Westerbeke 12C-TWO, 120D-TWO Operator's Manual

SERVICE

MANUAL

MARINE

DIESEL

12C-TWO

PUBLICATION

NO.

REVISION 1

JUNE

2012

ENGINES

120-TWO

055411

J'~

rWESTERBEKE

J

WESTERBEKE

J

M'(LES

WEB

SITE:

NMMA

CORPORATION • 150

STANDISH

INDUSTRIAL

WWW.

WESTERBEKE.COM

Member

National

JOHN

PARK • TAUNTON

Marine

Manufacturers

HANCOCK

MA

Association

ROAD

02780

--

A

wARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET seek until

gasses

Weakness

YOU

OR

OUT

medical it

has

....

~~~~~\

L~~~~-_j

contain

gas.

Carbon

can

include:

and

Sleepiness

ANYONE

INTO

THE

attention.

been

inspected

Carbon

Monoxide

and

death.

ELSE

EXPERIENCE

FRESH

Shut

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

• Inability

ANY

AIR

IMMEDIATELY. down

the

unit

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They obtainable

DECAL

near

MONOXIDE

are

inexpensive

at

an

odorless

and

of

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptoms

and

is

and

should

your

engine

also

recommends

DETECTORS

quarters

your

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

do

not

restart

provided

be

fixed

or

generator.

of

your

and

easily

marine

by

to

a

installing

in

the

vessel. store.

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

WARNING

gasoline

its

constituents

of

California

birth

defects,

harm.

engine

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety caused by failure tions. Know when dangerous conditions exist necessary precautions and

your The following safety instructions are the American Boat

PREVENT

A

WARNING:

while

engine

these

connections!

• Do not operate this machinery without electrical enclosures and covers in place.

• Shut off electrical power before accessing electrical equipment.

• Use insulated mats whenever working on electrical equipment.

• Make sure your clothing and skin are dry, not damp

(particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working on electrical equipment.

• Do noit connect utility shore power to vessel's AC circuits, except through a ship-to-shore double throw transfer switch. Damage to vessel's AC generator may result

• Electrical shock results from handling a charged

capacitor. Discharge capacitor by shorting tenninals together.

PREVENT

A

WARNING:

exhaust

very

hot!

• Always check the engine coolant level at the coolant recovery tank.

A

WARNING:

•

In

case

before touching the engine or checking the coolant.

manual

machinery.

ELECTRIC

is

if

this procedure is not followed.

BURNS -HOT

system

of

an engine overheat, allow the engine

carefully. Most accidents are

to

follow fundamental rules

to

protect yourself,

in compliance with

and

Yacht Council (ABYC) standards.

SHOCK

Do

not

touch

AC

electrical

running.

Lethal

voltage

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

injury

and

precau-

and

take the

your

personnel,

connections

is

present

parts

or

engine

gets

or

death!

to

at

cool

PREVENT

A

• 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 vapors. removing the fuel lines, fuel filters, or other fuel system components

• Do not opeerate with a Coast Guard Approved flame anester removed. Backfire can cause severe injury or death.

• Do not operate with the air cleaner/silencer removed. Backfire can cause severe injury or death.

• Do not smoke or permit flames or sparks to occur near the fuel system. Keep the compartment and the engine/generator clean and free chances

• Be aware - Diesel and gasoline will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. fueling. Check below for fumes/vapor before running 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

equipment and out

• Do not fill the fuel tank(s) while the engine

• Shut off the fuel service valve at the engine when servicing

• 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

• Make sure a fire extinguisher is installed nearby and is

BURNS -FIRE

WARNING:

Use a suitable container

Fire

can

cause

injury

or

death!

of

spilled fuel or fuel

to

catch all fuel when

..

of

debris to minimize the

of

fire. Wipe up all spilled fuel and engine oil.

BURNS -EXPLOSION

WARNING:

or

death!

well-ventilated area away from spark-producing

the fuel system. Take care in catching any fuel that might spill.

DO NOT allow any smoking, open flames, or other sources of servicing. Ensure proper ventilation exists when servicing the fuel system.

free

of

leaks.

properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment.

Explosions

fire

near the fuel system or engine when

of

the reach

from

fuel

vapors

Open and ventilate cabin after

of

children.

can

in

a

is

running.

cause

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

To

prevent accidental starting when servicing the

generator, remove the 8 amp fuse from the control panel.

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect it last.

• Make certain all personnel are clear

starting.

• Make certain all covers, guards, and hatches are re-installed before starting the engine.

BATTERY

~----------------------------------------~

A

WARNING:

or

death!

• Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing.

• Never connect the negative(-) battery cable to the positive ( +) connection terminal 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 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 tum the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery.

BATTERY

A

WARNING:

severe

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid, which is destructive. off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

STARTING

Accidental

EXPLOSION

Battery

of

explosive gases.

ACID

Sulfuric

injury

or

death!

If

it comes in contact with your skin, wash it

starting

explosion

of

To

acid

in

batteries

can

cause

injury

of

the engine before

can

cause

injury

the starter solenoid.

avoid sparks, do not

can

cause

A

WARNING:

• Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds

are securely attached and no warping exists. Pay close attention to the manifold, water injection elbow, and exhaust pipe nipple.

• Be sure the unit and its surroundings are well ventilated.

• In addition to routine inspection

install a builder or dealer for installation

• For additional information, refer to ABYC T-22

(educational information on Carbon Monoxide).

-4

A

WARNING:

odorless nausea

• Do not use copper tubing in exhaust systems. Exhaust

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not

AVOID

A

or

• Do not service the engine while it is running.

gas.

or

sulfur causes rapid deterioration resulting in exhaust/water leakage.

through portholes, vents, or air conditioners. exhaust discharge outlet is near the waterline. water could enter the exhaust discharge outlet and close or restrict the

flow

of

exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some symptoms or signs poisoning are:

Vomiting Muscular twitching Dizziness Intense headache Throbbing in temples Weakness and sleepiness

MOVING

WARNING:

death!

situation arises in which it is absolutely necessary to make operating adjustments, use extreme care touching moving parts and hot exhaust system components.

Carbon

monoxide

carbon monoxide detector. Consult your boat

of

Carbon

Inhalation

monoxide

produces

death!

exhaust. Avoid overloading the craft.

of

carbon monoxide inhalation or

PARTS

Rotating

parts

can

(CO)

is a deadly

of

the exhaust system,

approved detectors.

(CO)

is

an

invisible

flu·like

symptoms,

of

copper tubing

If

the engine

as

of

cause

injury

If

to

gas!

toxic as

the

a

avoid

. .

II

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry when servicing equipment; tie back long hair jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught

• 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

• Stay clear

when the engine be caught

HAZARDOUS

A

WARNING:

in

moving parts.

is

operating.

of

the drive shaft and the transmission coupling

is

running; hair and clothing can easily

in

these rotating parts.

NOISE

High

noise

and avoid wearing loose

levels

can

cause

hearing

loss!

• 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

WARNING:

mentally

or

Do

not

physically

work

on

machinery

incapacitated

by

fatigue!

when

you

are

ABYC, INSTALLING

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

NFPA "Fire Protection Standard for Motor Craft"

Order

USCG "USCG 33CFR183"

Order

NFPA

AND

USCG

PUBLICATIONS

DIESEL

from:

ABYC 3069 Solomon's Edgewater,

from:

NFPA

11

Tracy Drive Avon Industrial Avon,

from:

U.S. Government Printing Office Washington, D.C.

MD

(National Fire Protection Association)

MA

02322

(United States Coast Guard)

ENGINES

Island Rd.

21037

Park

20404

FOR

OPERATORS

Many

of in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

GASOLINE

Preparations to install a gasoline engine or generator should begin with a thorough examination Yacht Council's (ABYC) standards. These standards are from a combination

Sections H-2 Ventilation

H-24 Gasoline Fuel P-1

Exhaust Systems

P-4

Inboard Engines

E-9 DC Electrical All installations must comply with the Federal Code

Regulations (FCR).

MANUAL

the preceding safety tips and warnings are repeated

ENGINE

of

the

AND

GENERATOR

of

sources including the USCG and the NFPA.

AB

YC standards

Systems

of

INSTALLATIONS

of

the American Boat and

particular interest are:

of

Engines

iii

& Generators

TABLE

OF

CONTENTS

INTRODUCTION

Serial

Number

Siphon

TESTING

Disassembly Assembly

ENGINE

AND

Break

FOR

TROUBLESHOOTING

DISASSEMBLY,

ASSEMBLY

DISASSEMBLY CYLINDER CYLINDER

Cylinder Valve Guide Replacement

Valve

Seat Installing the Cylinder Head Bolt Tightening Sequence

VALVE

VALVE VALVE

VALVE GEAR

TIMING

AND

Valve Removal Valve Inspection

INSTALLATIONNALVE

Torquing the Cylinder

CLEARANCE ADJUSTMENT/INJECTION

Timing Adjustment

CASE/GOVERNOR

Front Oil Seal Replacement Governor Shaft/Disassembly Inspection Installing the

GEAR/CAMSHAFT

Removing the Timing Gears Timing Valve Camshaft Removal Injection

CAMSHAFT/PISTONS AND

CONNECTING

Inspecting the Installing the Camshaft/Gears Piston and Connecting

PISTON

AND

Inspection Piston Ring Piston Ring Side Clearance Installation

Installing the Piston Rings Installing the Piston

.......................................................... 2

OVERHAUL

...........................................

(Charts) ...................

INSPECTION

PROCEDURES

HEAD

REMOVAL

HEAD

.......................................................

Head

Inspection

Repair

VALVE

SPRING

...................................................

Governor

Gear

Inspection

Pump

Camshaft Removal

RODS

Camshaft

CONNECTING

End

Gap

.....................................

........................................

INSPECTION

CLEARANCE

Head

Bolts

TIMING

............................................

Shaft

........................................

..........................................

Rod

Disassembly

ROD

.........................

and

Connecting Rod

A-7

.................

...............

................

17-18

3

8

9

10

11

12 12

13

14

15

16

CRANKSHAFT

Removal/Inspection Rear

Oil Seal Replacement Inspecting the Oil Clearance Installing the Crankshaft

CYLINDER

Inspection Bore Dimensions Cylinder Reboring

ENGINE

TORQUE

GOVERNOR

Disassembly/Inspection Installation

EXHAUST FUEL

INJECTION

FUEL

INJECTORS

GLOW

PLUGS

Fuel Lift Inlet

Fuel

TACHOMETER

ENGINE

Measuring Compression Belt

Adjustment Testing Oil Pressure Adjusting Fuel

Run/Shut-Off

RAW

WATER ATLERNATOR STARTER TRANSMISSION

ENGINE

WIRING

SERVICE STANDARD REMOTE

METRIC

............................................................

BLOCK

ASSEMBLY

.....................................................

..............................................

SPECIFICATIONS

SYSTEM

...........................................

MANIFOLD/HEAT

PUMP

............................................

.................................................

........ .-...................................................

Pump

Filter

............................................................

ADJUSTMENTS

Idle

Speed

PUMPS

TESTING

MOTOR

.......................................

Solenoid

..........................................

........................................

TESTING

......................................................

SPECIFICATIONS

DIAGRAMS

