Westerbeke 65A-FOUR User manual

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SERVICE MANUAL
65A-FOUR
MARINE ENGINE
.,,--.,26.0 AND 20.0KW EDER
-NET MOBILE/INDUSTRIAL
. GENERATORS '
3,28.5 and 25.5KW EDE D-NET
ARINE GENERATORS
PUBLICATION #053017
SECOND EDITION
APRIL 2009
~ WESTERBEKE
.,F WESTERBEKE CORPORATION. 150 JOHN HANCOCK ROAD
,:IL MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
AWARNING:
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
- Weakness and Sleepiness
- Throbbing in Temple{;
- Muscular Twitching
- Vomiting
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEOIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
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/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.
Engines & Generators

SAFETY INSTRUCTIONS
ImOOUCTION
Readthis safety numual carefuily. Most accidents are
caused by failure to follow fundamental rules and precau-
tWns. Know when dangerous condiJions exist and take the
necessary precautitJns to protectyourself, your personnel,
andyour machinery.
The following safety instructWns are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: lID not touch AC eltN:tricaJ COIIIIIIetIons
willie tJIJfIiOtlIs mnning, 01 wilen connected to sholtJ
"... LetIIaI milage Is PItJSBIIt at tIrtJstJ connections!
• Do not operate this machinery without electrical
enclosures
and covers in place.
• Shut offelectrical 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 COMect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
tIansfer switch. Damage to vessel's AC generator may
result ifthis procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: lID not touch hot BOgin. palls 01
BIhaust srsItJm compoOtlnis. A mnning engine gets
,." "",!
• Always check the engine coolant level at the coolant
recovery tank.
IA WARNING: StBam can couse injury 01 death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: FiltJ can caUBB injury 01 deathl
• 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 ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleanerlsilencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions f~m fuel vapors can couse
Injury 01 d.atIr!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed
when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before 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-ven-
tilated area away from spark-producing equipment and
out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when 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 shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this enviromnent.
~ WESTERBEKE
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
111 death!
• Disconnect the battery cables before servicIng the engine!
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
at 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 Igmted 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
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handlIng
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negatIve lead first
and reconnect it last whenservicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
_ injury or 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 off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifold!
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Don't run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your boat
builder or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an Invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust systems.
Exhaust sulfur causes rapid deterioration of copper tubing
resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. 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 of the
symptoms or signs ofcarbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
A WARNING: Rotating parts can cause injury
or 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.
-.,y WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces
or bracelets that
could
be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the 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 WARIIIING: High nIl. IBvels can cau. hBaring
/oss1
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARIIIING: Do not WIlde In machlnory whsn YIIU arB
mtmI1IIIt lIT physicallt IncapacltalBd by fatiguBI
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 yourequipment, and follow all safety
procedures.
ENGINE INSTAllATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination
of
sources including the USCG and the NFPA.
Sections
of the ABYC standards of particular interest are:
H-2 Ventilation
P-I Exhaust systems
P-4 Inboard engines
E-9
DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
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 Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
II Tracy Drive
Avon Industrial Park
Avon,
MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
-..v: WESJERBEKE
EngInes & Generstors
iii

