants.
Engines & Generators
2

ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problems,
and the recommendations to overcome these problems.This chart may be of assistance in determining the need for an engine
overhaul.
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 correct cables.
6. Defective starter. 5. Repair or replace starter.
6. Defective main drive section. 6. Check clutch for disengagement.
«-~
DEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
1. Bleed air from fuel system.
2. Clogged fuel filter.
2. Clean or replace fHter.
3. Low injection pressure.
3. Adjust injection pressure.
4. Inadequate spray.
4. Clean or replace nozzle.
5. Injection pump delivering insufficient fuel. 6. Repair or replace injection pump.
6. Injection too early.
6. Adjust injection timing.
MAIN ENGINE TROUBLES
1. Low compression.
a. Incorrect valve clearance.
a. Adjust valve clearance.
b. Inadequate contact of valve seat. b. Lap valve.
c. Valve stern seized. c. Replace valve and valve guide.
d. Broken valve spring.
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 of 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 .
3

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERIFICATION/REMEDY
LOW OUTPUT {tont.}
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. Wom piston ring.
3. Replace ring.
4. Worn piston or cylinder. 4. Replace piston and rabore 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 wom.
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.
INSUFACIENT 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 Rnd fuel leaks.
SMOKY EXHAUST WHITISH OR PURPLISH
1. Excessive engine oil. 1. Correct ai/level.
2. Excessive rise of oil into com bustion 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
4

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
PROBLEM PROBABLE CAUSE
Low oil pressure. 1. Low oil level. Blue exhaust smoke 1. Lube oil is diluted.
2. Wrong SAE type oil in the engine.
discharge from the
2.
High lube oil level.
3. Faulty or wrong type oil filter.
engine.
3. Crankcase breather hose is clogged.
4. Relief valve is stuck.
4. Valves are worn or adjusted
5. Faulty oil pump.
incorrectly.
6. Faulty engine bearings.
7.
Faulty oil filter.
5.
Piston rings are worn
or unseated.
High oil pressure.
1.
Dirty oil or wrong SAE type oif in the
engine.
2. Relief valve is stuck.
Black exhaust smoke 1.
Dirty flame arrester.
discharge from the
2. Lube oil is diluted.
engine.
3.
Valves are worn or incorrectly
No DC charge to the
1.
Loose/corroded battery charge
starting battery.
circuit connection(s).
2.
Faulty alternator regulator.
adjusted.
4. Piston rings are worn or unseated.
5. Cankcase breather hose is clogged.
3. Faulty DC alternator.
Poor Performance 1. Fuel pump clogged. Remove and
4. Slipping alternator drive belt.
at generator speed. replace.
5. Broken alternator drive belt.
2. Throttle body filter screen dirty.
3. Fuel filter contaminated.
Engines & Generators
43

DISASSEMBLY PROCEDURES
GENERATOR
PISTON
The piston's skirt is coated with molybdenum disulfied,
which reduces the piston slap noise and the entire operating
noise. This serves as a solid lubricant, like graphite or teflon
and helps resist metal wear even with little lube oil.
DYNAMIC BALANCER
An engine will vibrate due to piston reciprocation. Three-
cylinder engines
are much less prone to cause vibration than
a four-cylinder engine (second inertia). However, every
engine
has many moving parts in addition to its pistons and
cannot
be completely free from vibration. These engines are
fitted with two balancers to absorb the second inertia and
reduce vibration. One is
on the intake side and the other is at
the exhaust
side.
DRAINING THE COOLANT
Drain the coolant by removing the coolant drain plug on the
engine block. Also remove the manifold pressure cap and
open both drain plugs on the heat exchanger.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
COOLANT DRAIN/
DRAINING THE OIL
Drain the oil using the sump drain hose attached to the
front ofthe engine. The oil can also be pumped up thru the
dipstick hole.
REMOVE USING AN 8MM (11116") SOCKET
TO DRAIN THE OIL OR PUMP THE WARMED
OIL UP THRU THE HOSE.
Always observe the used oil as it is removed. Ayellow/gray
emulsion indicates
the presence ofwater in the oiL Although
this condition
is rare, it does require prompt attention to
prevent serious damage. Call a qualified mechanic should
water
be present in the oiL Raw water present in the oil can
be the result of a fault in the exhaust system attached to the
engine and/or a siphoning of
raw water through the raw
water cooling circuit into the exhaust, filling the engine. This
problem is often caused by the absence of an anti-siphon
valve,
its poor location orlack ofmaintenance.