............................................

DATA/STANDARDS

HARDWARE

OIL

FILTER

CONVERSION DATA ...............................

TORQUES

.................................................

21-22

........................................

24-25

EXCHANGER

.................

28-29

32-34

35-36 37-38

.................................

39-42

.........................................

.45-46

LIMITS

..................

.47-48

..........................

19

20

23

26 27

30

31

.43 .44

.49

50 51

Engines

& Generators

1

INTRODUCTION

SERIAL

The engine's model number and serial number are located on a nameplate mounted on the side the engine's serial number can also the engine block on the flat surface

and inboard information on the illustration as this will provide information and/or ordering repair parts.

. Fill

NOTES,

As this manual takes you through the disassembly, inspection and assembly procedure information will be highlighted by NOTES, CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

NUMBER

of

•

MODEL

in

the

infonnation

CAUTIONS

An operating procedure essential

LOCATION

the injection pump. Take the time to enter this

aquick

SPEC

reference when seeking technical

for

your

AND

of

your engine/generator, critical

of

the engine's manifold.

be

found stamped ihto

of

the block

of

the nameplate shown below,

MA

USA

reference.

~

just

SER.NO.

WARNINGS

to

note.

above

RAW

WATER

COOLING

CIRCUIT

Siphon-Break

For

installations where the water injected exhaust elbow is

to

or

will

be

close must

be

made to install a siphon-break in the raw water supply hose to the water injected exhaust elbow. The siphonbreak provides

prevent raw water from filling the exhaust system and the engine's cylinders when the engine

If

you have any doubt about the position injected exhaust elbow relative to the vessels waterline under the vessels various operating conditions,

break. This precaution

The

•

siphon-break must hose that is looped a minimum the vessels waterline. above the waterline during all angles

prevent siphoning.

NOTE:

A

siphon-break

cleaning

to maintain a siplwn-break damage.

Consult

below the vessels waterline, provisions

an

air vent in the raw water cooling system to

is

shutdown.

of

the water-

install

is

ensure

necessary

be

installed in the highest point

Tiris siphon-break

requires

proper

operation.

can

the

siphon-break

to

protect your engine.

of

20

inches (51cm) above

must

of

vessel operation to

periodic

inspection

Failure

result

in

catastrophic

rnanufacturerf<>r

always be

to

a siphon-

and

properly

engine

proper

of

a

maintenance.

A

CAUTION:

observed1 can

your

engine/generator.

A

WARNING:

followed1 can

ORDERING

· Whenever replacement parts are needed, always provide the generator model number, engine serial number, and generator serial number as they appear on the silver and black name-plate located on the generator end. You must provide us with this information so we may properly identify your engine/generator. In addition, include a complete part description and part number for each part needed (see the separately furnished WESTERBEKE packaged parts because parts are frequently not made to the same specifications as

original equipment.

Procedures1 which

result

in

the

damage

Procedures~

result

in

personal

if

which

injury

not

strictly

or

destruction

if

not

properly

or

loss

PARTS

Parts List). Also insist upon

will fit or generic

of

life.

SIPHON-BREAK LOOP

FOR

PART

N0.044010

ENGINE

The following sections contain detailed information relating to the proper operation characteristics components and systems disassembly, inspection and reassembly instructions for the guidance service and rebuilding facilities. The necessary procedures should be taken only by such facilities.

Additional detailed information and specifications vided in other sections generator, alternator, starter motor, engine adjustments, cooling pumps, etc.

WITH

STAINLESS

1"

HOSE

OVERHAUL

of

the engine. Included are

of

suitable equipped and staffed mmine engine

of

this manual, covering the

the major

are pro-

2

TESTING

HOW

TO

DETERMINE

Cause

Generally, the time at which an engine should be overhauled is determined 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 or injection pump wear. The decrease in compression pressure is caused by many factors. or inspection and maintenance. is a good means caused by worn cylinders symptoms will occur:

These symptoms often appear together. Symptoms 2 and 4 can result also from excessive fuel injection, improper injection timing, and wear 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. compression pressure, incomplete combustion take place even properly. To determine the period important.to measure the engine compression pressure regularly. At the same time, the engine speed at which the measurement because the compression pressure varies with engine rpm. The engine rpm can be measured at the front end crankshaft.

NOTE:

cause may be

pressure to the injection pump will result

properly adjusted.

of

Low

Compression

by

various conditions such as lowered engine

It

is, therefore, necessary to determine a cause

causes on the basis

of

1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption

4 Hard engine starting

5 Noisy engine operation

if

of

compression pressure is made should be checked

In case

Pool

fuel quality, contaminates and loss

NOTE:

Make certain the engines valve clearances are

symptons that might, incorrectly, suggest an engine overhaul (cylinder misfire, white smoke, noise, etc).

of

fu~l

ENGINE

of

data produced by periodic

monitoring engine internal wear. When

or

of

the injectors. They are caused also

other parts

severe vibrations

injector problems, see FUEL INJECTORS.

An

incorrect valve clearance can cause

OVERHAUL

Oil analysis on a seasonal basis

piston rings, the following

If

of

the engine are operating

of

engine overhaul, it is

and

detonation noise, the

of

PERIOD

an engine lacks

of

fuel will

of

positive fuel

in

injector faults.

FOR

the

OVERHAUL

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 these parts.

When decrease limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high, blowby evident, and compression values are at minimum or below. Engine compression should be 28 kg/cm

280 rpm. The maximum difference between cylinders must not exceed

Minimum compression

for

overhaul.

NOTE:

refer to the Table

DISASSEMBLY

NOTE:

for

defects which cannot be found after disassembly and

cleaning.

• All disassembled parts should be carefully arranged in order to insure proper mating and reassembly in the proper directions and positions.

•

If

parts to be disassembled, the parts should be disassembled in a way that will allow them to be efficiently reassembled without any change in the engine's external appearance or its performance.

• Do not remove or disassemble the parts that require no

disassembly.

• Carefully inspect each part after its removal for damage,

deformation, and other problems.

• Carefully check gaskets, packings and oil seals, even

checking is not specified. Replace with new ones

• Be careful not to damage the disassembled parts. Keep the

parts clean.

• Use proper tools. Apply oil when necessary. Take special

care to keep the fuel system parts free from the intrusion of

ASSEMBLY

1.

Wash all parts, except for oil seals, 0-rings, rubber sheets, etc., with cleaning solvent and

2. Always use tools that are in good condition and be sure you understand how to use them before performing any

job.

3. Use only good quality lubricants. Be sure to apply a coat

of

4.

Be torques are specified.

CONDITIONS

of

wear

of

compression pressure reaches the repair

2

,

398 psi at

10%.

of

355 psi (25 kg/cm

For Testing Compression Pressure

of

Contents.

Before disassembly

of

reassembly. Mark or label the parts as needed

the disassembly procedure is complex requiring many

dust and dirt.

oil, grease

sure to use a torque wrench to tighten parts for which

or

and

cleaning, carefully check

dry them with pressure

sealant to parts as specified

2

) is an indication

and

Oil Pressure,

if

defective.

..

if

of

air.

Engines & Generators

3

ENGINE

TROUBLESHOOTING

The following troubleshooting chart describes certain problems relating to engine service, the probable causes these problems, and the recommendations to overcome these problems. This chart may be determining the need for an engine overhaul.

PROBLEM

HARD

STARTING

of

assistance in

LOW

CRANKING

1.

Engine

oil

2.

Run-down

3.

Worn

battery.

4.

Battery

terminals

5.

Defective

DEFECTIVE

1.

Air

2.

Clogged

3.

Low

4.

Inadequate

5.

Injection

6.

Injection

MAIN

1.

Low

2.

3.

4.

5.

starter.

INJECTION

trapped

fuel

injeCtion

pump too

ENGINE

compression.

a.

Incorrect

b.

Inadequate

c.

Valve

d.

Broken

e.

Compression

f.

Piston

g.

Worn

Burnt

glow

Faulty

glow Incorrect Governor

PROBABLE

SPEED

viscosity

too

battery.

loosely

SYSTEM

in

fuel

passage.

filter.

pressure.

spray.

delivering

early.

TROUBLES

valve

clearance.

contact

stem

seized.

valve

spring.

leaks

ring

seized.

piston

ring

plug.

plug

operation.

governor

spring

lever

out

CAUSE

high.

connected.

insufficient

of

valve

through

and

cylinder.

position.

of

POSITION

of

seat.

cylinder

NOTE:

The

engine~

ampere manual reset circuit breaker. The preheat solenoid is mounted on the same bracket.

fuel.

head

gasket.

electrical system is protected by a 20-

VERIFICATION/REMEDY

1.

Replace

engine

oil

with

less

viscous

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

2.

Replace

3.

Check

4.

Set

5.

Correct

terminals

or

air or

injection

or

injection

a.

Adjust

b.

Lap

c.

Replace

d.

Replace

e.

Replace

f.

Replace

g.

Overhaul

preheat

lever

battery.

replace

from

fuel

replace

valve

valve.

valve valve gasket.

piston

engine.

glow

plug.

circuit.

to

starting

spring

and

correct

starter.

system.

filter.

pressure.

noule.

injection

timing.

clearance.

and

valve

spring.

and

piston

position.

cables.

pump.

guide.

oil.

ring.

LOW

OUTPUT

COMPRESSION

INJECTION

1.

Incorrect

2.

Insufficient

3.

Low

injection

INSUFFICIENT

1.

Air

trapped

2.

Clogged

3.

Contaminated

INSUFFICIENT

1.

Clogged

SYSTEM

injection

injection.

pressure.

FUEL

in

fuel

filter.

fuel

INTAKE

air

cleaner.

OUT

OF

timing.

system.

tank.

AIR

ADJUSTMENT

Engines & Generators

4

See

1.

2.

3.

1.

2.

3.

1.

HARD

Adjust Repair Check

Check Clean

or

Clean

tank.

Clean

STARTING

injection

timing.

or

replace

injection

noule

and

retighten

replace

or

replace

injection

and

connector.

filter.

air

cleaner.

pump. adjust

pressure.

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

LOW

OUTPUT

EXCESSIVE CONSUMPTION

(cont

OIL

PROBABLE

..

)

OVERHEATING

1.

Low

coolant

level.

2.

Loose

V-belt.

3.

Incorrect

4.

Low

OIL

1.

Defective

2.

Broken

3.

Loose

4.

Loose

5.

Broken

6.

Loose

OIL

1.

Leaking

2.

Bent

3.

Worn

4.

Worn

OIL

1.

Defective

2.

Worn

injection

engine

oil

LEAKAGE

oil

gear

case

drain

rocker

LEVEL

RISING

injection

or

twisted piston piston

LEVEL

FALLING

stem

valve

and

level.

seals. case

plug.

cever

cover

connecting ring. or

cylinder.

seal.

valve

CAUSE

timing.

gasket.

attaching

gasket.

attaching

pump.

guide.

bolts.

rod.

1.

Add

coolant.

2.

Adjust

or

3.

Adjust

injection

6.

Add

engine

1.

Replace

2.

Replace

3.

Retighten

4.

Retighten

5.

Replace

6.

Retighten

1.

Repair

2.

Replace

3.

Replace

4.

Replace

1.

Replace

4.

Replace a valve

VERI

Fl

CAT

replace

timing.

oil.

oil

seals.

gasket.

bolts. plug.

gasket.

attaching

pump

plungers. connecting ring. piston

and

stem

seal.

and

I 0

N/REM

V-belt.

bolts.

rod.

rebore

valve

EDY

cylinder.

guide.

EXCESSIVE CONSUMPTION

SMOKY

FUEL

EXHAUST

ENGINE

BODY

1.

Noisy

knocking.

2.

Smoky

exhaust.

3.

Moving

parts

4.

Poor

compression.

5.

Improper

6.

Improper

INSUFFICIENT

1.

Air

NOZZLE

1.

Seized

2.

Worn

IMPROPER FUEL WHITISH

1.

Excessive

2.

Excessive

intake

TROU3LES

nozzle.

LEAKS

OR

a.

Poor

b.

Seized

c.

Excessive

valve valve

obstructed.

FUEL

PURPLISH

engine rise

piston

TROUBLES

nearly

seized

timing. clearance.

INTAKE

AIR

oil.

of

oil

into

combustion

contact.

piston

ring.