TABLE OF CONTENTS
Testing for Overhaul. ........................................... 2 Valves..........................................................
.41
Engine Compression......................................2 Rocker Arm .................................................43
Engine Troubleshooting ....................................... 3 Timing Gear/Crankshaft..............................44
General Description ............................................. 8 Camshaft......................................................45
Cylinder Block...............................................8 Idler Gear.....................................................46
HalfFloating Head Cover.............................8 Balancing Shaft ...........................................47
Cylinder Head................................................8 Piston/Connecting Rod................................48
Piston and Piston Rings.................................9 Crankshaft....................................................50
Dynamic Balancer.........................................9 Crankpin ...................................................... 51
Governor...................................................... 10 Cylinder....................................................... 53
Disassembly Procedures ................................. .. 11 Oil Pump......................................................53
Generator .....................................................
11
Servicing S ·fi t·
peci ca Ions ................................... 55
Radiator Models ..........................................
II Engine Adjustments ........................................... 61
Propulsion Engines ...................................... II
I' . T' .
nJectton Immg .......................................... 61
Preparation for Disassembly........................ 11 Valve Clearance...........................................62
Remove Interior Components......................
II Oil Pressure/Oil Change..............................63
Remote Stop/Start Panel ............................
lla
Fuel System ....................................................... 64
Assembly Procedures ....................................... . 12 Injectors ....................................................... 65
Surface Preparation ..................................... 12 Injection Pump.............................................65
Gasket Information......................................
12 Glow Plugs ..................................................65
Engine Assembly Instructions ...... ..................... 13 Raw Water Pump ............................................... 66
Heat Exchanger ...........................................
13 Wiring Diagram (#52952) EDE ........................... 67
Marine Transmissions.................................. 13
Wiring Diagram (#54469) EDER ....................... 67a
Radiators...................................................... 13
Wiring Diagram (#31944) 65A·Four ................ 67b
Engine Tuning ............................................. 13
Specifications· 65A·Four ................................ 68
Disassembly/Assembly (Engine) ........................ 14
Specifications· 33Kw EOE ............................. 68a
Cylinder Head and Valves ...........................
14
Specifications· 28.5Kw EDER ....................... 68b
Cylinder Head Gasket ................................. 16 Generator Specifications .................................. 69
Governor Housing Assembly ......................
18
Torque Specifications ....................................... 70
Injection Pump............................................. 19
Special Tools ..................................................... 72
Thermostat................................................... 20 Generator Information ....................................... 83
Injection Nozzle...........................................20
Terminal Board Connections ............................. 84
Fuel Camshaft and Governor Weight..........23
Electronic Regulator ......................................... 85
Injection Pump Assembly............................24
Generator Servicing .......................................... 87
Water Pump/Oil Cooler...............................26
Generator Troubleshooting (Chart) ................... 88
Gear Case.....................................................27
EDE Testing the Voltage .................................... 89
Oil Screw and Strainer ................................29
Internal Wiring Schematic ................................ 91
Piston and Connecting Rod.........................29 Changing Hertz and Voltage ............................. 92
Flywheel and Crankshaft............................. 31 AC Output Configurations ................................. 92
Flywheel Housing........................................32
Generator Parts Breakdown .............................. 93
Crankshaft....................................................33
Metric Equivalent .............................................. 95
Starter Motor Service ...... .................................. 34
Metric Conversion Chart ................................... 96
Alternator Service ............................................. 37
Index ............................................................... 97
Servicing (Engine) ............................................ .40
Cylinder Head..............................................40
~ WESTERBEKE
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
is not necessarily due
to trouble with the engine itself, but is
sometimes caused by injector nozzle wear orinjection pump
wear. 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 Lowengine poweroutput
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 the injectors. 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. Satisfactory combustion is
obtained only under sufficient compression pressure. If
an
engine lacks compression pressure, incomplete combustion
offuel will take place even
if other parts ofthe 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 ofthe crankshaft.
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 ofwear
of these parts.
When decrease
of compression 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
Check the compression pressure. To do this warm the engine,
remove all fuel injectors,or glow plugs, disconnect the
fuel
shut-off solenoid wire, and install a compression adapter in
the injector hole or glow plug hole .. Connect a compression
tester on the adapter
and crank the engine with the starter
motor until the pressure reaches a maximum value. Repeat
this process for
each cylinder. Look for cylinders with
dramatically lower compression than the average of the
others.
COMPRESSION PRESSURE (Faclary Spec.)
at 250 RPM 626 PSI
44 Kgl/cm'
4.32 MPa
ALLOWABLE LIMIT
al250 RPM 472 PSI
33.2 Kgl/cm'
3.26 MPa
If a weak cylinder is flanked by healthy cylinders, the
problem
is either valve or piston-related. Check the valve
elearances for the weak cylinder, adjust
as needed, and test
again.
If the cylinder is still low, apply a small amount of oil
into the cylinder to seal the rings, and repeat the test. If the
compression comes up, the rings are faulty.
Abnormally high readings on all cylinders indicate heavy
carbon accumulation, a condition that might be accompanied
by high pressures and noise.
NOTE: In case of severe vibrations anddetonation noise, the
cause may befuel injectorproblems, see FUEL INJECTORS.
Poorfuel quality, contaminants and loss
of po sitivefuel
pressure to the injection pump will result in faults.
TESTING ENGINE
COMPRESSION
When re-installing the glow use anti-seize compound.
34.3 to 39.2 N·m
Nozzle holder
3.5 to 4.0 kgf·m
25.3 to 2B.9 ft-Ibs
t9.6 to 24.5 N·m
Tightening torque Over1low pipe nut 2.0 to 2.5 kgf·m
14.5 to tB.t ft·lbs
49.0 to 6B.6 N·m
Nozzle holder assembly
5.0 to 7.0 kgl·m
36.2 to 50.6 ft·lbs
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 ofassistance in determining the need for an engine
overhaul.
PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY
HARO STARTING LOW CRANKING SPEEO
1. Engine oil viscosily 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.
5. Defective starter.
5. Repair or replace starter.
6. Defective main drive section.
6. Check clutch for disengagement.
OEFECTIVE INJECTION SYSTEM
1. Air trapped in fuel passage.
1. Bleed air from fuel system.
2. Clogged fuel filter. 2. Clean or replace filter.
3. Low injection pressure. 3. Adjust injection pressure.
4. Inadequate spray. 4. Clean or replace nozzle.
5. Injection pump delivering insufficient fuel.
5. 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 stem seized. c. Replace valve and valve guide.
d. Broken valve spring. d. Replace valve spring.
e. Compression leaks through cylinder head gasket. •. 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. Airtrapped 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 aireleaner. 1. Clean or replace air cleaner.
(continued)
~ WESTERBEKE
Engines & Generators
3