PREPARATION FOR DISASSEMBLY
• Clean or wash the engine exterior.
• Do not remove or disassemble the parts that require no
disassembly.
• When disconnecting sensor wires, label and tape the ends.
• Perform disassembly in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when
necessary. Take special care to keep the fuel system parts
from intrusion ofdust and dirt.
• Parts must be restored to their respective components from
which they were removed at disassembly. This means that all
parts must be set aside separately in groups, each marked for
its component, so that the same combination or set can be
reproduced at assembly.
• Pay attention to marks on assemblies, components and
parts for their positions or directions. Put on marks, if
necessary, to aid assembly.
• Carefully check each part orcomponent for any sign of
faulty condition during removal orcleaning. The part will
tell you how it acted or what was abnormal about it more
accurately during removal or cleaning.
DISASSEMBLY
With the engine securely mounted on an engine stand, begin
disassembling the engine in a logical
order. When removing
electrical components (alternator, start
motor, etc) carefully
label
the cables and wires.
With the exterior components removed, use the detailed
instructions
in this manual to disassemble/assemble the
main engine.
CAREFULLY LABEL
TERMINAL CONNECTIONS
AND CABLES
BOLTS
BACK
PLATE---.
Engines & Generators
5

ASSEMBLY PROCEDURES
GENERAL INFORMATION
Surface Preparation
Thoroughly remove all substances deposited on the gasket
application surfaces
using a gasket scraper or wire brush.
Check to ensure that the surfaces to which the silicone gasket
is to be applied is flat. Make sure that there are no oils,
greases and foreign substances deposited on the application
surfaces. Do not forget to remove the old sealant that
remains in the bolt holes.
ASSEMBLY
• Wash all parts, except for oil seals, O-rings, rubber sheets,
etc. with cleaning solvent and dry them with air pressure.
• Always use tools that are in good condition and be sure
you understand how to use them before performing any
job.
• Use only good quality lubricants. Be sure to apply a coat
of
oil, grease or sealant to parts as specified.
• Be sure to use a torque wrench to tighten parts for which
torques are specified.
• When the engine is assembled, new gaskets and O-rings
must be installed.
GASKET INFORMATION
The engine has several areas where form-in-place RTV
silicone gaskets are used such as LOCTITE 598 or GE
RTV 100. To ensure that the gasket fully serves its purpose,
it is necessary to observe some precaution when applying the
gasket Bead size, continuity and location are very important.
Too thin a bead could cause leaks and too thick a bead could
be squeezed out oflocation causing blocking or narrowing of
the fluid feed lines. To eliminate the possibility of leaks from
ajoint, it is necessary to apply the gasket evenly without a
break
while observing the correct bead size.
The gasket material used in the engine is a room temperature
vulcanization
(RTV) type and is supplied in a l40z (400
grarn) applicator/tube. The RTV hardens as it reacts with the
moisture in the atmospheric air and can be used for sealing
both engine oil
and coolant assemblies.
APPLY GREASE
EXTERNAL SNAP RING INTERNAL SNAP RING
PLACE THE SHARP EDGE.
AGAINST THE DIRECTION
aFFORCE
When reassembling external or internal snap rings, position
them so that the sharp edge faces against the direction from
which force is applied.
ALTERNATOR INSPECTION
When rebuilding the engine, the alternator should be cleaned
and inspected. The housing can be wiped off with a solvent
and the alternator terminal studs should be cleaned with a
wire brush. Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness.
Turn the rotor pulley by hand. Itshould turn smoothly.
Depending on when the alternator was last serviced, the
brushes may need replacing. If the altemator is at all suspect,
send it to a service shop for testing and overhaul, or
the more detailed alternator section in this manual.
Engines & Generators
6

ASSEMBLY INSTRUCTIONS
Be aware of these common problems that can occur during
assembly.
Insufficient Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the waterjacket. These
fasteners should be sealed with Permatex
No.2 or the
high-tech equivalent.
Reversed orientation. Most gaskets, many bolt washers, and
all thermostats are asymmetrical.
Mechanical damage. Run fasteners down in approved '
torque sequences and in three steps-ll2,
213, and 111 torque.