piston-to-cylinder

or

excessively

clearance.

worn.

chamber.

1.

See

2.

See

3.

Repair

4.

See

5.

Adjust.

6.

Adjust.

1.

Remove

1.

Replace.

2.

Replace.

Replace

Find

fuel

1.

Correct

a.

b.

c.

KNOCKING. SMOKY

EXHAUST

or

replace.

LOW

COMPRESSION;

obstruction.

with

proper

leaks.

oil

level.

Check.

Replace

or

clean.

Replace

or

correct.

fuel

HARD

(Cetane

STARTING.

#45

or

better).

(continued)

5

ENGINE

TROUBLESHOOTING

PROBLEM

SMOKY

EXHAUST

ABNORMAL OR

NOISE

SOUND

(cont.

1

WHITISH

d.

Worn

e.

Low

f.

Excessive

3.

Injection

4.

Insufficient

BLACKISH

1.

Engine

a.

Poor

b.

Improper

2.

Insufficient

3.

Improper

CRANKSHAFT

1.

Badly

worn

2.

Badly

worn

3.

Melted

CONNECTING

1.

Worn

connecting

2.

Worn

crankpin.

3.

Bent

connecting

PROBABLE

OR

PURPLISH

valve

stem

engine

oil

pressure.

timing

is

too

compression.

OR

DARK

body

troubles.

compression.

valve

intake

air

fuel.

AND

MAIN

bearing. crankshaft.

bearing.

ROD

AND

rod

rod.

CAUSE

(cont.

and

valve

viscosity.

late.

GRAYISH

clearance.

(air

cleaner

BEARING

CONNECTING

big

end

bearing.

guide.

clogged).

ROD

BEARING

d.

e.

3.

Adjust.

4.

See

a.

2.

Clean

3.

Replace

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

VERIFICATION/REMEDY

Replace. Replace.

f.

Correct.

LOW

COMPRESSION;

See

LOW

COMPRESSION;

b.

Adjust.

air

cleaner.

with

proper

fuel.

bearing

and

grind

crankshaft.

bearing

and

check

bearing.

crankshaft.

bend

or

replace.

HARD

STARTING.

HARD

crankshaft.

lubrication

STARTING.

system.

ROUGH

OPERATION

PISTON,

1.

2.

3.

4.

VALVE

1.

2.

3.

4.

INJECTION

1.

2.

3.

4.

GOVERNING

1.

2.

PISTON

Worn

cylinder.

Worn

piston

Piston

seized.

Piston

seized

MECHANISM

Worn

camshaft. Excessive Worn Worn

Uneven Control Worn

Inadequate

Governor

Fatigued

valve timing fan

pulley

PUMP

injection. rack

delivery

lever

governor

PIN,

AND

pin.

and

ring

worn

clearance.

gear.

bearing.

SYSTEM

malfunctioning.

valve.

injection

SYSTEM

nozzle

malfunctioning.

spring.

PISTON

or

damaged.

spray.

RING

1.

Rebore

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

1.

Adjust

injection

2.

Disassemble,

3.

Replace.

4.

Replace

1.

Check

governor

2.

Replace.

cylinder

piston. piston piston

check

injection

to

oversize

and and

or

replace

nozzle.

shaft

rebore

rings.

and

correct

and

replace

cylinder.

parts.

injection

correct

piston.

pump.

operation.

(continued)

6

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMITTENT EXHAUST

SOUND

ENGINE

!

1.

Main

a.

Overheated

b.

Carbon

2.

Too

I

3.

Too

I

4.

Improper

I

KNOCKING

1.

Poor

2.

Injection

a.

b.

c.

d.

3.

Improper

a.

b.

c.

d.

1.

Fuel

2.

Fuel

3.

Water

PROBABLE

KNOCKS

engine

early high

compression.

Worn Pinion Broken Worn

Poor Poor After-injection Nozzle

filter

pipe

troubles.

cylinder.

deposits

injection

fuel.

WITH

pump

plunger.

is

delivery

nozzle. spray. chattering.

needle

clogged. sucks

mixed

in

WITHOUT

in

DARK

malfunctioning.

not

air.

fuel

CAUSE

'

cylinder.

timing.

pressure.

SMOKE

in

mesh

valve

seat.

drip.

valve

seized.

MUCH

with

control

spring.

SMOKE

rack.

a.

See

b.

Clean.

2.

Correct.

3.

Correct.

4.

Replace

1.

See

a.

b.

c.

d.

a.

b.

c.

d.

1.

Clean

2.

Retighten

3.

Replace

VERIFICATION/REMEDY

OVERHEATING;

with

proper

LOW

COMPRESSION;

Replace. Correct. Replace. Replace.

Clean

or

replace

Repair

or

replace

Repair

or

replace

Replace.

or

replace.

pipe

fuel.

joints

LOW

fuel.

nozzle.

nozzle. nozzle.

or

replace

OUTPUT.

HARD

STARTING.

pipe.

OVERHEATING

LOW

OIL

PRESSURE

NOTE:

Refer

to

the Table

procedures

Valve Clearance Injection Timing

Oil Pressure Engine Compression

for

the following:

1.

2.

3.

4.

5.

6.

7.

1.

2.

3.

4.

of

Contents

V-belt

slackening Damaged Lack

of

coolant.

Low

oil

level Knocking. Moving

parts

Defective

Worn

Bearings.

Relief

valve Clogged Diesel

oil

dilution

for

or

slippery

water

pump.

or

poor

seized

or

thermostat.

malfunction.

cooler.

of

the

testing

and

with

oil

quality.

damaged.

oil.

adjustment

oil.

1.

Adjust,

2.

Replace.

3.

Add.

4.

Add

5.

See

6.

Replace.

7.

Replace.

1.

Engine

2.

Overhaul

3.

Repair.

4.

Injection

replace

or

change.

KNOCKING.

overhaul

oil

pump.

pump

replace

repair.

clean.

bearings.

7

DISASSEMBLY

PROCEDURES

REMOVE

EXTERIOR

COMPONENTS

Unplug the instrument panel wiring harness. Drain the transmission fluid and unbolt the transmission.

NOTE:

Refer

Label any

to

the

Table

lines,

hoses or cables as you separate

of

Contents for information on

them.

Transmissions.

1.

Remove the Label the wires

start

motor, drive belt,

and

cables.

and

the alternator.

2. With the hoses disconnected, remove the thermostat and

housing

housing gasket, leaving the temperature

sender.

3. Remove the bell housing

and

the circuit

breaker

pre-heat solenoid bracket.

4. Remove the engine

5. Remove the oil filter, oil hoses

Make note

of

6. Remove the transmission

back

plate.

and

the hose arrangements.

damper

mounting bracket.

plate from the

engine flywheel.

7. Remove the engine mounted complete with its

WATER

PUMP for parts breakdown.

8. Remove the engine one end

of

adapter

heat

each hose connected to the part being

raw

water

pump,

mounting plate. See

exchanger.

If

possible, leave

RAW

removed.

9.

Remove the exhaust components from the exhaust manifold

a) Remove the exhaust elbow (if applicable) from the

lower surface cracks

b) Remove the exhaust nipples, elbows

of

the manifold. Clean

and

defects. Replace as needed.

and

plugs from

inspect for

the manifold.

c)

Remove the water connectors from the ends

manifold. Be sure arrangement

d) Examine

and

e)

Flush

all

replace as needed.

out

the coolant recovery tank

to note the proper location

of

each for proper alignment.

parts

for defects, corrosion

and

clear its hose

passage. Set aside to re-install on the boat.

10. Remove the coolant circulating

pump.

Refer

COOLANT PUMP ASSEMBLY.

11. Remove the

air

intake silencer

and

the intake

manifold.

12.

Prepare

to disassemble the

main

engine.

of

wear

to

the

and

The

engine

suitable

should

engine

LABa

be

stand.

THE

WIRES

securely

mounted

on

TRANSMISSION DAMPER

PLATE

WHEN

REMOVING

THE

MOUNTING LOCK WITH A RING BREAK

a

THE

FLYWHEEL

TOOL

BOLTS,

GEAR

TAB

WASHER

8

CYLINDER

HEAD

REMOVAL

1.

Remove the engine heat exchanger. If possible, leave one end

of

each hose connection attached

removed. For maintenance, see HEAT EXCHANGER.

2.

Remove the starter motor. For starter motor repair, see STARTER

3.

Remove the flywheel.

4. Remove the engine backing plate.

5. Unbolt elbows at head and remove the exhaust manifold in

its entirety. See EXHAUST MANIFOLD.

6.

Remove the engine alternator and raw water pump.

7.

Remove the engine mounted fuel filter and fuel line injection pump. (Note the arrangement ers

on banjo bolts at fuel filter and injection pump.)

8. Remove the thermostat housing and the thermostat. Leave temperature sending unit in place.

9.

Remove the coolant circulating pump.

10. Remove the air intake silencer.

MOTOR

to

the part being

of

sealing wash-

INTAKE

MANIFOLD

to

SEQUENCE

FOR

LOOSENING

CYUNDER

HEAD

BOLTS

SUB

!JOLTS

FRONT~

8. Lift the cylinder head off the engine.

9.

Remove the cylinder head gasket. Clean the cylinder head and the cylinder block surface from which the gasket has been removed.

10. Remove the injector assemblies and glow plugs from the cylinder head.

11. Remove the exhaust manifold from the cylinder head.

12. Remove the valve retainers, valve springs and valves from the cylinder head. When removing each valve retainer, depress the retainer against the valve spring and remove the retainer lock. Identify each valve by putting a mark indicating the number the valve

13. Remove the valve stem

is

removed.

HOSE~

of

the cylinder from which

~CAP

seal. s __

·

~

'.\:,YJ

D-RING

I

Now

the basic engine is ready for disassembly, cleaning, and

repair if necessary.

1.

Remove the high pressure injector line assembly. When disconnecting each injector line from the injection pump side delivery valve holder, grasp the holder with a wrench to

prevent it from loosening. After removing the pipe assembly, plug the nozzle holders and delivery valve holders to prevent intrusion

2.

Disconnect the glow plug lead wire.

3. Loosen the fresh water pump drive belt and dismount the belt, idler pulley and bracket.

4.

Disconnect the air breather hose.

CYLINDER

5.

Remove the rocker cover.

6.

Remove the rocker shaft assembly.

7.

Loosen the cylinder head mounting bolts equally and gradually in the numerical order as illustrated and remove the fold).

HEAD

REMOVAL

cylinder head assembly (including the exhaust mani-

of

dust.

VALVE

SPRING

NIPPLE-----/

ROCKER

COVER

GASKET

RETAINER

CYLINDER HEAD

GASKET

9

CYLINDER

HEAD

Cylinder

Clean the cylinder and the cylinder block surface from which the gasket has been removed. Carefully check the cylinder head for cracks or straightedge and a thickness gauge to check the surface for distortion and warpage.

Check the valve guides and valve contact surfaces.

Cylinder

head

Head

distortion

Inspection

any

other damage

repair

limit:

as

shown below. Use a

0.004

in

{0.1

mm)

Check

wear

and

/

Valve

Seat

Repair

If

a valve seat is found defective, reface it or have a machine

shop install a new seat.

Sinkage

of Standard Limit

NOTE:

in normal condition. Resurface the valve seat so that it contacts the mid-ponion

guides

for

damage.

valve

0.019in

(0.5mm)

0.059in

(1.5mm)

When checking valve sinkage, the valve guide must be

ofthe

valve face.

VALVE

SINKAGE

f'Width

, 1.3-1.8mm

/',

',

of

Valve

Contact

Check

valve

contact,

damage

and

Valve

Guide

If a valve guide

1.

Remove the valve guide by pressing at its upper end and pull it out to the valve seat side.

2.

Install the valve guide by press fitting the guide from the upper side

(±0.5) from the valve spring seat face.

wear,

the

sink

of

the

seat

face.

Replacement

is

found defective, replace

of

the cylinder head to a height

D.25mm-~-f

(0.984

in)

0.12

mm

(0.472

in)

....,.l:--+--

and

6.6

Check

water

it.

of

:1:0.015

(0.295

for

leaks.

oil,

and

14mm

mm

in)

cracks;

Remove

sludge,

carbon

damage

all

sealant

deposits.

so·

\

RESURFACING

(INTAKE

Installing

Installation removal. Pay attention to the following.

1.

Renew the cylinder head gasket. No application sealant is necessary. On the upper front the engine model to which the gasket careful not to confuse it with a gasket for another engine model.

2;

Tighten the cylinder head bolts shown going through that order two or three times. Tighten each bolt a little at a time to

the specified torque.

CYUNDER

FRONT

THE

VALVE

AND

EXHAUST)

The

Cylinder

of

the cylinder head

HEAD

SEAT

Head

BOLT

TIGHTENING

is

in the reverse order

of

the gasket

is

applicable. Be

in

the numerical order

untiJ.

all are tightened

SEQUENCE

of

is

PRESS-ATTING

THE

VALVE

GUIDE

I'WIWESTERBEKE

l Engines & Generators

10

VALVE

1.

2.

3.

4.

REMOVAL

Dismount the cylinder head assembly. Depress

and remove the retainer lock.

Remove the valve. Inspect

defective parts.

the

valve retainer (to compress the valve spring)

REMOVING

VALVES

all

the components and repair

AND

or

replace any

VALVE

SPRING

INSPECTION

Valve

Spring spring fitting pressure with a valve spring tester and, if the pressure is less than the limit, replace the spring.

Pressure Standard limit

NOTE:

Measure the fitting pressure after compressing the

spring several times.

Valve

Spring

of

the valve spring and

replace it.

Fitting

(load)

Test

13.0951bs/1.398in

-15%

Free

Length

Pressure

(5.94

kg/35.5

Check.

if

the free length

Check. Check the valve

mm)

Measure the free length

is

less than the limit,

SQUARENESS

Squareness Standard

Limit

Valve

Spring the valve spring and, spring

..

CHECK

GAUGE

Check

2•

3•

Squareness

---'~

Check. Check the squareness

if

it

is

more than the limit, replace the

of

Standard

VAlVE

SPRING

TESTER

Valve

Inspection

Valve

Stem

Wear

Inspection.

diameter is less than the standard, replace the valve.

Valve

Stem

Standard Margin

Standard

limit

1.

