Westerbeke 65A-FOUR Service Manual
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Westerbeke 65A-FOUR Service Manual

Westerbeke 65A-FOUR Service Manual

Marine engine; d-net mobile/industrial generators; d-net marine generators
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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

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  • Page 1 MARINE ENGINE .,,--.,26.0 AND 20.0KW EDER -NET MOBILE/INDUSTRIAL . GENERATORS ' 3,28.5 25.5KW EDE D-NET ARINE GENERATORS PUBLICATION #053017 SECOND EDITION APRIL 2009 WESTERBEKE WESTERBEKE CORPORATION. 150 JOHN HANCOCK ROAD ,:IL MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780 WEBSITE: WWW.WESTERBEKE.COM...
  • Page 2 WESTERBEKE and should be fixed to 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...
  • Page 3 • Make sure a fire extinguisher is installed nearby and is before touching the engine or checking the coolant. 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...
  • Page 4 Acid may splash on the skin or into the eyes ing parts and hot exhaust system components. inadvertently when removing electrolyte caps. WESTERBEKE -.,y Engines & Generators...
  • Page 5 SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.

  • Page 6: Table Of Contents

    Generator Parts Breakdown ......93 Flywheel Housing ........32 Metric Equivalent ..........95 Crankshaft............ 33 Metric Conversion Chart ........Starter Motor Service ........Index ............... Alternator Service ..........Servicing (Engine) ..........Cylinder Head ..........40 WESTERBEKE Engines & Generators...

  • Page 7: Testing For Overhaul

    TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD ENGINE COMPRESSION Check the compression pressure. To do this warm the engine, . Cause of Low Compression remove all fuel injectors,or glow plugs, disconnect the fuel Generally, the time at which an engine should be overhauled shut-off solenoid wire, and install a compression adapter in is determined by various conditions such as lowered engine the injector hole or glow plug hole ..

  • Page 8: Engine Troubleshooting

    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 &...
  • Page 9 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 6. Add engine oil. level.
  • Page 10 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) WESTERBEKE "MJI" Engines Generators &...
  • Page 11 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY ENGINE KNOCKS WITHOUT MUCH SMOKE KNOCKING 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.
  • Page 12 Check engine speed. Generator Frequency Check fuel supply. Inspect filters/replace filters. Test fuel pump operation. 3. Amperage load. 3. Check load with amprobe. LED Display - Compartment ambient temperature Ventilate compartment. too high. edges tum pink. WESTERBEKE -.¥ Engines Generators &...

  • Page 13: General Description

    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.

  • Page 14: Piston And Piston Rings

    The four cylinder engine is fitted with BALANCER SHAFT balanced weight on the crankcase to absorb the second inertia mentioned above and reduce vibration. WESTERBEKE Engines Generators &...

  • Page 15: Governor

    It is balanced with the the arrow B which stops the engine. centrifugal force of the flywheel weight to produce low- To stop the engine manually, move the external stop lever to the left. speed output (torque output). WESTERBEKE '9Y' Engines & Generators...

  • Page 16: Disassembly Procedures

    • 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 RADIATOR DISASSEMBLY/ASSEMBLY WESTERBEKE Engines Geners/ors &...

  • Page 17: Remove Interior Components

    Generators only) manifold. 8. Remove the engine heat exchanger. If possible. leave 12. Prepare to disassemble the main engine. one end of each hose connected to the part being (Marine Engines and Generators only) . removed ..WESTERBEKE Engines & Generators...

  • Page 18: Assembly Procedures

    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 GREASE is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces.

  • Page 19: Engine Assembly Instructions

    ENGINE ASSEMBLY INSTRUCTIONS ALTERNATOR INSPECTION ENGINE TUNING OPERATION When rebuilding the engine. the alternator should be cleaned After re-assembly, the unit must be test run. This will ensure and inspected. The housing can be wiped off with a solvent that the engine/generator operates to its specifications. Fill and the alternator tenninal studs should be cleaned with a the engine cooling system with an antifreeze mixture and the engine oil sump with lube oil API specifications of CF, CG4.

  • Page 20: Cylinder Head And Valves

    DISASSEMBLY I ASSEMBLY Cylinder Head and Valves Cylinder Head Cover and Nozzle Holder _",IN,JEClrION PIPE 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.
  • Page 21 DISASSEMBLY ASSEMBLY Rocker Arm and Push Rod 1. Remove the rocker arm (1) as a unit. 2. Remove the push rods. 3. Detach the bridge arm. (When reassembling) • When putting the push rods onto the tappets, check to see if their ends are properly engaged with the tappet recess .