Exceptions are torque-to-yield bolts and rocker arm shaft
fasteners. The former are torqued as indicated. The
latter-rocker shaft fasteners should be brought down in very
small increments, working from the center bolts out. Gaskets,
especially head gaskets, might also be damaged during
assembly, they should be positioned with great care.
ASSEMBLY
NOTE: The exhaust manifold, which was disassembledfrom
the cylinder head, should be inspected before re-assembly.
a. Remove the exhaust elbow from the lowersurface of
the manifold. Clean and inspect for cracks and defects.
Replace as needed.
b. Remove the exhaust nipples~ elbows and plugs from
the manifold and heat exchanger.
c. Remove water connectors from the ends of the
manifold. Be
sure to note the proper location and
arrangement of each for proper alignment.
d.· Examineall parts for defects, corrosion and wear and
replace as needed.
e. Flush out the coolant recovery tank and clear its hose
passage. Set aside to re-install on the boat.
HEAT EXCHANGER
Install thc heat exchanger, replace the heat exchanger zinc
and attach new hoses with new clamps to the cooling system.
Refer to the
COOLING SECTION in this manual for HEAT
EXCHANGER service.
ENGINE TUNING OPERATION
After re-assembly, the engine must be tuned. This will ensure
that the engine operates at its maximum efficiency. Fill the
engine cooling system with an antifreeze mixture and the
engine oil sump with a lube oil API specification of CF, CG-4,
CH-4, CZ-4,
or SAE lSW-4C.
1. Mount the engine on a test bench and connect the fuel
lines.
2. Connect the electrical wiring. Refer to the
WIRlN(f DIAGRAM.
3. Connect the air intake line to the air cleaner.
4. Connect
the exhaust pipe.
5.
Crank the engine with the starter (non-ignition
operation)
for about twenty seconds. This will
pre-lubricate the engines internal components and
fill
the fuellincs.
6. Start the engine and allow it to run at a rated rpm for
five minutes.
7. Remove
the cylinder head cover while tbe engine is
running.
S. Check that the engine oil continuously circulating
from the oil pump to the valve rockers through the
cylinder head.
If there is no oil circulation or if the oil circulation is
sluggish, stop the engine and make the appropriate repairs
or adjustment.
Re-install the cylinder head cover.
9. Monnt the engine on a test bench and connect the fuel
lines.
lO.Check the engine for oil, fuel, coolant and air intake
leakage.
1l.Check for abnormal noise and odor.
12.Check for abnormal electrical charging.
13.Check
the engine fastening parts for looseness.
14.When
the engine coolant temperature reaches
7SoC (l67°F)
or more, increase the engine speed to
2000 rpm and allow it to run for twenty seconds. .
This
will give the engine the essential run-in operating
time.
15.Adjust the engine operationspeed to the specific
value.
16.stop the engine to comp!ete the tuning procedure.
Refer to the following pagesfor details of sub-assemblies.
These sections also include: Wiring Diagrams, Engine
Specifications, Torque Diagrams, Starter Motor, Alternator
and Raw
Water Pump.
Engines & Generators
7

DISASSEMBLY/ASSEMBLY
CYLINDER HEAD COVER
1. Remove the top ofeach glow plug and remove the glow
plug strap.
2. Remove the breather hose.
3. Remove the head cover bolts.
4. Remove the cylinder head
cover.
BREATHER.
HOSE
When Reassembling
HEAD COVER
SCREWS
Check to see if the cylinder head cover gasket is not
defective.
TIGHTENING TORQUE
CYLINDER HEAD COVER SCREW __ 6.9 -11.3 N-m
0.7 -1.15 Kgf-m
5.1 - 8.32 ft-Ibs
BREATHER VALVE
COVER
GASKET
HEAD COVER
. COVER
GASKET
CYLINDER
HEAD COVER
SCREWS
INJECTION PIPES
1. Loosen the scerws on the pipe clamps.
2. Detach the injection pipes.
When Reassembling
Blowout dust inside the pipes.
TIGHTENING TORQUE
INJECTION PIPE RETAINING NUT __ 24.5 - 34.3 N-m
2.5 - 3.5 Kgf-m
18.1 • 25.3 ft-Ibs
NOZZL~ HOLDER ASSEMBLY AND GLOW PLUG
1. Remove the overflow pipe assembly.
2. Remove the nozzle holder assemblies using a 21mm
socket wrench.