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEOY
LOW OUTPUT (c.nI.) 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. Retig hten 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. Relighten 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. Oelective 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 EXHAUSr
3. Moving parts nearly seized or excessively worn.
3. Repair or replace.
4. Poor compression. 4. See LOW COMPRESSION; HARO 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.
•• Check.
b. Seized piston ring.
b. Replace or clean.
c. Excessive piston-to-cylinder clearance. c. Replace or correct.
(contmued)
Engines & Generators
4

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE
VERIFICATION/REMEDY
SMOKY EXHAUST (cant.,
WHITISH OR PURPLISH (cant.,
d. Worn valve stem and valve guide. d. Replace.
e. Low engine oil viscosity. e. Replace.
f. Excessive oil pressure. I. 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 ROO 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. Rebare 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 worn 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.
ROUGH OPERATION
INJECTION PUMP SYSTEM
1. Uneven injection. 1. Adjust injection or replace parts.
2. 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)
"MJI" WESTERBEKE
Engines & Generators
5

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEOY
KNOCKING
ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a.Overheated cylinder. a. See OVERHEATING; LOW OUTPUT.
b.Carbon deposits in cylinder. b. Clean.
2. Too early injection timing. 2. Correct.
3. Too high injection pressure.
3. Correct.
4. Improper luel. 4. Replace with proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
1. See LOW COMPRESSION; HARD STARTING.
2. Injection pump malfunctioning. 2. AdjusVRepair.
3. Improper nozzle.
a. Poor spray. a. Clean or replace nozzle.
b. Poor chattering. b. Repair or replace nozzle.
c. After-injection drip.
c. Repair or replace nozzle.
d. Nozzle needle valve seized.
d. Replace.
INTERMlmNT
1. Fuellilter clogged. 1. Clean or replace.
EKHAUST 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 mallunction.
2. Overhaul oil pump.
3. Clogged oil cooler. 3. Repair.
4. Diesel dilution of the oil. 4. Injection pump repair.
HIGH OIL PRESSURE
1. Wrong type of oil. 1. Replace.
2. Relief valve defective 2. Replace.
RAW WATER IN CYLINDERS
1. Fail of syphon valve or exhaust system .. 1. Clean out, inspect exhaust system, replace.
FUEL MIXING WITH 1. Injection pump broken. 1. Rebuild, replace.
LUBE OIL
2. Injection pump's plunger is worn. 2. Replace.
3. Deficient nozzle injection. 3. Replace nozzle
WATER MIXING WITH
1. Delective head gasket. 1. Replace.
LUBE OIL
2. Cylinder block/cylinder head flawed. 2. Replace.
(continued)
Engines & Generators
6