  • Page 22: Cylinder Head Gasket

    DISASSEMBLY I ASSEMBLY 2 Notches 1 Notch Selecting Cylinder Head Gasket Without Notch • Replacing the Cylinder head Gasket 1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket. 2. Replace the same notch (a), (b) or (c) as the original cylinder head gasket.
  • Page 23 DISASSEMBLY ASSEMBLY GOVERNOR 7. Slide off the governor connecting rod (7) from the rack pin of CONNECTING ROD (7) injection pump assembly. ~;o-===ffFt':~-Hr--RACK 8. For convenient sake, temporarily hook the start spring on the PIN (51 rack pin hole of the governor connecting rod. 9.

  • Page 24: Governor Housing Assembly

    DISASSEMBLY ASSEMBLY INJECTION PUMP GEAR (5) 4. Temporarily tighten the injection pump gear mounting nut by hand. 5. Fix the injection pump unit and tighten the injection pump gear mounting nut to the specified torque. S. Take off the fuel cam shaft lock screws (2) and tighten the ---""-' plugs (1) for plugging.
  • Page 25 3. install the injection pump unit to the injection pump gear (5) . • NOTE • When installing the injection pump unit to the injection pump gear, make sure that the key is fit in the keyway of injection pump gear. WESTERBEKE Engines & Generators...

  • Page 26: Thermostat

    DISASSEMBLY I ASSEMBLY Thermostat Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove THERMOSTAT the thermostat cover. 2. Remove the thermostat assembly. (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket. •...
  • Page 27 33.3 ft-Ibs HOUSING (5) GOVERNOR ,----FORK LEVER (4) ."::J::-__ IIOOiHACTUATOR (1) FORK LEVER SHAFT I ·,ClIP (2) '~~::r==a~f:~lli::= BOIOST ARMS 3) nr--Rnln<T SPRING (4) GOVERNOR SPRING PIN (5) PIN (5) REMOVING THE C/R-CLIP BOOST ARMS AND SPRING WESTERBEKE Engines & Generators...
  • Page 28 DISASSEMBLY ASSEMBLY SPEED CONTROL LEVER (1) Remove the speed contra) lever and the return spring. 2. Remove the governor lever assembly from the governor housing. 3. Remove the start spring and the stop spring. Stop Lever 1. Remove the stop lever (1) and the return spring. 2.

  • Page 29: Fuel Camshaft And Governor Weight

    23.510 27.5 N·m COVER Injection pump 2.4 10 2.B kgf·m mounting screw 17.4 to 20.3 ft-Ibs Tigntening torque 17.71020.6 N·m Injection pump I.B 10 2.1 kgf·m mounting nut 13.01015.2 ft-Ibs GOVERNOR WEIGHT (5) BEARINGS B WESTERBEKE Engines & Generators...
  • Page 30 • When taking out the injection pump assembly, be careful CONNECTING ROD against the governor connecting rod. (When reassembling) • Install the new injection pump according to the installing STARTER SPRING (6) procedure. ~GOVERNOR -'-----------CONNECTING ROD (7) WESTERBEKE Engines & Generators...

  • Page 31: Injection Pump Assembly

    DISASSEMBLY ASSEMBLY Installing Procedure of Injection Pump Assembly 1. Install the fuel injection pump assembly (1) in its unit (2), and hook the governor connecting rod to the rack pin of the fuel injection pump assembly. 2. Place the service jig (3) in the stop solenoid mounting hole of the fuel injection pump unit.

  • Page 32: Water Pump/Oil Cooler

    DISASSEMBLY I ASSEMBLY ORIVE PULLEY Alternator Drive Pulley 1. Lock the flywheel in place. CRANKSHAFT 2. Remove the crankshaft screw. SCREW 3. Draw out the drive pulley. (When reassembling) 255.0 274.6 N·m Tightening torque Crankshaft screw 26.0 28.0 kgf·m 188.1 202.5 ft·lbs Alternator Drive Fan Pulley RADIATOR MODELS...

  • Page 33: Gear Case

    • Mount the injection pump gear (1) after installing the gear case. 23.5 27.5 N·m CamShaft set screw 2.8 kgf·m 17.4 20.3 h-Ibs Tightening torque 23.5 27.5 N·m Idle gear mounting ..-i...-IDLE GEAR (1) 2.8 kgf·m screw 17.4 20.3 «-Ibs CRANK """ WESTERBEKE 'GEAR Engines Generators &...
  • Page 34 DISASSEMBLY ASSEMBLY CAMSHAFT Idle Gear 1 and Idle Gear 2 (For Balancer Modell 1. Remove the idle gear mounting screws. MOUNTING Draw out the idle gear (3). SCREWS (When reassembling) • When install the idle gear (3), be sure to place the 4th cylinder piston at the top dead center in compression then, align all mating marks on each gear to assemble the tifTling gears, set the idle gear last.