3. Remove the copper gasket and heat seal.
4. Remove the glow plugs
When Reassembling
Replace the copper gasket and heat seal with a new one.
TIGHTENING TORQUE
NOZZLE HOLDER ASSEMBLY_49.0 - 68.6 N-m
5.0 - 7.0 Kgf-m
36.2 - 50.6 ft-Ibs
OVERFLOW PIPE ASSEMBLY
RETAINING NUT 19.6 - 24.5 N-m
2.0 - 2.5 Kgf-m
14.5 -18.1 ft-Ibs
GLOW PLUG 19.6 - 24.5 N-m
2.0 - 2.5 Kgf-m
14.5 -18.1 ft-I~s _.
&
/~.f1.b~'f
I
! NOZZLE
n HOLDER
~ ASSEMBlY ..
~ (/("' ..
Engines & Generators ,'(:f'l) c/
8 i ~.:o,I~"'-.

DISASSEMBLY/ASSEMBLY
NomE HEAT SEAL REMOVAL PROCEDURE
NOTE: Use a Phillips head screw driver that has a diameter
that is bigger than the seal hole. Approximately 1/4" (6mm)
1. Place the screw driver lighly into the heat seal hole.
2. Tum the screw driver three or four times each way.
3. While turning, slowly pull the heat seal out together with
the copper gasket.
4. If the heat seal drops, repeat the procedure.
When Reassembling
The heat seal and the copper gasket must be changed when
the injection nozzle is removed for cleaning or service.
SCREW
DRIVER
NOZZLE HOLDER
ASSEMBLY
GOPPER
GASKET
CYLINDER HEAD
1. Loosen the pipe clamp and remove the water return pipe.
2. Remove the cylinder head screw in the order ofR or N
toA.
3. Lift up the cylinder to detach.
4. Remove the cylinder head gasket.
When Reassembling
1. Replace the cylinder head gasket with a new one.
2. Tighten the cylinder head screws after applying sufficient
oil.
3. Tighten the cylinder head'screws in a diagonal sequence
starting
from the center in the order ofA to N or R.
4. Tighten them uniformly or the head may deform in the
long run.
TIGHTENING TORQUE
CYLINDER HEAD SCREW __ 93.1 - 98.0 N-m
9.5 -10.0 Kgf-m
68.7·72.3 ft-Ihs
ROCKER ARM AND PUSH ROD
R OR N TO A :TO LOOSEN
1. Remove the rocker arm bracket mounting bolts.
2. Detach the rocker arm assembly.
3. Remove the push rods.
When Reassembling
After installing the rocker arm, be sure to adjust the valve
clearance.
TIGHTENING TORQUE
ROCKER ARM BRACKET SCREW __ 23.5 - 37.5 N-m
2.4 - 2.8 Kgf-m
17.4 - 20.3 ft-Ibs
~
GROOVE
~j C!)b E!)g
n ef ~c ~
(A) 00 00 00
em 0 (!';:le 0 6d,o ~I
3Cylinder~1 0 a -U0h
(8)
.A TO N OR R: TO TIGHTEN
R OR N TO A :TO LOOSEN
en eu
€:Ij ®b
00 00
(A)
4 Cylinder ~m 00e~d q01 J
eq 0 E!li 0 ¥ O.h 0 lOP
~ . A TO N OR R: TO TIGHTEN
ER HEAD
MAKER CERTAIN THE PUSH
RODS ARE PROPERLY ENGAGED
IN THE GROOVES WHEN REASSEMBLINGV' WESTERBEKE \
Engines & Generators
9

DISASSEMBLY /ASSEMBLY
TAPPETS
1. Remove the tappets from the crankcase.
When Reassembling
1. Visually check the contact between the tappets and
cams for proper rotation. If a defect is found, replace
the tappets.
2. Before installing the tappets, apply engine oil thinly
around them.
NOTE: Do not change the combination of the tappet and the
tappet guide.
VALVE SPRING REPLACER
VALVES
STEM
SEAL
~~COLLET
VALVE
CAP
1. Remove the valve caps.
2. Remove the valve spring collet, pushing the valve spring
retainer
by the valve spring replacer.
3. Remove the valve spring retainer, valve spring and valve
stem
seal.