If valve refacer. exceeds the service limit, replace the valve.

2. If the valve stem end has been indented with an oil stone.

6.6

mm

(0.260

in)

1.0

mm

(0.039

in)

0.5

mm

(0.019

in)

the valve face is found .worn down. resurface

If

the margin

limit

If

the valve stem

of

the resurfaced valve

·---:r--

45.

}/C:::::;:::::=:::::=::::::l:=l=-=

/

INSPECTING

Free

1.595

in

1.5

in

is

by

wear. flatten

VALVES

length

(40.5 (39.3

bent or

it

with a

Test

mm) mm)

its

it

WESTERBEKE

Engines

& Generators

11

VALVE

INSTALLATION

/VALVE

ADJUSTMENT

/INJECTION

TIMING

Installation

Install the valve and valve springs. Refer to the illustrations and callouts shown below.

NOTE:

Be careful not to damage the spring and stem seal by excessively compressing the spring when installing the valve spring.

Mount the Cylinder Head Assembly and adjust the valve clearances.

D.375in

·

(14.Bmm)

Witlllhe

depresud

lhe

spring,.

retainer

lock.

retainer--

to

compress

instaU

lhe

INSTALLING

0

SPRING

CYUNDER

HEAD

BOLT

TIGHTENING

FRONT~.

SUB

BOLTS

NOTE:

The Rocker Assembly (Rocker Arms, Shaft

are not

in

the engine when the cylinder head bolts are retight-

ened

in

tliis procedure.

SEQUENCE

and

Stays)

VALVE

CLEARANCE

INSTAlliNG

SPRING

TORQUING

NOTE:

ing the valve clearances.

Tighten the cylinder head bolts according to the the sequence shown. Make sure the engine is cold when this is done. Before applying the specified torque to the bolt, loosen it to 1/2 dure according to the numbered sequence shown in the illustration.

TORQUE

Bolts

11,

Bolts

#3;

ROCKER

All main bolts are

All sub bolts are Rocker shaft hold-down bolts are

head flats.

Rocker Cover

THE

CYLINDER

Cylinder head bolts must be retightened before adjust-

of

a turn and then apply the torque. Follow this proce-

HEAD

BOLTS

SPECIFICATIONS:

#2

·14.4 •

#4,

#5,

SHAFT

21.71b·fl

116,

HOLD-DOWN

Hold

(2.0 • 3.0

111,

118, • 54;2 • 61.41b-ft

Kg-m)

BOLTS:

14mm

across the bolt head flats.

12mm

across the bolt head flats.

Down

Cap

Nuts-

(7

12mm

THE

RETAINER

.5 • 8.5

Kg~m)

across the bolt

(lOmm

socket) (snug)

1/4

Firing

NOTE:

easier rotation

1. Set the piston in the cylinder to

2. Rotate the crankshaft observing the movement

3. Adjust the Intake and Exhaust valves for cylinder #1..

4. Rotate the engine crankshaft

Order:

Removal

Center (T.D.C.) clearance: 0.010 in (0.25 nun) cold for both intake and exhaust valves.

valves Center TDC be in alignment with the timing mark on the front gear case.

direction

1·2

of

the engine's glow plugs will allow

of

the engine's crankshaft.

be

adjusted at Top Dead

of

the the compression stroke. Valve

for

cylinder

of

its compression stroke. To confirm this, the

timing mark

of

#1

and place the piston at Top Dead

on

the front crank shaft pulley should

180 degrees in the normal

rotation and adjust the valves for cylinder #2.

of

for

the

Engines & Generators

12

19°

VALVE

TIMING

POINTER

ADJUSTMENT

CRANKSHAFT

PUllEY

TIMING

MARKS

/INJECTION

TIMING

Injection

If

your engine's

the

engine will

start.

well-established fuel injection

follows:

NOTE:

fuel delivery position when

do

this, side cover move

fully

1. Remove the high pressure

No.

2.

Remove

"0"

the

3. Reinstall only

high pressure that the end that pointing line during

Rotate the.engine's crankshaft in rotation compression stroke.

Move

the (as fuel (no crankshaft pulley should be directly aligned with indicator

If

the specified injection timing ( attained, adjust the timing thickness of shim material under the injection pump's mounting Changing changes the injection timing To required. required.

numbers.

Pump

Timing

fuel

not

operate

Have

the

injection pump delivery rate checked by a

The

injection pump fuel rack needs

unscrew

the

to

the

1 injector and the

ring and remove the delivery xalve spring beneath

holder.

to

the electric viewed from

line,

drips).

advance

the

fuel shut

to

expose

fuel rack

left)

position piston

throttle lever

until

At this instant, the(19" BTDC)timing mark

on

flange

the

To Refer

to

secure

the

No. 1 fuel

the

fuel

would

away

from the engine fuel

the

timirig

lift

pump.

the

instant

the front of the gear case ±

to

change the injection timing

shim thickness

the

timing, decrease the shim thickness,

retard the timing, increase

to

your Parts List

Adjustment

injection timing

properly,

perfonning this spill

the

injection pump fuel

the

full fuel delivery position

it

in

this

No. 1 fuel

delivery valve holder over

delivery valve holder

line

to

the delivery

connect

check.

No.

to

its

Slowly rotate

front), catching the

the

by

is

not properly adjusted,

and

shop.

Adjust

off

solenoid and

position

fuel

line from between

delivery

to

the

will

its

normal direction of

1 at the beginning of

full

open position

the

fuel

completely stops

19"

BTDC) cannot

increasing or decreasing

by

0.004 inch

by

approximately

for

shim

(Spill

may

be

the

injection

to

be

in

timing.

remove

rack.

then

proceed.

valve

and

reattach

holder.

Attach it

fuel

injector

flow

and

crankshaft clockwise

fuel

from

.5

degrees.

point.

(0.01mm)

one

the

shim part

Timing)

difficult

Manually

from

the

thickness,

the

full

the

(move

the

holder.

is this

itS

operate

the

No.

flowing

on

timing

be

the

degree.

as

to

as

To

the

so

1

the

as.

FUEL

INJECTION

PlUNGER

PUMP

13

GEAR

CASE

ASSEMBLY

1.

Remove the drive belt and the crankshaft pulley.

2.

Remove the alternator.

side

GASKET

For see CIRCULAnNG

of

the injection

pump

COOLANT

3. Remove the water pump assembly.

WATER

PUMP

ASSEMBLY

SHEAVE

--..

·~

•

~

.

1

~-

~'-~1/JJff>..~.....-

4. Remove the tie-rod cover from pump.

5.

Being careful not to let the spring fall into the case,

remove the tie-rod and the tie-rod spring.

6.

Remove the governor case cover.

7. Remove the gear case assembly.

8. Inspect the disassembled parts. Replace parts worn

beyond standard and service limits.

ffie

CASE I GOVERNOR

breakdown,

PUMP.

Check for

flaws.

Governor

NOTE:

SYSTEM

1. Taking care to not scratch the gear case, remove the expansion plug. \

2. Remove the grooved pin.

3. Draw out the shaft and the two bushings.

Shaft

For

additional information refer to the GOVERNOR

section.

'W'~

SHAFT,........-

Disassembly/Inspection

Check tor

~

springs

fatigue.

l~~

':1

1

GOVERNOR

Check

BRACKETS

for

bends

and

twists.

/~Check

PRESS·Fm'ING

SLIDING

joint

for

damage.

SHAFT

SLEEVE

wear

and

THE

BUSHING

wear.

and

damage.

Check

Plunger Assembly and

L-------------

Front

Oil

Seal

Replacement

Remove and replace the front oil seal. Apply a thin coat of case. engine oil to the circumference and the lip before press-fitting it to the gear case cover.

movement.

for

smooth

of

wear

the new seal

FLUSH

WITH

THIS

PLANE

Press-fit two new bushings into place

EXPANSION PLUG

GROOVED

INSTAWNG

5. Check the governor parts for wear, damage, and fatigue. If

any parts are defective, repair or replace them.

Installing

Install the governor shaft press-fit the expansion plug into the shaft hole

the

Governor

Shaft

in

the reverse order

as

illustrated.

THE

GOVERNOR

of

removal then

in

the gear

Torque

5.8

(0.8 -1.0m-kg)

SHAFT

OIL

PUMP

-7

.OH-Ib

14

Torque

10.8

·15.9H·Ib (1.5-

0--

TAPER

2.2m-kg)

PLUG

TIMING

GEAR I CAMSHAFT

REMOVING

1.

Remove the snap ring and disassemble the idler gear.

2.

Remove the valve camshaft and the injection pump camshaft on which the gears are press-fitted, remove the gears.

3.

Remove the crankshaft. Remove the crankshaft

THE

TIMING

GEARS

.-

-

Inspect

all

gear

teelli

tor

wear damage. replace

If

the

any

gear.

gear

is

defective,

gear.

TIMING GEAR

CASE

and

Installation

Press-fit the crankshaft gear onto the crankshaft.

Press-fit the valve camshaft gear and the ignition pump

camshaft gear onto their respective shafts. Install the gear assemblies

1.

Turn the crankshaft the compression stroke.

2. Install the valve camshaft and injection pump camshaft.

3. Install the idler gear so that the timing marks on it are

aligned with the marks on the other gears.

4. Check that the timing gears are all in alignment.

GEAR

TIMING

MARKS

VALVE

If

cedure:

1. Dismount the cylinder head assembly.

2.

3. Pull out the tappets.

4. Remove the gear case assembly.

5. Remove the camshaft stopper bolt.

6.

CAMSHAFT

only the camshaft is being removed, use the following pro-

Pull out the push rods.

Draw out the camshaft assembly.

in

the following sequence.

to

set the

#1

cylinder to T.D.C. On

REMOVAL

Timing

Carefully inspect the gears, gear teeth and gear bushings. Check the clearance between the idler gear bushing and its shaft.

Idler standard

Limit

When in camshaft to idler.

Backlash

Standard

Gear

Inspection

Gear

Bushing

Clearance

0.03-

0.07mm

0.2mm

assembled, check the backlash between the two gears

mesh.

Idler gear to crankshaft, injection pump to idler, and

Between

Gears

0.01 • 0.14mm

0.3mm

(0.001 -0.010in)

(O.OOSin)

(0.0003-

(0.012in)

0.005in)

INJECTION

1.

Disconnect the injection pumps.

2.

Remove the injection pump assembly.

3. Remove the gear case.

4. Remove the shaft rear cover.

5. Pull the shaft out to the front side.

PUMP

CAMSHAFT

15

REMOVAL

.INJECTION

PUMP

CAMSHAFT

Inspecting

The

Make a thorough valve

camshafts.

ing

and

the

cam

tappets.

Check

ball

bearings

for

wear

and

noise.

Injection

Pump

Camshaft

Standard Limit

30mm

0.7mm

CAMSHAFT I PISTONS

Camshaft

inspection of

Check

lobes

for

Cam

(1.18in)

(0.027in)

the

injection

the

Oldham's coupling,

wear.

Also check

Check

-for

Inspect

Oldham's

Coupling

for

wear.

Lobe

Height

pump

the

for

wear

TAPPET

Check contact surface

push

cam

and

each

rods

lobe

damage.

for

cam

and

wear.

the

ball

bear-

and

AND

CONNECTING

the

rings

from

Remove Using

the

piston

each

setting tool,

RODS

pistorr

with

pull

out

the

piston

piston. Protecting your eyes

draw the

snap (and sometimes hammer out) piston pins, these discouraged. Instead, time should be taken either

with

a heat

fall

out of heated pistons.

While the piston

the

from

each side.

might

be

tapered; if

bind

as

it enters

NOTE:

The number stamped on the rod

correspond to the cylinder number. Sometimes these numbers

are scrambled

Stamp the correct numbers on the vent confusion, deface the originals.

with

safety glasses, disengage

rings. Although mechanics generally

practices

to

heat

gun

or

by

is

the

or

missing,

still

warm,

If

the

bore

far boss.

using a hot plate.

check for bore

the

binds at the

is

misaligned,

and

the mechanic must supply them.

pads

Pins

integrity.

center,

the

shank

and cap should

provided and,

the

ring

from

and press

will

the

will

pliers.

each

with-

out

are

pistons,

almost

Insert

bore

click

to

pre-

or

Valve

Camshaft

Standard Limit

Installing

Coat

the

reverse

Position marks

on

and

adjust

(NOTE

IDLER

TIMING

PISTON

Remove Chalk

the

each

connecting

Remove assembly Take

care

shaft

rod,

rod

Lobe

Height

27.37mm

1.0rtlm

The

cam

order

the

timing

the

GEAR/

GEAR

AND

the

(1.078in)

(O.D39in)

Camshafts/Gears

lobes

and

of removal.

marks

idler

gear.

fuel

injection timing and valve clearances.

MARKS

1 &

CONNECTING

oil

pan, gasket

cylinder number

rod

to

the

connecting rod cap

and

draw

the

not

to

allow the connecting

and

cylinder.

cap,

piston,

etc.) classified

r7t\

t..m:ASURING

bearings with oil

on

the

gears aligning

After installation

2)

ROD

DISASSEMBLY

and

the oil screen

on

the

side

prevent confusing

from

each piston

assembly upward

rod

Keep

the

removed

by

cylinders.

CAM

then

install

them

is

complete check

-CRANKSHAFT

strainer.

face

of

the

connecting

from

the

to

scratch

parts

(connecting

HEIGHT

them

in

with

the

GEAR

big end of

rods.

and

rod

cylinder.

the

crank-

PRESSING PISTON

PISTON

OUT

PISTON

CONNECTING

ROD

Inspect end

play

or

twist.

End

play

Standard:

0.0039(0.1 -0.35mm)

SETTING

TOOL

Inspect wear, streaks. clearance piston Standarrl:

0.0027 • 0.0033/n (0.07·

for

0.0138/n

BEARINGS-

Check

seiziJre,

and

fusion.

Oil

Clearance

Standard:

0.00087 • 0.0020/n {0.022-

piston

seizure,

Check

between

and

cylinder.

0.84mm)

PISTON

Inspect

lor

wear

and