  • Page 35: Piston And Connecting Rod

    Fit the crank pin bearing in place: its centrally groove side toward the connecting rod, and the non-grooved side toward the cap. 78.5 83.4 N·m Connecting rod screw 8.5 kgf·m Tightening torque 57.9 61.5 ft-Ibs ALIGN WESTERBEKE Engines & Generators...
  • Page 36 MARK THE SAME NUMBER ON ge s uc on e cy er wa ,causing a serious rou e. THE CONNECTING ROD AS THE . PISTON SO AS NOT TO CHANGE THE COMBINATION MTGS. MAR (12) WESTERBEKE -..y: . Engines & Generators...

  • Page 37: Flywheel And Crankshaft

    DISASSEMBLY ASSEMBLY Flywheel and Crankshaft Flywheel 1. Install the flywheel lock so that the flywheel does not turn . • NOTE • Do not use an impact wench. Serious damage will occur. Detach the flywheel screws. Remove the flywheel. (When reassembling) •...

  • Page 38: Flywheel Housing

    Possible gap must be 0.05 mm (0.0020 in.) or smaller. 49.0 55.9 N·m Crankcase 2 mounting 5.7 kgf·m screw 36.2 41.3 It·lbs Tightening torque 77.5 90.2 N·m Flywheel housing 9.2 kgf·m mounting screw 57.1 66.5 ft·lbs FLYWHEEL HOUSING WESTERBEKE Engines & Generators...

  • Page 39: Crankshaft

    137.3 to 147.1 N·m Main bearing case Tightening torque 14.0 to 15.0 kgf·m screw 101.3 to 108.5 «-Ibs ~:a;;t~~~~~;:~;2:,-)FOURTH MAIN EARING CASE THRUST BEARING WESTERBEKE --.v- Engines & Generators...

  • Page 40: Starter Motor Service

    OF MICA 32mm Factory spec. 1.2598 in. Commutator 0.0. 31.4 CORRECT INCORRECT Allowable limit 1.2362 in. ~MICA 0.50 to 0.80 mm Factory spec. 0.0197 to 0.0315 in. Mica undercut 0.20 mm Allowable limit 0.0079 in. WESTERBEKE -..yo" Engines & Generators...
  • Page 41 STARTER MOTOR SERVICE Brush Wear If the contact face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier calipers. A BRUSH lENGTil 3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.
  • Page 42 STARTER MOTOR SERVICE Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. If it does not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

  • Page 43: Alternator Service

    ALTERNATOR SERVICE DESCRIPTION The stator is connected to a three-phase, full-wave bridge rectifier package which contains six diodes. The bridge converts the AC generated in the stator to a DC output for 60 AMP ALTERNATOR battery charging and accessories, Power the regulator and the field of the integral regulator alternator is provided by the field diode (or diode trio) package contained in the alternator.
  • Page 44 ALTERNATOR SERVICE Reassembling the Brush 1. Fit the brush with its sliding face in the clockwise direction when viewed from front. • IMPORTANT TWO BRUSHES • Be sure to keep the 2 brushes deep in the brush holder. Otherwise the rotor and the rear section can not be filted into position.
  • Page 45 1. Check the continuity across the "B" terminal and the "F" terminal of IC regulator with an ohmmeter. 2. The IC regulator is normal if the conducts in one direction and CHECKING CONTINUITY does not conduct in the reverse direction. 8 TERMINAL ...v: WESTERBEKE Engines & Generators...

  • Page 46: Servicing (Engine)

    4. Wash away the red permeative liquid on the cylinder head surface with the detergent (2). Ac-AA Ie-AS A!i;f 5. Spray the cylinder head surface with the white developer (3). flawed, it can be identified as red marks.' ~~~WESTERBEKE Engines & Generators...

  • Page 47: Valves

    SERVICING Valve Recessing DEPTH ,*-.l-U)) 1. Clean the cylinder head, the valve face and seat GAUGE 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
  • Page 48 SERVICING Replacing Valve Guide (When removing) 1. Using a valve guide replacing tool, press out the used valve guide. (When installing) 1. Clean a new valve guide, and apply engine oil to it. "~M 2. Using a valve guide replacing tool, press in a new valve guide until it is flush with the cylinder head as shown.