4. Remove the valve
When Reassembling
1. Wash the valve stem seal and the valve guide hole and
apply engine oil sufficiently.
2. After installing the valve spring collets, lightly tap the
stem to assure proper fit with a plastic hammer.
NOTE: Do not change the combination of the valve and the
valve guide.
INJECTION PUMP
1. Remove the stop solenoid and the hi-idling body.
2. Remove the engine stop lever and stop solenoid guide.
3. Remove the fuel injection pump assembly.
NOTE: Before removing the injection pump assembly, be sure
to remove the stop solenoid, hi-idling body, engine stop lever
and stop solenoid
guide.
HI-IDLING
BODY
WfO -
When Reassembling I II n
1. Before attaching the stop solenoid, hi-idling body and
solenoid guide, install the injection pump first into
position.
2. Replace the hi-idling body gasket with a new one.
3. Before fitting the stop lever to the gear case, install the
solenoid guide first into position. Then attach the stop
lever
and use it to see if it functions well.
4. Before fitting the idling limiter in place, attach the
solenoid guide and the engine stop lever in their
respective positions.
5.
When installing the stop solenoid, be careful to keep the
O-ring in place.
6. Be sure to insert the push rod of the stop solenoid into
the hole at the center of the solenoid guide.
TIGHTENING TORQUE
HI-IDLING 800Y __ _
o
Engines & Generators
10

DISASSEMBLY I ASSEMBLY
INJECTION PUMP (CO NT.)
U
STOP
SOlENOID-4::::::='~~~
GOVERNOR SPRINGS AND SPEED CONTROL PLATE
NOTE: Use a l.2mm diameter hard wire with its end hooked,
overall length of200mm (7.87 in). The tip of a wire is bent t
like a hook
to grasp the governor springs.
1. Remove the injection pump cover.
2. Remove the speed control plate mounting nuts and bolts.
3. Using the special tool, undo the large governor spring
from the fork lever.
4. Using the special tool, undo the small governor spring
from the fork lever.
S. Set the speed control lever as shown.
6. Take out the speed control plate with care and do not let
the large and small governor springs come off this plate
and fall into the gear case.
lVhen Reassembling
1. Hook the small spring first and then the large governor
spring
on the speed control plate.
2. Put the specific tool from the injection pump side to
catch the large governor spring., Keep this spring slightly
extended
and place the speed control plate in its specified
position.
3. Using the special tool, hook the small governor spring
onto the fork lever.
NOTE: Be careful not to stretch the small governor spring too
long because it may get deformed permanently.
Using the specific tool, hook the large governor spring onto
the fork lever.
Make sure both the governor springs are tight on the fork
lever.
Apply and tighten up the two bolts and two nuts on the speed
control panel.
Check that
the speed control leverpositions at low idle after
assembling
the governor springs.
Check that
the speed control lever returns to the high idle
position rather than the low idle position after moving the
lever to the maximum speedposition.
Finally attach the injection pump cover
in position.
SPECIAL TOOL
WIRE HOOK
STEP 1
STEP 3
INJECTION
PUMP
LARGE·
@~rG
STEP 5
STEP 6
~
STEP 4
SPEED CONTROL'
PLATE

DISASSEMBLY/ASSEMBLY
GOVERNOR SPRINGS AND SPEED CONTROL PLATE (CO NT.)
STEPS
DRIVE PULLEY
1. Lock the flywheeL
2. Remove the drive pulley mounting nut.
SPECIAL __
TOOL
3. Remove the drive pulley with gear puller.
4. Remove the feather key
When Reassembling
Apply grease to the splines ofthe coupling.
TIGHTENING TORQUE
FAN DRIVE PULLEY MOUNTING NUT 137.3 -156.9 N-m
14.0 -16.0 Kgf-m
101.3 -115.7 ft·lbs
DRIVE PULLEY
LARGE
SPRING
STEP
Engines &Generators
12
SPECIAL
TOOL
PEED CONTROL
LEVER
DRIVE PULLEY
STEP 10
SPRING

DISASSEMBLY I ASSEMBLY
GEAR CASE
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case.
3. Remove the O-rings.
When Reassembling
IDLE GEAR
CAM GEAR
1. Apply liquid gasket (Three bond 1215 or equivalent) INJECTION PUMP GEAR
both sides of the hour meter gear case gasket.