damage.

o I

tor

contact,

flaking,

o.osimm)

for

and

the

§

~

-

~:;~~n~;!ct

for

damage

and

wear.

PISTON

Inspect

ring

grooves

for

wear.

16

PISTON

AND

CONNECTING

ROD

INSPECTION

Put each piston ring into the cylinder bore and with the piston to position the ring on square

der wall. Measure the ring gap with a feeler gauge.

measurement exceeds the service limit, replace that piston ring.

of

When only the replacement reboring (honing)

sured at the least worn place

new rings having the same size

. available for servicing are sized into three classes:

OS,

and 0.50 OS.

Measuring Standard

Limit

(All

Ring

(All

Rings)

Gap

Rings)

of

the cylinder, position the ring to

0.006 • O.D16in

0.059in

rings is to be made, without

of

the cylinder skirt. Install the as

the piston. Piston rings

(0.15-

(1.5mm)

0.40mm)

push

the ring

with the cylin-

If

the

be

SID,

mea-

0.25

INSTALLATION

FRONT

MARK

(ARROW)

PISTON

Ring

Set

positions:

No.1

Ring,

No.

2R::=@"ng,

oil

ring.

FRONT MARK

ROD FRONT

-----111111

MARK

PUSH

-

...

ROD

~OS

"T"markand

size

mark.

"T"

mark

and

""'mad<

Piston

Measure the side clearance for each piston ring

groove the ring

Ring No. 1 Limit

No. 2 Standard Oil

NOTE:

Ring

in

the piston.

~ith

Side

Clearance

Limit Standard

No. 1 Ring

Side

Clearance

If

a new one.

0.012in

0.002 • 0.004in

0.007in

0.001 • 0.002in

is

of

the

semi-keystone

the service limit is exceeded, replace

(0.3mm)

(0.05 • 0.09mm)

(0.2mm)

(0.03 • 0.07mm)

type.

~

set

in the ring

-.

111111111111

OS

size

Align

notches accurately each

with

other.

STO = without

0.25=

TIGHTENING TORQUE:

23.0 • 25.3ft·lb (3.2 • 3.5m-kg)

Install

Set the piston ring gaps to the proper position as shown in the illustration. Coat the rings and cylinder wall with oil.

/

OILRING'l

FRONT~

NO.2

The

Piston

,

~

RING

GAP~

Rings

0.50=Biue

~

/

identiOcation paint.

White

NO. 1 RING

~

JJ

JOINT EXPANDER OIL

RING

color

OF

GAP

COIL

OF

17

PISTON

AND

CONNECTING

ROD

Place a heavy

Gently

hand. coated

Install

Using a piston ring compressor grooves, push the piston and rod assembly down into the cylinder. Be careful not to break the rings by excessively knocking the head the piston and the connecting rod are toward the front engine.

press

The

with

hammer

down

entire

fresh

The

as

shown.

with

the

surface

should

lube

oil.

Piston

of

the piston. Note that the front marks on

Ioree

of

your

be

l

And

Connecting

to

l

Rod

Assembly

compress the rings into the

of

CRANKSHAFT

the

Coat the bearing surface engine oil. Fit each cap to the connecting rod using the match marks that were put on the before disassembly. In the event a

new rod does not have a mark, position the notches (provided

for preventing the bearing from rotating) on the same side

of

the connecting rod caps with

..

CAP

Torque:

23 -35

(3.2 -3.5

ft-lb

m-kg)

REMOVAL INSPECTION

1.

Loosen the flywheel bolts and remove the flywheel.

2.

Loosen the crankshaft pulley nut and remove the pulley.

3. Remove the oil seal assembly.

4.

Remove the main bearing caps.

5. Remove the crankshaft.

6.

Inspect all disassembled parts and repair or replace any parts that warrant inspection procedures.

AND

OF

THE

it

CRANKSHAFT

Inspect

the

journals

uneven

wear.

wear

Inspect of

the

Check

of

joumat

Crankshaft

and

b(Jnd.

Check

CRANKSHAFT

Refer to the illustration callouts for

and

pins

for

crac/c$,

contact

surfaces.

for

damage

to

Gear.

ASSEMBLY

damage

and

clogging

of

the

end

face

o/1

holes

\

Rear

Oil

Seal

Replacement

Pry out the oil seal with a screwdriver and press a new rear

seal into the oil seal case.

Pryoutthe Rear

Oil

Seal

and

replace

new

Oil

Seal.

FLYWHEEL

Torque:

with

BOLTS

60-

65

R-Ib

Check and

distortion.

(8.0 • 9.0m·kg)

for

wobble

PULLEY

NUT

Torque:

72-

86

R-Ib

(10.0-

12.0m-kg)

Check

for

wobble.

18

CRANKSHAFT

INSPECTING

To

check

out-of-round wear, the diameter

journal should be measured at two places along

or

main journal, in two directions "A" and "B" each place. necessary, next

undersize.

worn

beyond the service limit, replace the crankshaft.

INSPECTING

Oil

clearance

main

journal or crankpin from the inside diameter

main

bearing or rod bearing.

rod

bearings for tapering wear and out-of-round

inside

diameter

be

measured. After its bearing cap is fastened at the specified torque,

measure the bearing at two places along the length

the

bearing and in the directions "A" and "B" each place

shown.

If

one.

If

the

crankshaft

with

one

THE

CRANKSHAFT

the

crankpins

regrind the crankpins and main journals

If

THE

is

calculated by subtracting the diameter

of

necessary, replace the worn bearing with a new

oil

clearance still exceeds the service limit, regrind

to

of

the corresponding undersize.

and

main journals

of

any crankpin or main journal has been

CRANKSHAFT

To

check the main bearings and

each main bearing or rod bearing should

the next undersize and replace the bearing

for

tapering and

each crankpin or main

the

crankpin

to

OIL

CLEARANCE

of

the

wear,

Bearing

tightening

torque:

(36 -38

(5.0-5.5 m-kg)

ft-lb)

the

of

the

as

If

of

®[]

NOTE:

A crankshaft which

to

any undersize.

Main

Journal

Diameter

Standard Limit

Crankpin Standard

Limit

Main

Journal

0.25

US

.50

US

Crankpin

0.25

US

0.50

US

Oil

Clearance

Main

Bearing

Rod

Bearing

Tightening Main

Bearing

Rod

Bearing

Crankshaft

INSTALLING

Refer

ThrUst for

1.693in

-o.0275in

Diameter

1.575in

-o.0275in

Undersize

30.885-

30.704-

Undersize

28.715 • 28.727in

28.535 • 28.5461n

Service

D.OD4in O.OD6in

Torque

Cap

Nut

End

Play

THE

to

the callouts in the illustration below.

bearing

No. 2 cap.

only

:

MEASURING

(43mm)

(-D.7Dmm)

(4Dmm)

(-0.7Dmm)

Diameter

30.896in

30.715in

Diameter

LimH

(0.1Dmm) (0.15mm)

36 • 38 23 -35

0.002-

MAIN

has

been sized cannot be reground

(42.715-

(42.465 • 42.48Dmm)

(39.715(39.465 • 39.48Dmm)

ft·lb

(5.0 -5.5m-k)

ft-lb

(3.2 • 3.5m-k)

D.DD7in

(0.05-

CRANKSHAFT

BEARING

42.73Dmm)

39.73Dmm)

0.175mm)

J.D.

Direction installation

of

Crankshaft

0.002 -0.007

(0.05-

end

0.175

cap.

FRONT

¢:=

play;

in

mm)

19

~-•

bS/desealscoated

'

•

\

J:

\j~

INSTAWNG

with

sealant

(Three

Bond

1212).

_.-

Make

cylinder (common rear

THE

........

cap

/lush

with

block

end

to

front

end

faces).

CRANKSHAFT

face

and

CYLINDER

BLOCK

STARTER BRACKET

BEARING CAP

CYLINDER

Check the cylinder block for cracks and damage. sary, repair cooling water passages are not clogged and, remove with compressed air or a wire.

Cylinder

Standard Wear

Limit

for

Rebore

NOTE:

next oversize, the remaining cylinders must also be rebored to the same oversize.

Cylinder

Use the following procedure when reboring a cylinder:

Select a piston size:

a.

0.25mm

b. Measure the piston diameter.

Reboring finish dimension

(Piston OD) +(Clearance)- (Honing Allowance [0.2mm])

Clearance

BLOCK

or

Bore

2.99in

When it is necessary

INSPECTION

replace it entirely. Check to see that oil or

Dimensions

(76 ± 0.03mm)

0.008in

(0.2mm)

for

Reboring

Over Size (OS) or 0.50mm OS

between

piston

and

0.0027 -0.0033in

cylinder

(0.071 -0.084mm)

__

a cylinder to be rebored to the

=

~-----k~

If

neces-

if

clogged,

2.99in

(76 ± 0.10mm)

(A-D)

MEASURE

DIAMETER----'--~

HERE

MEASURING

·

FRONTm

·w

DIRECTION

CYUNDER

rt-----lf-'---,..

2.1c-·~o~-.-·

(55mm)

PISTON

OF

MEASURING

BORE

.----

DIAMETER

MEASURING

POSITIONS

BEARING CAP

APPROX.

FROM

-

__

UPPER

POSITION

0.393

in

END

(10

mm)

20

ENGINE

Install

1. Inspect the thermostat housing

2. Install the temperature switch

3. Install a new thermostat and gasket (the old thermostat

4.

TEMPERATURE

the

Thermostat

Apply some sealant to the gasket when reassembling.

their wires.

can become a spare). When installing the new thermostat and gasket, apply a thin coat the gasket.

A thermostat can be checked for proper operation placing it in a pan perature open noticeably (with travel on the order (0.0098- 0.0197mm) and be fully opened when the water is boiling.

SWITCH

WATER

of

the water to a boil.

and

Thermostat

and

the housing gasket.

and

sender and reconnect

of

sealant to both sides

of

cold water and then raising the tem-

The

thermostat should

Housing

of

114- l/2in

Lubricate

at

Assembly

by

ASSEMBLY

Install

pipe.

Use new sealing washers throughout, in the same order

as were the old washers.

Injector

See

FUEL

Install

pound on the threads.

Glow

of

Plug

To

test the glow plugs, see GLOW PLUGS

Mount

Rocker

Connect the

line

Connect tion

pump

Attaching

Install Install

Mount the

flywheel bellhousing.

The heat exchanger should be serviced at engine overhaul. Refer to EXHAUST MANIFOLD/HEAT EXCHANGER.

Install the

the

fuel injection nozzles. Install the fuel overflow

Tightening

the

Arm

the the

the

Torque

INJECTORS

glow plugs

Tightening

rocker

Cover

Tightening

the

fuel line

to

the

injection

the

high

to

injectors. Reinstall the line clamp.

Nuts

Torque

bellhousing.

air

intake

engine

alternator

and

Torque

arm

to

pressure

18-

22

silencer.

heat

43 • 51

ft-lb

(5.0 -6.0

connectors. Use anti-seize com-

7.2-

10.8

ft-lb

cover

and

Crankcase

Torque

1.8 -2.9

the

engine

pump.

Use new sealing washers.

injector

fl-lb

(2.5-

3.0

exchanger

m-kg)

(1.0-

1.5

ft·lb

(0.25 -0.40

mounted

lines

from

m-kg)

and

engine

m-kg)

vent

hose.

m-kg)

fuel filter

the

injec-

oil cooler

and

on

THERMOSTAT

Check

housing

tor

cracks.

Install the coolant

Coolant

Pump

See

COOLANf

complete breakdown Adjust the injection timing. See

INJECTION TIMING.

Mount the oil filter installing the new filter apply a thin coat to

the rubber gasket. Tighten by hand.

the

Mount

Mounting

Bracket

Install the intake manifold.

lnlake

Manifold

Mount the fuel filter assembly.

pump

Assembly

front

Tightening

CIRCULATING

of

bracket

engine

Tightening

Torque

assembly.

Torque

the coolant

and

mounting

Torque

33 -49

11.6 -17.4

12 -11

PUMP

pump

install a

bracket.

ft-lb

ft·lb (1.6-

for coverage

assembly.

new

filter. When

of

clean engine oil

(4.6 -6.8

n-Ib

m-kg)

(1.6 • 2.4

2.3

m-kg)

of

m-kg)

the

A

CAUTION:

the

polarity

from

the

and

wiring

Install the alternator support bolt through the alternator leg (underside) into the engine casting.

Swing the alternator into position and fasten. Lightly tighten.

Adjust belt tension. Tighten both bolts and recheck belt tension.

Support

bolt

Adjusting

NOTE:

alternator

See-.AL1ERNATOR for service

bracket

Make certain the belts are peifectly aligned with the

ers

as needed, to align the alternator.

Connect

be

reversed, a powerful

battery

into

the

harness.

Torque

Values

bolt

Torque

Values 9 ·1 0 n-Ibs

and

engine pulleys.

the

alternator

alternator,

on

15-18

If

not, insert

and

testing

properly. current damaging

the adjusting bracket

fl-lbs

(1.26

or

Should

would

flow

the

diodes

(2.1

-2.52

m-kg)

-1.4

m-kg)

remove spac-

21

ENGINE

Install the

proper alignment with the crankshaft pulley. Check tension. Refer Install the oil Install the Install the Reinstall the engine electrical harness.

Mount

tank

Manifold

See EXHAUST MANIFOLD/HEAT EXCHANGER for service and inspection.

Install new hose connections system.

raw

water

pump

and

drive

to

RAW

WATER

and

starter

breaker

the complete exhaust manifold

to

the cylinder head.

Mounting

Bolts

PUMP. water motor.

panel

Torque

sender

and

the

Values

and

20 -24

belt. Insure

switch.

preheat

and

H-lb

clamps

it

solenoid.

the expansion

(2.

7 -

3.3

m-kg)

for

the cooling

is

in

ASSEMBLY

9.

Mount lines.

10.Check the engine for oil, fuel, coolant

leakage.

11.Check for

12.Check for

13.Check the engine fastening

14.When the engine coolant 75°C (167°F) 2000

This will give the engine the essential run-in operating

15.Adjust the engine operation speed to the specific

16.Stop the engine to complete the tuning procedure.

the engine on a test bench

abnormal

rpm

and

time.

value.

and

noise

and

odor.

abnormal

or

electrical charging.

parts

for looseness.

temperature

more, increase the engine speed to

allow

it

to

run

for twenty seconds.

connect the fuel

and

air

intake

reaches

A

CAUTION:

to

WESTERBEKE's

ENGINE