  • Page 49: Rocker Arm

    3. If the clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again. If it still exceeds the allowable limit, replace also the rocker arm shaft. MEASURING THE 1.0. ROCKER ARM -..v: WESTERBEKE Engines & Generators...
  • Page 50 SERVICING Pysh Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25mm MEASURING PUSH ROD ALIGNMENT Push rod alignment Allowable limit 0.0098 in.
  • Page 51 Intake 37.63 mm valve 1.4815 in. Factory spec. Exhaust 38.96mm valve 1.5338 in. Intake and exhaust cam heighl Intake 37.13 mm valve 1.4618 in. Allowable limit Exhaust 38.46 mm valve 1.5141 in. WESTERBEKE MEASURING CAM HEIGHT & Generators Engines...

  • Page 52: Idler Gear

    1. Clean a new idle gear bushing and idle gear bore, and apply REMOVING • INSTALLING engine oil to them. 2. Using an idle gear bushing replacing tool, press in a new bushing (service parts) to the specified dimension. REPLACING THE IDLER GEAR BUSHING WESTERBEKE Engines & Genera/ors...
  • Page 53 0.0079 in. Balancer-shaft journal 50.92 to 50.94 mm Factory spec. 0.0. 2.0047 to 2.0055 in. 51.08 Balancer-shaft bearing 51.01 to Factory spec. J.D. 2.0083 2.0110 BALANCER SHAFT JOURNAL ..• /-----, --c-J MEASURING tHE BALANCER SHAFT JOURNAL ..WESTERBEKE Engines & Generators...
  • Page 54 O.Ot 18 to 0.0177 in. Compression ring 1 . 2 1.25 Allowable limit 0.0492 in. 0.25 to 0.45 mm Factory spec. 0.0098 to 0.0177 in. ring 1.25 Allowable limit 0.0492 in. MEASURING THE RING GAP ...v WESTERBEKE Engines & Generators...
  • Page 55 6. If the measurement exceeds the allowable limit, replace the connecting rod. Connecting rod O.05mm Allowable limit alignment 0.0020 in ..WESTERBEKE Engines & Generators...

  • Page 56: Crankshaft

    2. Rotate the crankshaft on the V block and get the misalignment (half of the measurement). • 3. If the misalignment exceeds the allowable limit, replace the crankshaft. 0.02mm CRANKSHAFT Crankshaft alignment Allowable limit 0.00079 in ..v: WESTERBEKE Engines & Generators...

  • Page 57: Crankpin

    Dimension B 0.0394 to 0.0591 in. radius 0.0394 0.0591 radius 52.777 to 52.790 mm 52.577 to 52.590 mm Dimension C 2.077810 2.0783 In. 2.07DO to 2.0705 in. (0.8·S) The crankpin must be fintl-fjl'Jished to higher than vvvv WESTERBEKE Engines & Generators...
  • Page 58 (302 to 392 OF), and fix the sleeve to·the crankshaft as shown. 4. Press fit the sleeve using the auxiliary socket for pushing . • NOTE • Mount the sleeve with its largely chamfered surface facing outward..WESTERBEKE Engines Genera/ors &...

  • Page 59: Oil Pump

    2. If the clearance exceeds the allowable limit, replace the oil pump rotor assernbly. 0.04 0.16 mm Factory spec. FEELER Clearance between 0.0016 0.0063 GAUGE inner rotor and outer rotor Allowable limit 0.0118 in ..v: WESTERBEKE Engines Generators &...
  • Page 60 0.02510 0.075 mm Factory spec. 0.0010 0.0030 in. Clearance between rotor and cover 0.225 mm Allowable limit 0.0089 in. PLASTIGAGE 9.3 N·m Tightening torque Oil pump cover screw 0.80 0.95 kgf·m 6.9 tt-Ibs . WESTERBEKE ..,y" Engines Generators &...
  • Page 61 0.0091 to 0.0106 in. Intake Valve Timing Open 0.24 rad (14 before T.D.C. Close 0.61 rad (36 after B.D.C. Open Exhaust Valve Timing 0.79 rad (45 before B.D.C. Close 0.29 rad (17 LQ,C_. __ . altel" "~-. ,."WESTERBEKE , Engines & Generators...
  • Page 62 0.0007 to 0.0017 in. Valve Arm Bridge 9.050 to 9.065 mm (1.0.) 0.3563 to 0.3569 in. Valve Arm Bridge 9.023 to 9.032 mm Shaft 0.3552 to 0.3556 in. (0.0.) Alignment Push Hod 0.25 mm 0.0098 in. WESTERBEKE Engines Generators &...
  • Page 63 0.0079 in. 0.0007 to 0.0020 in. 1.0. 98.15 mm Cylinder Bore 98.000 to 98.022 mm 3.8582 to 3.8591 in. 3.8642 in. 1.0. 98.500 to 98.522 mm 98.65 mm Cylinder Bore 3.8839 in. (Oversize) 3.8780 to 3.8788 in. WESTERBEKE Engines & Generators...