CRANK GEAR
2. Check to see ifthere are four O-rings inside the gear
case.
3.
Apply a thin film ofengine oil to the oil seal and install
it.
4. Before installing the gear case gasket, apply a non-drying
adhesive.
CRANKSHAFT OIL SLINGER
1. Remove the crankshaft collar.
2. Remove the O-ring.
3. Detach the crankshaft oil slinger.
When Reassembling
1. Insert the crankshaft collar after installing the gear case to
the cylinder body.
CRANKSHAFT OIL SLINGER
~~~~~, .... (..--CRANKSHAFT COLLAR
OIL PUMP DRIVE GEAR·--I-+~""""
IDLER GEAR
1. Remove the external snap ring.
2. Detach the idler gear collar.
3. Detach the idler gear.
When Reassembling
1. Check to see that each gear below is aligned with its
aligning mark.
Idle gear and crank gear
Idle gear and camshaft gear
Idle gear and injection
pump gear
IDLER GEAR (FOR BALANCER MODEL)
1. Remove the external snap ring.
2. Detach the idler gear collar.
3. Detach the idler gear.
When Reassembling
1. Check to see that each gear below is aligned with its
aligning mark.
Idle gear and crank gear
Cam gear and balancer gear
Idle gear and injection pump gear
Idler gear and balancer gear
INJECTION PUMP GEAR
\1
Engines &Generators
13
Oil PUMP DRIVE GEAR

DISASSEMBLY I ASSEMBLY
CAMSHAFT SET BOLT
CAMSHAFT
1. Remove the camshaft set bolts and draw out the camshaft.
When Reassembling
1. When installing the idler gear, be sure to align the
alignment marks on the gears.
TIGHTENING 'tORQUE
CAMSHAFT SET BOLT 23.5 - 27.5 N-m
2.4 - 2.8 Kgf-m
17.4 - 20.3 ft-Ibs
CAMSHAFT AND BALANCER SHAFT
1. Remove the camshaft set bolts and draw out the camshaft.
2. Remove the balancer shaft 1set bolts and draw out the
balancer shaft 1.
3. Remove balancer shaft 2 set bolts and draw out the
balancer shaft 2.
When Reassembling
1. When installing the balancer shaft 1 and 2, be sure to
place the 1st and 4th cylinder pistons at the top dead
center in compression, then align all marks on each gear
to assemble the timing gears, set the idle gear last.
TIGHTENING TORQUE
CAMSHAFT SET BOLT 23.5·27.5 N·m
2.4 - 2.8 Kgf·m
17.4· 20.3 ft-Ibs
BALANCER SHAFT SET BOLT_23.5- 27.5 N-m
2.4 - 2.8 Kgf-m
ClCs::=~=~===::=, 17.4 - 20.3 ft-rbs
FORK LEVER HOLDER
FUEL CAMSHAFT AND FORK LEVER ASSEMBLY
1. Remove the fuel feed pump.
2. Detach the fuel camshaft retainer.
3. Remove the three fork lever holder mounting screws.
4. Draw out the fuel camshaft assembly and fork lever
assembly at the same time.
When Reassembling
1. After installation, check to see that the fork lever is fixed
to the fork lever shaft and that they can tum smoothly in
the holder.
1.
2.
3.
FORK LEVER 1 FORK LEVER 2
BALANCER SHAFT 1
BALANCER SHAFT 2
STERBEKE
ines & Generators
OIL PUMP
14

DISASSEMBLY I ASSEMBLY
CRANK GEAR
1. Draw out the crank. gt<ar with a puller.
2. Remove the feather key.
OIL PAN AND OIL STRAINER
1. Remove the oil pan mounting screws.
2. Remove the oil pan
by lightly tapping the rim of the pan
with a wooden hammer.
3. Remove the oil pan gasket.
4. Remove the oil strainer and O-ring.
OIL STRAINER
After cleaning the oil strainer, check to see that the filter
mesh is clean and install it.
2. Visually check the O-ring, apply engine oil and install it.
3. Securely fit the O-ring to the oil strainer.
4. Apply a liquid gasket (Three bond 1215 or equivalent) to
the oil pan side
of the oil pan gasket.
S. To avoid uneven tightening, tighten the oil pan mounting
screws in diagonal order from the center.