After re-assembly, the unit must be test run. This that the engine/generator operates to its specifications. Fill the engine cooling system with

the engine oil sump with lube oil API specifications of CI-4 CG-4, CH-4

1.

2.

3.

4.

5.

6.

7.

8.

TUNING

Mount lines.

Connect the electrical wiring. Refer

WIRING DIAGRAM.

Connect the Connect the exhaust pipe. Crank

operation) pre-lubricate the engines internal components and the fuel lines.

Start

the engine

for five minutes. Remove the cylinder head cover while the engine is

running.

Check from the oil cylinder head.

If

there sluggish, stop the engine and make the appropriate repairs or adjustment.

Re-install the cylinder head cover.

Check

all

AC

and

DC

wiring

connections

wiring

schematics

and

diagrams.

OPERATION

an

antifreeze mixture

or C-14 SAE 15-40.

the engine

the engine with the

for

that

is

no oil circulation or if the oil circulation is

on

a test bench

air

intake line to the

about

twenty seconds. This will

and

allow it to

the engine oil continuously circulating

pump

to the valve rockers through the

starter

run

and

cm;mect the fuel

to

the

air

cleaner.

(non-ignition

at

1000 to 1200

will

ensure

and

fill

rpm

Refer to the following pages These sections also include: Wiring Diagrams, Engine Specifications, Torque Diagrams, Starter Motor, Alternator and

Raw Water Pump.

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 water jacket. These fasteners should be sealed with Permatex high-tech equivalent.

Reversed orientation. Most gaskets, many bolt washers, all thermostats are asymmetrical.

Mechanical damage. Run fasteners down torque sequences and in three steps-1/2, 2/3, and Exceptions are torque-to-yield bolts and rocker arm shaft fasteners. The former are torqued 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.

for

details

of

as

indicated. The

sub-assemblies.

No.

2 or the

in

approved

1/1

torque.

and

22

TORQUE

SPECIFICATIONS

..

COMPONENT

Alternator

Back Connecting Cooiant Coolant Coolant Coolant Crankshaft *Cylinder

Cylinder Engine Exhaust Fuel

Flywheel

Glow Glow

Governor

Idler Injection Injection Injection Injection

Injection Lock

Bracket

Plate

......................................

Rod Pump Pump Temperature Temperature

Pulley

Head

M8

(12)

Bolts

M1 0 (14)

Solenoid

M30

M4

Relief

Taper

M16

Bolts 4-11

Head

Mounts

Manifold

(36)

....................................

bolt

Plug,

M1 0 (12)

Plug

Lead

(7)

........................................

Assembly Plunger Plug

Gear

Thrust Nozzle Pipe Pipe Pump

(17)

....................................

Pump

Nut

........................................

FHB(M-KG)

..........................

Cap

M8

(14)

................................

Pulley

.•....................

Sender Switch

Nut,

M16

Bolts

(wet)

1,

2, 3 ................

..............

Cover

......................

..............................

............................

Locknut

M1 0 (17)

...................................

Flare Nut,

..................

......................

Wire

Frtting

Assembly

Plate

..................

to

Body

Nut

..................

M12

Delivery

Drive

Gear

................

(17) Valve

......

........

..........

(24)

Nut,

.........

........

Holder

27 -38 24 -35 231212

9 9 -

..

72 -86

14

54 -61 2 -3 23 -34 20-

28.9-

61 -68

11 -14.5

0.7

28.911 -23

15 -23

25.318 -22 18 -25

25.3 -28.2

29-

(3.8 -5.3) (3.3 -4.8)

28.2

(3.2-

17

(1.6 -2.4)

-17 (1.613

(1.2 -1.8)

13

(1.2 -1.8)

(1

0 -

-21

(2.0(7.8-

(0.3 -0.45)

(3.2 -4.

24

(2.7-

36.2 (8.5 -9.5)

(1.5 -2.0)

-1.0

(0.1 -0.15)

36.2

(4.0 -5.0)

(1.5 -2.2)

(2.2 -3.2)

36.2 (2.5 -3.0) (2.5 -3.5)

51

(4.0-

3.5)

2.4)

12)

3.0)

8.5)

7)

3.3)

(4.0-

5.0)

.

(3.5-

4.0)

(3.5 -3.9)

7.0)

COMPONENT

Injection

Injectors

Intake Main Nozzle

Nozzle

Oil

Rear

Rocker

Thermostat Timing Torque Water

Pump

M10

(14)

...................................

..........................................

Manifold

Bearing

Holder

M20

(21)

....................................

Retaining

M16

(21)

....................................

Union

M12

(17)

....................................

Drain

Hose

Filter

M20

(17)

...................................

Pan

Bolts Pressure Pressure Relief

M8

M16

Sender Switch

Plug

Oil

Seal

Arm

Assembly

Arm

Cover Cover Shaft

(12)

......................................

Housing

Gear

Case

Spring

Temperature

(17)

....................................

FT-LB

Hollow

Screw

.7.2-

36 -38

..............................

Cap

..........................

(fitting

to

engine),

Nut,

Color

Fixing

Nut,

Plug

M18

(19)

........•.........................

...................... 9-13

........................

................................

Cap

............................

..................

..........................

Nut,

M6

(1

0)

Hold-down

Set

Bolt,

......................

....................... ~ ..

Locknut

Gauge

......

..........

............

Joint

12 36 -38

36.1 -43.3

25.3 -28.9

18.0-

36.1 -43.3

.7.9-

12 -17

9 -

28.911 -14 11 -15

1.8-

3.6 -5.0

10.8 6 - 8 126 - 9

14.4-

(M-KG)

10.8

(1.0-

(5.0 -6.0)

-17 (1.6(5.0 -5.5)

21.6

9.4

(1.1-

(1.6 -2.3)

(1.2

13

(1.2 -1.8)

36.1 (1.5 -2.0)

(1.5 -2.2)

2.9

(0.25(0.5 -0.

-15.9 (0.8 -1.1)

17

(1.6 -2.4)

(0.8 -1.2)

21.6

1.5)

2.4)

(5.0 -6.0)

(3.5 -4.0)

(2.5

-3.0)

(5.0 -6.0)

1.3)

-1.8)

(4.0-

5.0)

0.40)

7)

(1.5-

2.2)

(4.0-

5.0)

NOTE:

Hardware listed is metric, with values given as follows:

Flywheel

*(wet)

oil film wiped have not been removed and need only to be retorqued, then no oil is needed.

Bolt,

M1 0 (17)

M1

0 indicates Metric, 1

(17)

indicates 17mm across the flats

indicates that the bolts

on

them before they are

Omm

(if

thread diameter;

removed) are

retorqued.lfthe

ofthe

bolt head.

to

have a thin

bolts

23

GOVERNOR

SYSTEM

INSPECTING

Check for

fatigue.

THE

Check smooth

springs

GOVERNOR

levers

for

movement.

COMPONENTS

Check for

wear.

smooth

sliding

sleeve

damage,

movement.

and

INSTAWNG

TORQUE

When inspected and defective the

ADJUSTING

THE

SPEED

SPRING

the

torque

spring

torque spring set

SCREW

CONTROL

SET

using

LEVER

ASSEMBLY

set

has

been disassembled

parts

replaced, reassemble

the

following procedure:

Approx

I--;

0.7~~if_

I

~

(2/

/SPRING

/PRING

and and

adjust

CASE STOPPER

Disassembly

With

the

tem.

When

rod

cover

tie-rod

from

ment.

Governor

To

remove

been

driven

Loosen

check

Inspect

NOTE:

When

the

them

for

After

press-fitting smooth before

installing

(20mm) Install

the

so

that

the

and

operation

the

and

gear

case

removing

by

the

rack.

Removal

the

levers,

into

bolts

inspecting

bearing

the

reassemble

proper

operation.

with

the

governor

play

angle

Check

sliding

joint

for

wear

damage.

Inspection

removed,

side

the

governor

that

on

each

and

them.

governor

spring

disassemble the governor

the

gear case, be sure

of

the

fuel

pump and disconnect

Replace

pull

fasten

the

rotation.

between

all

parts that warrant replace-

out

the

grooved

lever and speed control

the

levers

and

a malfunctioning governor also

gear

case

side.

the

levers

and

grooved

Deflection must

pin,

check

Coat

the

o-rings

not

spring installed.

lever

and

the

levers

Check

weight

for

wear

and

damage.

sleeve and

sys-

to

remove

pins

shafts.

shafts, checking

the

exceed 0.787in

speed control lever

(5°)

is

the

which

have

lever.

shaft

for

with

oil

minimized.

tie-

SPECIAL

NUT

NOTE:

The illustration shows the early version

Spring Set. The current version is a solid unit.

Assemble

Use

the spring jection.

To

measure

vertical position

MEASURING

Then the

center probe pushed

the

adjusting

stopper

put the dial

which

the

I

SPRING

of

its does

against

from

the

Torque

screw

the

spring

projection

as

illustrated.

STOPPER

gauge

end

face

not

compress

spring

Spring

to

set

keep

probe

using

stopper

Set

the

projection of

case

to

the torque spring set

PROJECTION

against

a dial gauge

the torque spring

end.

·get

the

spring stopper

of

the Torque

the

torque

specified pro-

in

with

a sensitive

when

the

at

24

GOVERNOR

SYSTEM

Leaving the dial gauge set, its condition unvaried, depress the spring stopper and slide over the torque spring set support spring case. Read the deflection responds to the projection spring case (Measurement should be made repeatedly for an accurate measure). For the models which do not require any torque spring action, set the projection to a value ofO to -0.4.

After making the adjustment tighten the locknut to a torque of

5.8 - 9 ft-lb (0.8 - 1.2kg-m).

TORQUE

SPRING

SET

SEALING (STAKE

CAP

AFTER

of

the dial gauge which cor-

of

the spring stopper from the

Tum

in

this

until

about

idling

Torque

the

engine's

50

rpm

speed.

Adjust

to number tums:

=2.2

specified

of

TURNS

Set drops high

SETTING)

in

the range

Spring

speed

from

loosening

TORQUE

NOTE:

generator installed generator capacitor.

Use the following procedure to install and adjust the Torque Spring Set.

1.

2. Tum

3. From this position, tum back the torque spring set by the

4. Install the torque spring set sealing cap and stake the cap

FUEL

The fuel run solenoid the fuel injection pump. The solenoid's plunger pushes against the fuel rack on the fuel injection pump. When this solenoid de-energizes, it shuts down the engine. See ENGINE ADJUSTMENTS for assembly instructions.

SPRING

This adjustment is done at engine overhaul with no

Set the speed control to the high idling speed (3200 rpm) position by adjusting the high speed set bolt.

in

the torque spring set until the engine speed drops

about

50 rpm from the high idle speed.

specified number at that position with the special nut.

= 2.2 turns

N

to prevent further loosening.

RUN

SOLENOID

SET

INSTALLATION

or

with the leads removed from the

of

turns (N). Lock the torque spring set

is

mounted on the engine block aft

of

SPECIFIC

TORQUE

SPRING

SET

NOTE:

The illustration shows the early version

Spring

Set.

The current version is a solid unit.

of

the Torque

25

EXHAUST

MANIFOLD I HEAT

EXCHANGER

EXHAUST

The

cylinder head, should be inspected before reassembly.

1. Remove the exhaust elbows from the lower sllRace

manifold. Clean and inspect for cracks and defects. Replace as needed.

2. Remove the exhaust nipples, elbows and plugs from the

manifold.

3. Remove water connectors from the ends Be each for proper alignment.

4. Examine all parts for defects, corrosion and wear and

replace as needed.

5. Flush out the manifolds interior with a liquid cleaner and

rinse thoroughly with fresh water.

6. Use a pipe cleaner to clear the passage that connects the

coolant recovery tank tubing.

7. Flush out the coolant recovery tank and it's connecting

tube.

MANIFOLD

exhaust manifold, which was disassembled from the

of

the manifold.

sure to note the proper location and arrangement

of

the

Check the manifold pressure cap. Open the valve by pulling it and make sure it closes when released. Make certain the

If

upper and lower seals are in good condition. replace the cap.

HEAT

EXCHANGER

The heat exchanger should an engine overhaul.

1.

Disconnect the hoses and remove the hose fittings, petcock, drain plugs and zinc anode. Also, remove the end

fittings and gaskets.

2. Inspect the tube (casing) for wear and dents,

suspect replace the heat exchanger.

3. Clean out any zinc debris and pressure test the coolant

and raw water passages.

4.

When

reassembling, install new gaskets and 0-rings. Apply some lubricant to the new gaskets and to the petcocks and fittings as you install them.

5. Install a new zinc anode.

CHECKING

be

inspected and serviced during

any doubt,

THE

PRESSURE

if

CAP

at all

CLEAN

OR

REPLACE

EXHAUST

ASSEMBLY

1.

If

the manifold was removed as an assembly and left intact, it can reverse order new ones.

Manifold Bolts

Torque

2.

If

the manifold has been disassembled, follow the steps below.

a.

Loosely attach the elbows to the cylinder head and the

manifold using new gaskets.

sealant.

b.

Gradually tighten each fitting to make sure

alignment

steps.

Manifold

Bolts

Torque

c. Reinstall the exhaust connections and plugs into the

manifold using Loctite-Anti-Seize on the threads.

be

replaced on the cylinder head in the

of

removal.

Mounting

Values

of

all the parts. This should be done in three