  • Page 64: Timing Gear/Crankshaft

    0.20 mm 0.093 to 0.120 mm Compression Ring 2 to Ring Groove 0.0037 to 0.0047 in. 0.0079 in. Clearance 0.15 mm Oil Ring to Ring Groove 0.02 to 0.06 mm 0.0059 in. 0.0008 to 0.0023 in. WESTERBEKE Engines Generators &...

  • Page 65: Camshaft

    SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Clearance Tappet to Tappet Guide 0.020 to 0.062 mm 0.07 mm 0.0008 to 0.0024 in. 0.0028 in. Tappet Guide Bore 24.000 to 24.021 mm (1.0.) 0.9449 to 0.9457 in. Tappet 23.959 to 23.980 mm (0.0.) 0.9433 to 0.9441 in.
  • Page 66 14 Vat 4000 min-I (rpm) Alternator Resistance 2.8 to 3.3 Rotor Coil 0.0. 22.1 mm 22.7 mm Slip Ring 0.894 in. 0.870 in. 5.0mm Length 18.5 mm Brush (Alternator) 0.197 in. 0.728 in. Resistance Approx. 1.0 Glow Plug ..-v- WESTERBEKE Engines & Generators...

  • Page 67: Cylinder

    16.6 to 26.8 ft-Ibs Tightening torque 17.7 to 20.6 N·m Injection pump unit 1.8 to 2.1 kgf·m mounting nut 13.0 to t 5.2 ft-Ibs See the "Injection Pump Unit" Disassembly and Assemble section. FLYWHEEL VIEWING THE FLYWHEEL WESTERBEKE Engines Generators &...

  • Page 68: Valve Clearance

    ENGINE ADJUSTMENTS Checking Valve Clearance • IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the HC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (gear case side) comes to the compression top dead center.
  • Page 69 100 hours of operation thereafter. For recommended oil use SAE 15W-40 ~':I~-8mlm [11/161 SOCKET (oil viscosity). WESTERBEKE recommends the use of synthetic oil. USING AN 8MM {lJ/76', SOCKET W",IWUIVt THE OIL OR PUMP THE WARMED UP THRU THE HOSE 2.

  • Page 70: Fuel System

    39.2 Nm Nozzle holder 4.0 kgf·m 25.3 28.9 ft·lbs 19.6 24.5 N·m RETAINING NUT (7) Tightening torque 2.5 kgf·m Overflow pipe nut 14.5 18. I ft-Ibs 49.01068.6 N·m 7.0 kgf·m Nozzle holder assembly 36.2 50.6 ft-Ibs WESTERBEKE ...,yo Engines & Generators...

  • Page 71: Injectors

    Use care when connecting and tightening the will purge air from the fuel system and provide a continuous fuel supply line so as not to distort the inlet filter. flow of fuel as the engine is running..v- WESTERBEKE Engines Generators &...
  • Page 72 NOTE: The parts slwwn along with a glycerine pack are included in SCREW (4) M6 1.25 16MM WESTERBEKE'S PUMP KiT#052650 WASHER (4) 031783 017012 with the exception of the pump body and the adapter flange. SHAFT BALL BEARING (2) ~nUULU'~H O-RING SPACER PRESSES AGAIN:;7...
  • Page 73 #52951 MARINE GENERATORS 1------ W",' I~i, "('~ 'yom !I~ ~ I! • _~I. .1!1!1!1!:lldr~~+-I.II, I •• " 'W:':','·','·','·"·,',';, Ill,;' , ·:,lli " 1'" • ' I !! If;~ 000000 ::Iii !!! ' r-----------------~ • ---c 1" D - - - - - - - - - - - - - - - - - _I - .., ..~""...
  • Page 74 :'jJ 'D-NET MOBILE/INDUSTRIAL GENERATORS +J ' ~I 11'~ 'l'l1'l11";1 ..""ll L_----------=~~:;;;;:;;,=::==~~ 6"7a - - - l"'fATlWESTERBEKE -, Engines & Generators...
  • Page 75 65A-FOUR WIRING DIAGRAM #39144 SI~~' '"' SIARHR t-------~~~-~-T:------~M~----------~ r--- -- 1 .. - i= - - - ·-1 GlOWP~I/GS Tc' ! "3 COR"' " All[RNATOR TIM£R OHLl~ ~t\G ,wh(W u!tbf F lIH SOL , - - - - ' NOTE>: .-- . - - . - -...
  • Page 76 65 A -FOUR WIRING SCHEMATIC #39144 1 - - - - - I SEC NOH Z &) J..l!Lt'..lI.ti l!ill.lli lonro~~~ 6t~~QJuDuH~, COfolfl(;UUlIOM SHOIN ,S fOR is''' OLDER MOons MH MAY[ COHII£CTO~ fOR RUN suUNO'O AND BLACK .,Ar IS CDNN(CHD 10 TUWINH ON SOL[NOID "t;...