OIL
PISTONS
1. Completely clean the carbon out of the cylinders.
2. Remove the connecting rod cap.
3. Tum the flywheel to bring the piston to top dead center.
4. Draw the piston upward
by lightly tapping it from the
bottom
of the crankcase with the handle of a hammer.
S. Draw out the other piston in the same method as above.
When Reassembling
1. Before inserting the piston into the cylinder, apply
enough engine oil to the piston.
2. When inserting the piston into the cylinder, face the mark
on the connecting rod to the injecting pump.
NOTE: Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking it.
Place the piston rings with their gaps at 0.79 rad (45°)from
the pistons pin direction.
Carefully insert the pistons using a piston ring compressor.
When inserting the piston in place, be careful not to scrape
the molybdenum disulfide coating off its skirt. This coating is
useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been ptess-fitted, the piston is
still hot and the coating easily peels off. Wait until the piston
cools
down.
TIGHTENING TORQUE
CONNECTING ROO SCREW __ 44.1 - 49.0 N-m
4.5 - 5.0 Kgf-m
32.5 - 36.2 ft-Ibs
CONNECTING ROD CAP
CONNECTING ROD SCREW
Engines &Generators
15

DISASSEMBLY I ASSEMBLY
PISTON RING AND CONNECTING ROD
1. Remove the piston rings using a piston ring tooL
2. Remove the piston pin and separate the connecting rod
from the piston.
When Reassembling
0.79 rad (45 ") 0.79 rad (45
0)
1. When installing the rings, assemble the rings so that
the manufacturers mark near the gap faces the top of
the piston.
-L--f--l'c---r--.L.T----I-t-l-PISTON PIN HOLE
2. When installing the oil ring onto the piston, place the
expanderjoint on the opposite side of the oil ring gap.
3. Apply engine oil to the piston pin.
4. When installing the piston pin, immerse the piston in
80°C (176"F) oil for 10-15 minutes and insert the piston
pin into the piston.
S. When installing the connecting rod to the piston,
align the mark on the connecting rod to the fan-shaped
concave.
NOTE: Mark the same number on the conneeting rod and the
piston so lwt to change the combination.
SECOND RING
Engines & Generators
16
0:79 rad (45 0)
PISTON RING COMPRESSOR
CONNECTING ROD
~ PISTON
\.
~
~'STONPIN
PISTON PIN SNAP RING 'e
MARK
FAN-SHAPED CONCAVE

MARK
DISASSEMBLY I ASSEMBLY
PISTON RING AND CONNECTING ROD (CONT.)
/
EXPANDER JOINT -.0
FLYWHEEL
1. Lock the flywheel.
2. Remove two of the flywheel screws.
3. Insert two flywheel guide screws in the holes.
4. Remove the remaining flywheel screws.
5. Remove the flywheel slowly along the guide screws.
Wlzen Reassembling
1. Insert two of the flywheel guide screws.
2. Check to see that there are no metal particles, on the
flywheel mounting surfaces.
3. Apply engine oil to the threads and the undercut surface
of the flywheel bolt and fit the bolt.
TIGHTENING TORQUE
FLYWHEEL SCREWS 98.0 -107.8 N-m
10.0 -11.0 Kgf·m
72.3 - 79.5 ft·lbs
FLYWHEEL SCREW
BEARING CASE COVER
1. Remove the bearing case cover mounting screws.
Remove the inside screws first and then the outside
screws.
2. Screw the two removed screws into the screw hole
of the
bearing case coverto remove it.
NOTE: The length of the inside screws and outside screws are
different sizes. Be aware of the size of the inside and outside
screws.
BEARING CASE COVER MOUNTING SCREW~
OIL SEAL
BEARING CASE COVER GASKET
BEARING CASE GASKET
BEARING CASE COVER
~~
··~\)t\ J)
When Reassembling
1. Align the bearing case gasket and the bearing case cover
gasket.
2. Install the bearing case cover positioning the casting
markUP.
3. Apply engine oil to the oil seal lip and be careful that it is
not rolled when installing.
4. Tighten the bearing case cover mounting screws evenly
in a diagonal order.
TIGHTENING TORQUE
BEARING CASE COVER ___ 23.5 • 27.5 N·m
MOUNTING SCREW 2.4 • 2.8 Kgf·m
17.4 - 20.3 ft-Ibs
/
o
FLYWHEEL GUIDE SCREW
)
Engines & Generators
17