ENGINE TROUBLESHOOTING
Problem Probable Cause
Veriftcatlon/Remedy
Exhaust smoking problems
1.
Blue smoke. 1.
Incorrect grade of engine oil.
1a. Crankcase is overfilled with engine oil (oil is blowing out
through the exhaust).
2. White smoke.
2. Engine is running cold.
28. Faulty injector or incorrect injector timing.
3. Black smoke. 3. Improper grade of fuel.
3a. Fuel burn incomplete due to high back pressure in exhaust or
insufficient air for proper combustion (Check for restrictions in
exhaust system; check air intake.).
3b.lmproperly timed injectors or valves or poor compression.
3•. lack of air - check air intake and air filter. Check for proper
ventilation.
3d. Overload.
LCD QISPLAYS
No LCD Display
1.
Check battery. 1. Battery on.
2.
20 amp breaker off. 2. Turn breaker on.
Oil Pressure
1.
Oil level low/oil leak. 1. Check oil level, add oil and repair leaks.
2.
Lack of oil pressure 2. Test oil pressure. If OK, test oil pressure sendor, inspect oil
filter, inspect oil pump.
3.
Ground connection. 3. Check ground connection.
4.
Faulty control module. 4. Inspect all the plug connections/replace.
Coolant Temperature 1. Check system coolant level. 1. Add coolant. Check for leaks.
2.
Check water pump drive belt.
2.
Adjust belt tension, replace belt.
3.
Faulty Temp sensor. 3. Check sensor/replace.
4.
Ground Connection. 4. Check ground circuit.
5.
Faulty control module. 5. Check plug connectionslreplace.
Exhaust Temperature
1.
Check sea water flow. 1. Inspect thru hull fitling, hose and strainer. Correct as needed,
2.
Faulty exhaust temp switch. 2. TesVreplace.
3.
Ground Connection. 3. Check ground circuit.
4.
Faulty control module. 4. Check plug connections.
5.
Sea water pump. 5. Inspect impeller/replace.
Battery Voltage
1.
Check alternator drive belt. 1. Adjust tension/replace if worn.
2.
Check charge voltage. 2. Check excitation. replace/repair alternator
3.
Check battery connections. 3.
Check + and - cables from battery to engine.
4.
Faulty control module.
4.
Check plug connectionslreplace.
Generator Voltage
1.
Check AC voltage output. 1.
Adjust voltageitroubleshoot generator for cause.
2.
Faulty control module.
2. Check plug connectionslreplace.
Generator Frequency 1.
Check engine speed. 1. Adjust.
2.
Check fuel supply. 2. Inspect filters/replace filters. Test fuel pump operation.
3.
Amperage load. 3. Check load with amprobe.
LED Display - 1.
Compartment ambient temperature 1. Ventilate compartment.
edges tum pink.
too high.
-.¥ WESTERBEKE
Engines & Generators
7

I GENERAL DESCRIPTION
CYLINDER BLOCK
This engine employs separate type crankcases -
the crankcase 1 with combustion parts and the
crankcase 2 which supports the crankcase 1 and
reduces noise.
Since it is a hanger type, you can easily assem-
ble and disassemble it. The cylinder is a linerless
type which enables good cooling operation, less
strain and good abrasion resistance.
HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm or so off the cylinder head. This
arrangement helps
reduce noise coming from the
. cylinder head.
RUBBER
PACKING
CYLINDER HEAD
CYLINDER
HEAD COVER
This engine employs a three valve system: two
inlet valves and double ports, and one exhaust
valve which produces good inlet inertia to
improve combustion efficiency and volumetric
efficiency. It also employs a new unique
combustion chamber with multiple injection
grooves.
Besides the conventional cross port system, it
employs the forced cooling method between
valves to eliminate heat distortion, thus enabling
durable and reliable configuration.
En'glnes & Generators
8
U---OIL PAN

GENERAL DESCRIPTION
PISTON AND PISTON RINGS
This engine employs the E-TVCS VERSION-II
so that the improved combustion surface at the
top of the piston enables more complete com-
bustion efficiency than the conventional models.
The profile and the offset of the piston are
optimized
to reduce piston slap. The oil jet at
the small end of the connecting rod reduces the
heat load of the piston.
TOP RING I I \
~~~G r; I \- .... ;:.
OILRING ~
PISTON
Three rings are installed in grooves in the
piston. The top ring is made
of nitrizing steel to
get more reliability than the chrome plated ring.
It is a keystone type ring to provide durability
against heavy load. At the Sliding part, a
special piston ring which is conformable to the
cylinder wall is employed. The second ring is
chrome-plated on the peripheral surface and it
is an undercut ring to prevent the holding of oil.
DEPRESSION
~~~_77GROOVES
The oil ring (3) has chamfered contact faces
and an expander ring, which increase the
pressure
of the oil ring against the cylinder
wall.
Several grooves are cut
on the topland to
help heat dissipate and to prevent scuffing.
DYNAMIC BALANCER
Engines are sure to vibrate due to the
reciprocation
of the pistons. theoretically, three
cylinder engines are much less prone to cause
vibration than four cylinder engines. However,
any engine has many moving parts
in addition
to its pistons and cannot be completely free
from vibration.
The
four cylinder engine is fitted with
balanced weight on the crankcase to absorb the
second inertia mentioned above and reduce
vibration.
-.v WESTERBEKE
Engines & Generators
9
PISTON TOPLAND
BALANCER SHAFT