Mounting

Values

20 · 24

20 -24

Do

not reuse the gaskets; install

ft-lb

(2.

7 -

3.3

m-kg)

Do

not use any gasket

ft-lb

(2.

7 -

3.3

m-kg)

of

THE

MANIFOLD

proper

NOTE:

All

of

the above can be accomplished by sending

the heat exchanger to a radiator shop. They will also service transmission

6. Repaint the assembled heat exchanger with

WESTERBEKE's

and

engine oil coolers.

heat resistant spray enamel.

t

HEAT

EXCHANGER

26

FUEL

INJECTION

PUMP

REMOVING

NOTE:

absolutely necessary. Injection pump service should be per-

formed by a qualified technician

ronment.

1. Disconnect the fuel injection pipes.

2. Remove the tie-rod clip cover.

3.

Remove the tie-rod clip and the tie-rod.

THE

INJECTION

Do

not disassemble the injection pump unless

PUMP

in

an extremely clean envi-

Disassembly

1.

Remove the stopper plate.

2.

Unscrew the delivery holder. Take out the delivery valve and valve spring.

3. Remove the tappet roller and stopper pin.

4. Remove the tappet, plunger spring, etc.

NOTE:

When replacing the plunger barrel, delivery valve,

etc.,

do

not loosen the adjusting screw

cylinder. When those parts have been replaced, it

to

measure fuel injection quantity by utilizing a pump

sary tester and cam box. should

be

kept classified by cylinders

fuel.

All

pans

that are removed from the pump

and

plate

for

is neces-

and

immersed in clean

each

DELIVERY

HOLDER

VALVE

PLUNGER

PLUNGER----

VALVE--

SEAT

BARREL

-----Check tor

INSPECTION

PUMP

Scratches,

seizure.

Spring

fatigue.

OF

ASSEMBLY

rust,

Check Rack

movement. should (no

catching).

the

be

Control smooth

TAPPET ROLLER

It

/NJECTIIJII

(Three

PUMP

Cylinder

i

shown)

Injection

1. Insert the plunger barrel into the housing.

2. Install the delivery valve and valve spring. Temporarily tighten the holder.

3. Insert the control rack.

4. Insert the control pinion. Align the

rack with that on the pinion.

Pump

Assembly

__.....--Inspect

...,....-

matchmark

and

interference.

tor

wear

on

the

5. Install the spring upper seat.

6.

Insert the plunger spring.

7.

Fit the lower seat to the plunger. Insert the plunger into the barrel side.

8.

Depress the tappet roller assembly pin.

9. Tighten the delivery holder.

Delivery

holder

tightening

Torque:

25.3-

and

install the stopper

28.2

ft-lb

(3.5-

3.9

kg-m).

27

FUEL

INJECTORS

DISASSEMBLING

1.

Oamp

the nozzle holder in a vise, then remove the

cap nut.

2. Remove the pressure adjusting screw, then pull out the upper seat, spring and the push rod.

3. Clamp the nozzle holder in a vise, remove the nozzle nut then pull the nozzle out.

4. Clean the disassembled parts with clean diesel fuel, then remove the carbon adhering on the nozzle.

NOTE:

Do

5. After cleaning, check to see down into the valve seat by its own weight when setting the nozzle body upright position and inserting needle valve.

6. Check that there is no flaw surfaces and sliding surfaces

needle valve and,

not

use a metal

BODY SUB

AND

INSPECTING

tool

to

remove

if

the needle valve comes

or

other damage

of

the nozzle body and the

if

present, replace the nozzle assembly.

ASSEMBLY

the carbon.

on

mating

Inspect deformation breaks.

tor

wear.

and

I

Check

v:::.

.---SPRING

~

I

~DISTANCE

I

PIECE

assembly smooth immersed

kerosene.

FUEL

INJECTOR

sliding

in

for

while

INSTALLING

Install the nozzle and nozzle holder assembly in the reverse

of

order holder assembly, use a new copper washer.

removal. When installing the nozzle and nozzle

ASSEMBLING

Assemble in the reverse order lowing points:

1. To assemble the nozzle and nozzle holder, first assemble the pressure adjusting nut side, and temporarily tighten

nut

the

proper position, then mount the nozzle nut.

2. After the nozzle and nozzle holder have been assembled, check the injection starting pressure and spray condition.

Mount the nozzle and set the needle valve to

Torque

18-

22n-1bs

-i-

Fuel

Pipe

FUEL

LIFT

PUMPS

There is no maintenance required for the solid state fuel lift pump. This pump preheat is pressed. A distinct ticking can be heard when the pump is operating. connections.

Some early model engines and those engines equipped with 24 volt systems are equipped with a fuel lift pump which uses a replaceable filter. At overhaul, replace the filter and clean the pump exterior and the electrical connections. This pump, when operating properly, will also make a distinct ticking noise.

is

activated during the start sequence when

If

no ticking is heard, check the electrical

If

the pump has failed, replace it.

of

disassembly, noting the

(2.5-

3.Dkg-cm)

Torque

Connections

Torque

(5.0·6

18-

22n-1bs

36.2-

43.4n-lbs

........

}10Cyfimlerllnd

(2.5-

fol-

3.Dkg-cm)

.__NOZZLE

B.

NOTE:

For testing the injectors, refer to the following page.

ASSEMBLY

RETAINING

NUT

TORQUE

WRENCH

28

FUEL

LIFT

PUMP

SOLID FUEL

LIFT

STATE

PUMP

TESTING

FUEL

INJECTORS

REMOVING

NOTE:

1.

Disconnect the high pressure lines from the injectors and loosen the lines at their attachment to the injection pump and move them out bending the lines.

2. Using a 17mm long socket, remove the fuel return line in its entirety from the top lose the two sealing washers and banjo bolt that attaches

the fuel return line to each injector.

NOTE:

prior to lifting it out any rust hole. by carbon build up side with the

and

it

3. The injector seats in the cylinder head on a copper seal-

ing washer. This washer should be removed with the injector and replaced with a new washer when the injector is reinstalled.

INJECTION

1. Using the nozzle tester, check the spray pattern and

injection starting pressure limit, adjust or replace the nozzle. When using nozzle

·tester, take the following precautions:

THE

INJECTORS

Injector must be serviced

Clean the area around the base

or

debris from falling down into the injector

If

the injector will not lift out easily

aid

of

then lift it out.

in

a "clean room" environment.

of

the way

of

the injectors. Take care not to

of

the cylinder head to help prevent

or

the like, work the injector side to

the 17mm deep socket wrench to free

TESTING

of

the injectors. Avoid

of

the injector

and

nozzle.

If

it exceeds the

is held in

Inspecting

1.

Operate the hand lever one stroke per second to check rectly in its axial direction. A nozzle is defective injects fuel in an oblique direction or in several separate strips. Also, a spray in the form defect. These defects may sometimes be caused by clogging with dust and, therefore, all parts should be carefully cleaned before reassembly. (Care should be taken not to expose ones skin to this spray and cause infection.)

CHATIERING TEST

2. Apply the pressure

by operating the hand lever, and check the drips from the nozzle tip. on the bottom, it is considered defective and should be replaced. A very small amount remain on the tip indicate a defect.

Spray

Pattern

of

the nozzle tester at intervals

if

the fuel is injected cor-

of

particles indicates a

as

it may penetrate the skin

··~

·~

FAULTY

~~

.~~

of

1635 lb/in2 (115 kg/cm

If

it drips or has a large accumulation

of

fuel may sometimes

of

the nozzle; however, this does not

ij

.

·l

\\

.,,

r,·.

2

) to nozzle

of

if

it

FAULTY

of

fuel

A

CAUTION:

of

such

velocity

skin

of

fingers

enters

the

a.

If

the diesel fuel

replace it. Set the nozzle tester in a clean place where there is no

b.

dust or dirt.

c.

Mount the nozzle and nozzle holder on the nozzle tester.

Use the fuel at the approximate temperature

d.

of

68° F

e. Operate the hand lever

bleed the lever at intervals ing the injection starting

FUEL

INJECTION

(140

TO

150

PRESSURE

2

kgf/cm

)

13.73

The

spray

injected

that

it

may

penetrate

and

hands,

destroying

bloodstream,

At

the same time, clean or replace the filter.

(200

C)

air in the nozzle line, then move the hand

1991

TO

14.71

it

may

of

the nozzle tester is discolored,

of

nozzle tester several times to

of

one stroke per second while read-

pres~ure.

TO

2134

psi

MPa

cause

:

from

the

deeply

tissue.

blood

·.NOZZLE TESTER

v

nozzle

poisoning.

INJECTION

PRESSURE'/?~

into

If it

is

the

DRIP

TEST

~NORMAL

The injection starting pressure for the injectors is adjusted by increasing or decreasing the thickness

10

The shim has (0.05 mm), between 0.0049in (1.25mm).to 0.0669in (1.7mm) With each increased approximately replacing the shim, grip the retaining nut in a vise and remove the body with a wrench. Tighten the retaining nut to the specified torque.

different thicknesses for every 0.0020 in

0.0020in (0.05mm) increase, injection pressure is

~

""'LTY

of

the adjusting shim.

7l.llb/in2 (5.0 kg/cm

!

SHIM

~FAULTY

!\·

~i~

2

).

When

THICKNESS

~

ADJUSTING SHIM

I

29

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid.

PREHEAT is pressed at the control panel this solenoid

When should

"click" on and the glow plug should begin to get hot.

INSPECTION

To inspect the plug, remove the electrical terminal connec-

or

tions, then unscrew head. Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and bum

erosion;

if

unclamp each plug from the cylinder

it has eroded too much, replace the plug.

TESTING

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the other to the body glow plug will have a method can You can also use an ammeter to test the power drain (8 to 9 amps

A

to

the

testing

be used with the plug in

per

WARNING:

touch.

the

plugs.

plug).

Be

careful

of

the glow plug, as shown. A good

0.3 to 0.4

These

glow

not

Ohm

plugs

to

burn

resistance. This

or

out

of

will

become

your

fingers

the engine.

very when

hot

Re-install the plugs in the engine and test them again. The

for

TEST

10 to

more

plugs should get very hot (at the terminal end) within 15

seconds.

short circuit.

compound on the threads.

Glow

A

than

If

the plugs

When

Plug

Tightening

WARNING:

30

seconds.

don't

heat up quickly, check for a

reinstalling the glow plugs, use anti-seize

Torque 7 -11

Do

not

lb-fl

(1.0

keep a glow

TERMINAL

GLOWPWG

THE

OHMMETER

-1.5

plug

END

kg-m)

on

TIP

_GLOW

PLUG

FUEL

LIFT

PUMP

Periodically check the fuel connections

and make sure that are

tight and secure. The DC ground connection at one pump's mounting bolts should be clean and well secured the mounting bolt to ensure proper pump operation.

When energized thru the preheat circuit, the fuel purge air from of fuel

as

the engine

INLET

FUEL

To

ensure clean fuel into the fuel lift pump, there is a small

in-line fuel filter shoufd be replaced every 200 hours

no

leakage

is

the

fuel system and provide a continuous

is

nmning.

FILTER

filt~r

connected

to

the fuel lift pump elbow. This

to

and out

of

the

present and that the fittings

lift pump will

of

operation-.

pump

of

by

flow

the

30

TACHOMETER

TACHOMETER/HOUR

The tachometer/hour meter used ment panels contains common other volts alternator charging voltage supplied on

The tachometer circuit operates from tachometer input terminal while the alternator producing battery charging voltage 13.0-14.8 volts

The following are procedures a fault meter.

Hour

Check for the proper terminals.

1.

2.

Tachometer

Check for the proper terminal

1.

2.

3. Check for

4. Check electrical connections

Tachometer

1.

2.

3. Check that alternator

Tachometer

-a~

b. Adjust the tachometer using

ground.

the

tachometer.

the

back of

~ne

DC.

in

meter

Voltage Voltage

nections for terminal

the

of the diodes

either of

Inoperative

present - meter is defective - repair not

present - trace (

fault.

to

verify the operation.)

Inoperative

and

(-)

terminal with the engine running.

Voltage tion

AC output

ground.

minal

present - attempt adjusting meter through calibra-

access

hole.

voltage not present - check for proper alternator

voltage.

AC

to

alternator connection.

Sticking

Check

for

proper

terminal Check

terminal

alternator

and

(-)

for

good ground connection between meter

and

alternator.

pivot

Inaccurate

With

a hand-held tach on the front pulley retaining nut or with a strobe-type tach, read the front crankshaft pulley rpm

through the CAL. (calibration) access hole in the

tachometer. Zero the tachometer and then adjust it to the rpm indicated by the strobe or hand tachometer. (Verify

the rpm at idle and

tachometer

as

METER

in

propulsion engine instru-

two

separate electrical circuits