  • Page 77: Raw Water Pump

    400 - 600 (includes glow plugs) NOTE: Engine Idle Speed must be adjusted with the engille at nonnal operating temperature. Idle speed should be adjusted in the range specified where operates the smoothest. will Different model transmissions affect engine idle speeds. WESTERBEKE Engines & Generators...

  • Page 78: Specifications· 33Kw Eoe

    SPECIFICATIONS 33KW EDE ENGINE SPECIFICATIONS COOLING SYSTEM Engine Type Fresh water-cooled engine block, Diesel, four-cycle, four-cylinder, fresh General water-cooled, vertical in-line overhead valve thermostatically-controlled with heat exchanger. mechanism (46 hp at 1600 rpm maximum) Operating Temperature 160 -160" F (71 - 62" C) Aspiration Naturally aspirated Fresh Water Pump...
  • Page 79 122'F (50'C) maximum Recommendations NOlE: Forr;ed venUlaUan should be provided Generator Compartment maintain generator compartment Ambient Temperature NOlE: Forr:ed ventilation should be provided temperatures belaw 104'F (40'C). Recommendations to maintain generator comparlment temperatures below 104'F (40'C). WESTERBEKE Engines & Generators...
  • Page 80 NOTE: Forced venNfaNon should be provided Generator Compartment 122'F (50'C) maximum to maintain generator compartment Ambient Temperature tempellltures below 104'F (40·C). Recommendations NOTE: Forced ventilation shoufd be provided to maintain generator compartment tempellltures below 104'F (40"C). WESTERBEKE "toY Engines Generators &...

  • Page 81: Specifications· 28.5Kw Eder

    SPECIFICATIONS 20.0KW EDER AC GENERATOR (Single Phase) AC GENERATOR (3 Phase) Single Phase Brushless. six·pole. revolving field. Three Phase Brushless, six-pole, revolving field. Sealed Seal lubricated. single bearing design. 20.0 Kw - 60 Hertz lubricated, single-bearing design. 12 Lead lead reconneclable. (Double Della for 16.0 Kw - 50 Hertz reconnectable.

  • Page 82: Torque Specifications

    4.0 to 4.6 28.9 to 33.3 Governor weight mounting nut M12 x 1.25 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 Fuel camshaft stopper mounting screw 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 """ WESTERBEKE Engines & Generators...
  • Page 83 TORQUE SPECIFICATIONS Item Size x Pitch kgf·m ft-lbs N·m Governor housing mounting screw M6 x 1.0 1.0t01.15 9.8 to 11.3 7.23 to 8.32 Anti-rotation nut M5 x 0.8 2.8 to 4.0 0.29 to 0.41 2.1 to 3.0 M8 x 1.25 2.4 to 2.8 Balancer shaft set screw 23.5 to 27.5...