GENERAL DESCRIPTION
FORK LEVER
2
GOVERNOR
This mechanism maintains engine speed at a
constant level even under fluctuating loads and
provides stable idling and regulates maximum
engine speed by controlling the fuel injection
rate.
This engine uses a mechanical governor that
controls the fuel injection rate at all speed
ranges (from idling to maximum speed)
by
utilizing the balance between the flyweight's
centrifugal force and spring tension.
A
governor shaft for monitoring engine speed
is independent
of the injection pump shaft and
rotates
at twice the speed of conventional types,
providing better response to load fluctuation and
delivering greater engine output.
At Start
The stop solenoid (energized to run type) is
powered to release the stop lever.
As no centrifugal force is applied to the
flyweight (1), low tension of the start spring (2)
. permits the control rack to move to the starting
position, supplying the amount
of fuel required to
start
the engine.
At Idling
Turn the speed control lever (3) clockwise to
idle the engine. It tensions the governor spring
(4) to
pull the fork lever 2.
When the fork lever 2 is pulled, it moves the
torque spring pin (6) and fork lever 1 (7)
in the
direction
of the arrow A to restrain the weight.
In combination with the start spring tension, it
is balanced with the centrifugal force
of the
flywheel weight to maintain idling.
• At rated speed with full load and overload
As the speed control lever is changed from the middle
speed to high speed, the governor spring tension
increases to compress the torque spring
and move the
fork lever 1 in the direction of the arrow A.
The fork lever 2 moves until it reaches the output
limiting bolt to keep rated rotation and rated output.
When the engine
is overloaded, the engine rotating
speed decreases
and the centrifugal force of flywheel
weight decreases. Then the torque spring moves the
fork lever 1 in the direction of arrow A.
The control rack moves in the direction that increases
fuel supply to increase the output. It is balanced with the
centrifugal force of the flywheel weight to produce low-
speed output (torque output).
SPRING PIN (6)';~~~~Q\;;;;~-.T'J'!:="'5---
SPEEO CONTROL--ttt+~r
LEVER
FORK LEVER 1 (7)
IDLE ADJUSTING BOLT-'Oll~::h;",,<
FLYWEIGH1l1 )
NO·LOAD
ROTATION
OUTPUT LIMITING BOLT
TORQUE LIMITING BOLT
SPEEO CONTROL LEVER 131-H\+l
• To stop engine
GOVERNOR SPRING (4)
/ll-l.l..>..w.J-- CONTROL RACK
When the stop solenoid is turned off, the spring
tension of the solenoid is released, the rod extrudes and
the stop lever moves the control rack in the direction of
the arrow B which stops the engine.
To stop the engine manually, move the external stop
lever to the left.
'9Y' WESTERBEKE
Engines & Generators
10

DISASSEMBLY PROCECURES
GENERATOR
Unplug and disconnect the electrical connections on the out-
side and inside of the control box to allow for the removal of
the control box off the AC generator end. NOTE: Properly
photo or mark all connections to ensure proper reconnecting.
Remove the air hose between the control box and the engine
intake
box. Separate the exhaust hose at the water injected
elbow
and disconnect the fuel supply and return lines.
Drain the engine
oil and the coolant from the engine.
Carefully support
and then unbolt the generator backend
from the engine.
Additional generator information will be found
in the
GENERATOR section ofthis manual.
RADIATOR MODELS
COOLANT DRAIN
19MM HEX PLUG
Drain the coolant using the petcock found at the base
of
the radiator. Unbolt the radiator from the side support
brackets and lower the mounting frames. Remove the
radiator and
set aside for servicing.
Remove the DC charging alternator. Remove the four
bolts securing
the fan to the fresh water pump pulley
and remove the fan and pulley. Unbolt the fan guard and
remove it.
RADIATOR
DISASSEMBLY/ASSEMBLY
PROPULSION ENGINE
Unplug the instrument panel wiring harness. Drain the
transmission fluid and the transmission oil cooler hoses.
Detach
the oil cooler hoses and unholt the transmission
from the engine.
NOTE: Label any lines, hoses or cables as you separate them.
TRANSMISSION
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.
For transmission service and maintenance refer to the
units
Operator's mannal, To rebuild a transmission
contact the transmission manufacturer for the location
of
DAMPER
BOLTS
''''',"<I'T "u<DAMPER
PLATE FOR WEAR AND
BROKEN SPRINGS
PREPlUtAil(IN 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 or component for any sign of
faulty condition during removal or cleaning. The part
will
tell you how it acted or what was abnormal about it more
~ WESTERBEKE
Engines & Geners/ors
11

DISASSEMBLY PROCEDURES
REMOVE EXTERIOR COMPONENTS
With the transmission/generator/radiator separated from the
engine. begin the following step by step procedure to
disassemble the exterior parts.
NOTE: Mount the engine securely on a suitable engine stand.
1. Remove the start motor, drive belt, and the alternator.
Label the wires
and cables.
2 Witb the hoses disconnected, remove the thermostat
housing
and housing gasket, leaving the temperature
sender and switch in place ifapplicable.
3. Remove
the magnetic pick-up from the bell housing
(Generators only).
4. Remove the Hywheel heD housing and the circuit
hreaker/pre-heat solenoid mounting
bracket
Remove the engIne back plate.
S. Remove the oU filter, oU cooler, oU hoses and mounting
bracket. Make note
of the hose arrangements.
6. Remove
the transmission damper plate from the
engIne Hywheel
(Marine Engines).
7. Remove the engIne mounted raw water pump,
complete with its adapter mounting plate. See RAW
WATER PUMP for parts breakdown. (Marine Engines and
Generators only)
8. Remove the engine heat exchanger. If possible. leave
one end of each hose connected to the part being
removed (Marine Engines and Generators only) .
9. Remove the exhaustcomponents from the exhaust
manifold
a) Remove the exhaust elbow (ifapplicable) from the
lower surface ofthe manifold. Clean
and inspect for
cracks
and defects. Replace as needed.
b) Remove the exhaust nipples, elbows
and plugs from
the manifold.
c) Remove the water connectors from the ends ofthe
manifold. Be sure to note the proper location and
arrangement of each for proper alignment.
d) Examine
aU 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-instaD on the boat.
10. Remove the coolant circulating pump. Refer
to
COOlANTPUMPASSEMBLY.
11. Remove the air intake silencer and the intake
manifold.
12.
Prepare to disassemble the main engine.
.... WESTERBEKE
Engines & Generators
11a

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.
Be aware of these common problems that can occur during
assembly.
Insufticlent Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the water jacket. These
fasteners should be sealed with Pennatex No. Z 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-I/Z, 2/3, and 111 torque.
Exceptions are torque-to-yield bolts and rocker arm shaft
fasteners. The former are torqued as indicated. The
latter-mcker 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.
GREASE
INTERNAL SNAP RING. EXTERNAL 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.
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 of location 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 140z (400
gram) 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.
Engines & Generators
12