  • Page 84: Special Tools

    30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.) Red Check Code No : 07909-31371 Application: Use to check cracks on cylinder head, cylinder block, etc ..v: WESTERBEKE Engines Generators &...
  • Page 85 Application: Use for aligning the crankcase 1 and 2 (4.5276 In.) (2.2047 in.) (0.6693 in.) (0.7874 in.) (0.5512 mm dia. in. dla.) mm dia. (0.4331 In. dia.) mm dia. (0.5512 in. dia.) 17.5 (0.6890 in.) 17.5 (0.6890 in.) 35 mm (1.3780 in.) (0.7480 in.) WESTERBEKE Engines & Generators...
  • Page 86 SPECIAL TOOLS Gear Case Oil Seal Replacing Tool Application: Use to press fit the oil seal. 148.8 mm (5.8582 in.) f,.. (1.9685 in.) 18.8 mm (0.7401 in.) 13.7 13.9 (0.5394 0.5472 in.) f--- 11 mm (O.433 in.) I J K 18 mm dia.
  • Page 87 SPECIAL TOOLS Injection Pumo Gear Puller Application :Use for remove the injection pump gear from ".~]: governor shaft. dia. (0.39 in. dia.) Pitch 1.5 (0.75 in.) radius (0.02 in. radius) 0.89 rad (50 ") MIgl (O.39 in.) (0.79 in.) 5 mm (0.20 In.) (3.74 in.) (4.93...
  • Page 88 Chamfer 2.0 mm (0.079 in.) CO.3 Chamfer 0.3 mm (0.012 in.) Balancer Bushing Replacing Tool 1 Assembly Application: Use to press fit the bushing. name of ParI Q'ly Remarks Shaft Piece 1 (3). Piece 2 Boll M6 x Pl.0 WESTERBEKE EngInes & Generators...
  • Page 89 SPECIAL TOOLS Jig for Governor Connecting Rod Application :Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. A1 mm (O.0394 in. radius) (0.1181 In.) Chamfer 0.2 mm (0.0079 in.) (0.3937 in.) Chamfer 2 mm (O.OlB? in.) (0.3150 in.) dia.{1.3780 in.
  • Page 90 Chamfer 1 mm (0.04 In.) 3 mm (0.12 in.) (0.12 in.) (1.18in.) (1.38 in.) (1.36 in.) P1.25 in.l (2.09 4 mm (0.16 in.) (2.95 in.) in.) (2.24 (2.76 in.) 19.5 (O.77 in.) (0.47 in.) in.) (O.03 6 mm (0.24 in.) WESTERBEKE Engines & Generators...
  • Page 91 8.5 mm dia. (0.33 in. dia.) 0.4 mm (0.0157 in.) 3mm(0.12in.) 19 mm (0.75 in.) 45 mm dia. (1.77 in. dia.) Chamfer 0.5 mm (0.02 in.) 0.78 rad (45°) 36 mm (1.42 in.) 11.5 mm (0.45 in.) -..v: WESTERBEKE Engines & Generators...
  • Page 92 SPECIAL TOOLS 6) Joint 2 P1.25 Chamfer 1 mm (0.04 in.) :tDI dia. (1.18 in. dia.) ~I-'Y dia. (0.51 in. dia.) Chamfer 3 mm (0.12 in.) (0.12 in.) 45 mm (1.77 in.) (2.95 in.) 57 mm (2.24 in.) (3.35 in.) (2.76 in.) (15.51...
  • Page 93 SPECIAL TOOLS Balancer Bushing Replacing Tool 1 Componenls Parts 1) Shaft 498 mm (19.61 in.) 318.810319.2 (12.5726 12.5669 in.) Fl,u /- 102.810103.2 (4.047210 4.0630 in.) Lr?/P (2.36 in.) ·G -tt- K· ( 17 8 mm (0.31 in.) (0.20 in.) dla. (t.tS in. dia.) dia.
  • Page 94 SPECIAL TOOLS 3) Piece 2 Chamfer 0.1 rnm (O.004 in.) (0.04 in.) Chamfer 1 mm (0.04 in.) . - . - 54.31054.4 dia. (2.137810 2.1417 in. dia.) ---AL 34.025 34.05 dia. (1.3396 to 1.3406 in. dia.) 48.5 dia. (1.9094 in. dia.) 50.421 to 50.44 mm dia.

  • Page 95: Generator Information

    , - - - - - Carbon Monoxide Detector - - - - - , generator's capacity, and finally loaded to its full capacity as WESTERBEKE recommends mounting a carbon indicted on the generator's data plate. The output voltage monoxide detector in the vesssel's Jiving quarters. Carbon...
  • Page 96 TWELVE LEAD WINDING/TERMINAL BOARD CONNECTIONS AND (NOMINAL) VOLTAGES (SERIES WYE) (PARALLEL WYE) SERIES SERIES PARALLEL DELTA STAR STAR -:8:--N-7-'~ L 91' 10-11 10-12 10':11 1-12 9¢11 50 Hz L-L 230 volts 50 Hz L-L 400 volts 50 Hz L-L 200 volts 50 Hz t-N 115 volts 50 Hz L-N 230 volts 50 Hz L-N liS volts...

  • Page 97: Terminal Board Connections

    ELECTRONIC REGULATION SR7-2G AVR AMP FUSE ADJUSTABLE THRESHOLD OVERLOAD PROTECTION ""Hertz--,'jo~(-\-):E°O ADJUSTABLE THRESHOLD OF UNDERSPEED 1;!a1--tCDI~NEICT FOR 60Hz PROTECTION INTERVENTION rn---l REMOVE FOR 50Hz EXCITER FIELD DESCRIPTION The voltage regulator (AVR) ensures optimum AC generator In both of these cases, tlle SR7/2 supply can vary from 80 to performance.
  • Page 98 ROTOR _ _ _ IlIlllllWUIJ :,':1111 I~ ~~------;;,,,m--J--lJ ~ ~=~======i==,,,=-- __ -' - -===T-------.J W:::: NOTE: EXCITER DC VOLTAGE I AUXILIARY VOLTAGE In\c::=J NO LOAO 7.0 VUC 215 VAC FULllOAU 14.0 VUC 222 VAC VOLTAGE RmULATOR YEllOW , "",",WESTERBEKE , Engines & Generators...