ENGINE ASSEMBLY INSTRUCTIONS
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 tenninal 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.
Thrn the rotor pulley by hand.
It should turn smoothly.
Depending on when the alternator was last serviced. the
brushes may need replacing.
If the alternator is at all suspect.
send it to a service shop for testing and overhaul. or refer
to
the more detailed alternator section in this manual.
HEAT EXCHANGER (MARINE ENGINES/GENERATORS)
Install the heat exchanger. replace the heat exchanger zinc
and attach new hoses with new clamps to the cooling system.
Refer to the COOllNG SECTION in this manual for HEAT
EXCHANGER service.
MARINE TRANSMISSION (MARINE ENGINES)
1. Assemble Ibe damper plate to the flywheel.
2. Re-install Ibe
marine transmission and fill with the
correct amount of fluid. Do not overfill.
MOlE: Some transmissions. such as the Borg Warner Velvet
Drive require oil coolers. Oil coolers should be cleaned,
pressure tested and repainted at engine overhaul. The
transmission oil cooler hases should also be inspected.
ReJer to the text on HEAT EXCHANGERS.
RADIATORS
The radiator, cleaned. flushed, and pressure tested can be
assembled to the generator mounting rails. The fan can be
assembled to the engine.
Engine Mounts
Inspect the engines flexible mounts. Replace any that show
signs of wear, rust, or splits in the rubber isolators. In a
complete overhaul. all four should be replaced.
ENGINE TUNING OPERATION
After re-assembly, the unit must be test run. This will ensure
that the engine/generator operates to its specifications. Fill
the engine cooling system with an antifreeze mixture and the
engine oil sump with lube oil API specifications
of CF, CG4.
CH4 or
CI4 SEA 15-40.
1. Mount the unit on a test stand aud make the needed
fuel, elecrtical,
exhaust and coolant connections as
required.
2. Pre-lube
the unit if not already done or disable the fuel
solenoid/actuator
and intermittently crank the unit to
allow
the oil pump to prime the oil passages.
3.
Start the unit and monitor for proper operation like oil
pressure,
water temperature, DC charge, etc.
4. Allow the unit to come up to normal operating
temperature and check the engine speed. (Propulsion-
adjust engine idle speed for smoothest operation).
5.
Check unit for any leakage of oil, fuel or coolant.
Correct as needed.
6. Propulsion - Check fuJI no load rpm.
7. Load test the unit in gradual steps 114, 112, 3/4 and
full load
8. After load test, stop unit an allow to rest. Check all
fasteners and electrical connections to make sure they
are tight and secure. Check wire hose challing and
protect as needed.
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
13

DISASSEMBLY I ASSEMBLY
Cylinder Head and Valves
Cylinder Head Cover and Nozzle Holder
1. Remove the injection pipes (1) and overflow pipes.
2. Remove the glow plugs.
3. Remove the nozzle holder assembly (4) and copper gaskets.
4. Remove the heat seal.
5. Remove the head cover.
(When reassembling)
• Check to. see that the cylinder head cover gasket is not
defective.
• Be sure to replace the heat seal.
• TIghten the head cover mounting bolts to specified torque.
• Mount the return fuel check valve with the I mark in the
direction
of flow back to the taok. t
Cylinder head cover 6.9 to 11.3 N·m
0.7
to 1.15 kgf·m
mounting screw
5.1 to 8.32 It-Ibs
Injection pipe retaining
22.6 to 36.3 N·m
2.3 to 3.7 kgf·m
nut 16.6 to 26.8 It-Ibs
49.0 to 68.6 N·m
Tightening torque NOlzle holder assembly 5.0 to 7.0 kgf·m
36.2 to 50.6 It-Ibs
Overflowpipeassembly 19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
retaining nut 14.5
to 18.1 It-Ibs
19.6to 24.5 N·m
Glow Plug 2.0 to 2.5 kgf-m
14.5 to 18.1 It-Ibs
Nozzle Heat Seal Service Removal Procedure
• IMPORTANT
• Use a plug (phillips) screwdriver that has a dia. which is
bigger than the heat seal hole (Approx. 6 mm, 1/4 in.).
1. Drive screw driver lightly into the heat seal hole.
2. Turn screw driver three orfour times each way.
3. While turning the screw driver, slowly pull the heat seal out
together with the injection nozzle gasket..
If the heat seal drops, repeat the above procedure. Hmit seal
(4) and injection nozzle gasket (3) must be changed when the
injection nozzle is removed for cleaning or for service.
LIFTING EYE
CAUTION: IF THERE IS REASON TO REMOVE THE
ENGINES LIFTING EYE, 00 NOT ATTEMPT TO TAKE
OUT THIS STUO. SIMPLY REMOVE THE NUT AND
THE BOTTOM BOLT. THE STUD IS PERMANENTLY
ASSEMBLED THRU THE WATER JACKET.
o
GLOW
NOZZLE
COPPER
GASKETS
HEAT SEAL
HEAD COVER
Engines & Generators
14
PHilLIPS
_",IN,JEClrION PIPE
PIPE
INJECTION
NOZZLE
GASKET (3)
=:r.:3::s..\..L=- HEAT SEAL (4)