  • Page 99: Generator Servicing

    NOTE: When replacing the Magnetic Pick-Up (MPU) it WIRES MUST be replaced without cutting and splicing into the ~MIPU-I~AGINE1'ICPICK-UP existing wiring cable. Doing so will cause a erratic AC signal the controller. 0.03010 """ WESTERBEKE Engines Generators &...

  • Page 100: Generator Troubleshooting (Chart)

    GENERATOR TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ. FAULT PROBABLE CAUSE NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the 4. Open in exciter main stator winding. stator winding. 2.
  • Page 101 3. Open the generator's AC breaker. start the generator and 6. Monitor the auxiliary circuit voltage inlo tile regulator, observe the AC output voltage between the line and correct vollage should be 220 - 230 VAC indicating this neutral (residual l5-20VAC). circuit is ok..v- WESTERBEKE Engines Generators &...
  • Page 102 12 a-CLOCK POSITION Should the whole bridge replaced, remember to tighten the screws with a suitable wrench and strictly comply with the polarities and internal wiring diagrams in manual. ~~~~f--DIDDE WESTERBEKE Engines Generators &...

  • Page 103: Internal Wiring Schematic

    INTERNAL WIRING SCHEMATIC EXCITER ROTOR/ROTATING FIELD TRANSIENT r------------ - - - - i EXCITER ROTOR WINDINGS ~--I-Dt I--~~~ DIODE -"<------j 1 _______________________ -' GREEN EXCITER RDTOR WlIDIIGS ISOLATION DIODE PLATES Engines & Generators...

  • Page 104: Changing Hertz And Voltage

    DELTA~ • ·OOUBLE 08..TA- 13-W1RE SPLIT SINGlE PHASE) [Ii] 12·WIRE SINGLE PHASE) 120·240V/60 H1 240V/60 Hz IIO-220V/SO HI 220V/50 25.5-33.0 EDE I-PHASE / 3-PHASE NOTE: Tie off the L3 sensing connection when not in use. WESTERBEKE -.,.y" Engines & Generators...
  • Page 105 MECC ALTE GENERATOR MAINTENANCE/PARTS BREAKDOWN INSPECTION/CLEANING Periodically inspect the rotor carrier bearing. Replace this Remove all dirt, oil, grease and dust build up from the bearing at 10,000 hours of normal operation or sooner if external surface of the generator. Build·up reduces heat wear is evident.
  • Page 106 MECC ALTE GENERATOR ASSEMBLY OF THE GENERATOR TO THE ENGINE 4. Rotate the generator by hand two full revolutions to 1. Position the rotor assembly onto the flywheel aligning the ensure the generator rotates freely. Reinstall the rear holes in the drive discs with the holes in the flywheel. vent-cover.
  • Page 107 29/32 23.41562 27/64 0.421875 10.71562 59/64 0.921875 23.81250 7/16 0.4375 11.11250 15/16 0.9375 24.20937 29/64 0.453125 11.50937 61/64 0.953125 24.60625 15/32 0.46875 11.90625 31/32 0.96875 25.00312 31/84 0.484375 12.30312 63/64 0.984375 25.40000 0.500 12.70000 1.00 ..WESTERBEKE Engines Generators &...
  • Page 108 Degree Celsius (DC) = (OF - 32) x .56 UQUID WEIGHTS Diesel Oil 1 US gallon 7.13 Ibs Fresh Water = 1 US gallon 8.33 tbs Gasoline = 1 US gallon = 6.1 Ibs Salt Water = 1 US gallon 8.56 tbs WESTERBEKE Engines, & Generators...

  • Page 109: Index

    Fuel Lift Pump .............. 65 Service Specifications ............55 Glow Plugs ..............65 Special Tools ..............72 Injection Timing ............61 Specifications (65A-Four) ..........68 Injectors ................ 64 Specifications (33 EDE) ............ 69 Inlet Fuel Filter ............65 Specificatinns (28.5 EDER) ..........69a Oil Filter ..............

  • Page 110: Westerbeke

    -.v- WESTERBEKE Engines & Generators 3,1)91117-1138...

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