One

circuit operates the hour meter and the

The hour meter circuit operates

to

the (

instrument.

on

AC

voltage

in

the alternator

to

the

two

circuits

DC

voltage between (

+)

(Jump

12

volts

AC

voltage between tachometer input

No

results, repair or replace

voltage at tach terminal on alternator

AC

voltage between "tach

terminal.

is

well grounded

bolt.

at

and

supplied

the

engine is running,

follow

when

in

a tachometer/hour

+)

and

(-)

electrical con-

DC

to

meter(+)

from

tachometer input ter-

to

engine block at

of

the

crankshaft

idle.

with

+)

terminal

6-8

volts,

troubleshooting

and

(-)

or

replace.

meter.

inp."

a 5/64 or 2mm Allen wrench

the

rear of

high

rpm and adjust the

needed)

to

on

the

and

DC

to

(-)

a

12

fed

NOTE:

Current

dial

to

set

calibrating

TACHOMETER

NOTE:

In a new

the

tachometer engine's installations.

1.

Warm

Remove

cloth

pulley

2.

Start

3.

Aim confirm tachometer reading. Adjust the tachometer using instrument reading is

showing.

bring

4.

Set

the

has

been

speed

-

r

model

tachometers

the

tachometer

screw

is

CHECK

installation

may

rpm.

This

up

the

engine

any

specks

and

place a piece of suitable reflecting

to

facilitate

and

idle

the

light of

the

engine speed. Check

the

instrument coarse adjustment

Then

the

instrument

tachometer

factory

screws

have

"'

e

iil

e

!

-

to

the

crankshaft

then

used for

not

always

calibration

to

on

use

engine.

the

tachometer onto the reflecting

to

the closest

use

the

to

the

adjusted

been locked

fine

(New

Installation)

having

be

should

normal

the

crankshaft pulley

of a photoelectric type

fine

calibration adjustment

the exact

idle speed

and

the

~

- -

use a coarse

new

correctly

operating

R.P.M.

r~ading

in

"'

i

pulley

tuning.

instrument

calibrated

be

checked

temperature.

the

instrument

to

calibrate

that

as

(the

engine

idle screws

place).

'

-

- - ---

adjustment·

rprils.

panels,

in

all

with a clean

tape

on

tachometer.

tape

panel

in

the

panel

the

photo

the

photo

idle

and

high

(j)2

I

- -

The

to

the

new

the

tach

to

tach.

speed

·

to

by

j

-

31

L-~~r---~~~~~£V@

stAIIT

SIITCH

PI£•START

ENGINE

ADJUSTMENTS

ENGINE

Check the engine's compression pressure at 500 and 1250 operating hours Remove each glow compression pressure. The engine's cranking speed is at

MEASURING

Check the compression pressure. remove ail fuel injectors, shut-off solenoid wire, the injector hole or glow plug hole. Connect a compression tester

motor until the pressure reaches a maximum value. Repeat this process matically (at least of more than 35.5 psi (2.5 kg/cm

COMPRESSION

or

whenever engine performance is reduced.

plug and check each cylinder's

280 rpm.

COMPRESSION

To

do this warm the engine,

or

glow plugs, disconnect the fuel

and install a compression adapter in

on

the adapter and crank the engine with the starter

for each cylinder. Look for cylinders with dra-

20%) lower compression than the average

the others. Compression pressure should not differ by

2

)

at 280 rpm.

DRIVE

Excessive drive belt tension can cause rapid wear and reduce the service life A slack belt slipping, resulting in high operating temperatures.

The drive belt is properly adjusted deflected no less than 3/8 inch (lOmm) and no more than inch (12mm) as the belt is depressed with the thumb at the midpoint between beli. A spare

Adjusting

1.

2.

3. With the alternator loose, swing

4.

5.

BELT

ADJUSTMENT

of

the fresh water pump's bearing.

or

the presence

U'le

belt

or

beltS should always

A

WARNING:

drive

belt's

Loosen the alternator pivot bolt.

Loosen the alternator adjusting bolt.

belt is tensioned correctly.

Tighten both bolts. Check the tension again after the engine has been in

operation.

tension

Belt

Tension

Never

of

oil

two pulleys

attempt

while

the

on

the belt can cause belt

if

the belt can be

on

the longest span

be

carried

to

check

or

engine

is

In

operation.

it

outward until the drive

adjust

of

the belt

on

of

board.

the

112

the

If

a weak cylinder is flanked by healthy cylinder, the problem

or

is either valve for the weak cylinder, adjust as needed and test again. cylinder is still low, apply a small amount cylinder to seal the rings and repeat the test. comes up - the rings are faulty.

Abnormally high readings carbon accumulations, a condition that might be accompanied

NOTE:

In

case

cause

may

TORS. Poor fuel

fuel pressure

piston related. Check the valve clearances

of

oil into the

If

on

all cylinders indicates heavy

by

high pressures and noise.

of

severe vibrations and detonation

be

fuel injector

quality,

to

the

injection pump will

problems,

see

FUEL

contaminates and

result

loss

If

compression

noise,

INJEC-

of

positive

in

injector

the

faults.

When re-installing the glow plugs use anti-seize compound.

COMPRESSION

STANDARD MINIMUM

MAXIMUM

VALUES

(AT

280

(AT

ACCEPTABLE

RPM)

280

RPM)

DIFFERENCE

398.16

PSI

355.5

PSI

BETWEEN

(28Kg/cm')

(25Kg/cm'~

35.5

PSI

(2.5

Kg/em''

GLOW

To then unscrew Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and has eroded too much, replace the plug.

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the other to the body plug will have a with the plug in or out ammeter to test the power drain (12-13 amps per plug)

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to seconds. circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

PLUGS

inspect the plug, remove the electrical terminal connections,

or

unclamp each plug from the cylinder head.

bum

If

the plugs

of

the glow plug, as shown. A good glow

0.90

ohm

resistance. This method can be used

of

the engine. You can also use an

don't

heat up quickly, check for a short

erosion;

if

15

it

32

ENGINE

ADJUSTMENTS

TESTING

To test oil pressure, remove the hex head plug from the oil gallery and install a mechanical oil pressure gauge in its place. After warming up the engine, read the oil pressure

gauge.

OIL

NOTE:

reading

pressure

depending

OIL

PRESSURE

A newly

up

to

reading as

upon

PRESSURE

BETWEEN

started,

70

or

the

35

cold

engine

80

psi.

A warmed engine

low

as

30

load placed

AND

psi.

55

on

PSI

may

Oil

the

have

pressure

engine.

an

can

will

oil

have

MEASURING OIL

PRESSURE

OIL

PRESSURE

WITH

ADAPTER

THIS

MECHANICAL

INSTALLED

THE

ENGINE

OIL

PRESSURE

GAUGE

WHERE

BLOCK

SENDER.

TEST

THE

OR

IN

GAUGE

OIL

HOSE

PLACE

CAN

BE

ENTERS

OF

THE

·

pressure

an

oil

vary

OIL

PRESSURE

The oil pressure relief valve is located in the front gear case cover just below the in place by a 22mrn hexhead plug. This valve's cracking pressure is approximately 45 psi and operates to maintain the pressure in the engine's lubricating system.

OIL

PRESSURE

There is an oil pressure switch connected into the engine's oil gallery to monitor the engine oil pressure and to sound the panel alarm buzzer should a low oil pressure issue occur

(10-5 psi). The engine alarm buzzer is such cases

will sound continuously. When performing an engine overhaul, replace the oil

sure switch and the oil pressure sender. When installing the new parts apply a teflon sealant to the

threaded

sender.

Oil

A

etS, switch. Snap-On, switch

ends being careful not to close off the oil hole in the

Pressure

CAUTION:

vise

Use

will

Sender

grips

the

Proto,

cause

RELIEF

oil

pressure senders location. It is held

SWITCH

and

Switch

Oil

Pressure

or

pipe

wrenches

correct

New

Britain

oil

leaks

VALVE

Torque

Switch

socket

and

and/or

9 -13 ft·lb

·Do

on

the

which

othetS.

switch

(1.2

not

use

oil

pressure

is

available

Damage

failure.

-1.8

lock pli-

pres-

m-kg)

from

to

the

A

CAUTION:

checking rotating and and

LOW

A gradual loss

ings. A rapid loss . failure. For additional information on low , ings, see the ENGINE TROUBLESHOOTING chart. .

parts flywheel. do

not

OIL

Be

sure

to

stop

the

engine

the

engine.

such

Keep

wear

Keep

as

long

music

your

hands

the

cooling

hair

away

earphones.

fan,

from

away

v-belt,

rotating

PRESSURE

of

oil pressure usually indicates a worn bearof

oil pressure indicates a specific bearing

oil

before

from

p_ulleys,

parts

pressure read-

OIL

PRESSURE

SENDER

+

OIL

PRESSURE

SCHEMATIC

Check tor

tightness.

SWITCH

all

connections/finings

33

ENGINE

ADJUSTMENTS

ENGINE

The engine idling speed boat

IDLING

is

operating in

SPEED

is

pre-set

the

water other variables

at

the

factory

such

but once

as

propeller size, shaft length, ahd the transmission can affect idle

speed.

The

normal

idle speed for these engine

rpm

at

normal engine operating temperatures. Where ever in

this

rpm

range the engine operates the smoothest,

stall

when

the throttle

is

restarted

and

models

no

is

1000-1200

does

damper chatter

produces. ·

ADJUSTING

1.

Loosen

fuel

2.

Adjust hold

3.

Tighten

4.

Race remains

THE

the

locknut

injection

the

bolt

the

engine

the

locknut.

the

engine several

as

set.

IDLE

SPEED

on

the

idle adjustment bolt

pump.

so

that

the throttle control lever

at

a quiet idle (1000-1200

times

to

ensure

the

rpm).

idle

on

will

speed

not

the

is

the

THROTILE

\\

lEVER

CONTROL

OPTIONAL

The

fuel engine's block just pump. new

1.

Visual To below

2.

Thread

amount

3.

Thread

run

Proceed

fuel

run solenoid.

access

obtain

the

of the

FUEL

RUN/SHUT-OFF

solenoid

this,

fuel

Teflon

aft

as

follows

to

the

'remove

injection

locknut

is

mounted

of

and

fuel

the

onto

sealant

when

injection

pump.

the

to

solenoid into the

SOLENOID

in

a threaded hole

below

the engine's injection

installing a replacement or

pump's

fuel

rack

shut

off

lever

and

gasket

solenoid

the

threads

hole

and

then

apply

on

the

solenoid

on

the engine and

observe the solenoid plunger through the cover opening.

Allow into push

4.

Back position

LOCKNUT

5.

Properly solenoid. harness

adjacent

6.

Re-assemble

unit. energized. solenoid

the plunger

the

injection

the

plunger into the solenoid.

the

solenoid

with

TORQUE

connect

Two

and

inbmird

Make

certain

If

in

to

contact

pump.

out

1/4 -1/2

the

locknut

VALUE

the

three electrical

of

the

connections plug into

the

third grounds

threaded hole with

the

shut-off

the

unit

it

does

not

1/8 -1/4

tum

Do

lever

stops

and

till

the

fuel

not

thread further

of a tum

28.9-36.2

to

the

with

gasket

when

only

goes

shut-off

rack

and

move

so

and

secure

FT-LB

(4.0-5.0

leads

from

the

engine

engine block at

an

8mm

bolt.

and

test

the

solenoid

to

idle.

Thread

is

obtained.

on

the

is

needed.

just

a

small

as

it

M-KG)

the

run is

de-

the

fully

to

in

an

the

~

FUEL

SOLENOID

RUN

FUEL

RUN

PUSH

TYPE

VOLTAGE:

Coil

STROKE:

10V-

resistance

0.394

SOLENOID

15V

DC

is

1.6

n :t

:t

0.0197in

10%

(10

(at

20"

:t

0.5mm).

C).

FUEL

34

RUN

SOLENOID

0.394 (10

:t

0.0197in

:t

0.5mm)

RAW

WATER

PUMP

(PN.

033636)

EARLY

Disassembly

The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet and outlet port. They may be left in place or removed if they interfere with the pump disassembly. Note the port location and positioning if

removed.

1.

Remove the six cover plate screws (#13), cover plate

(#12), and the cover plate gasket(#ll).

NOTE:

Screw material should be stainless steel part number 034463. Also, replacement is recommended; however; keep the gasket submerged

reassembled.

and

not be reusable.

2.

Remove the impeller (#9) with its drive screw (#10) from

If

is

is allowed to

if

in

the pump housing.

3. Remove the screw (#4) and sealing washer (#5) and draw the cam (#6) from the oump housing.

4. Remove the circlip (#3).

5. Support the pump housing, at the mounting flange end, on an arbor press and with a drift, press out the shaft (#8) and bearings (#2) from the pump housing from the impeller end.

6.

With the pump housing supported, push the seals (#7) out

of

the pump housing. Push the impeller side seal out that side and then lift the spacer (#14) out. Then pushthe bearing side seal out that side,

7. Supporting the bearings inner face (#2), push the shaft of

(#8) out

NOTE:

or

corrosion.

the bearings.

Inspect all parts and replace those showing wear

Reassembly

1.

Install the seals (#7) and spaceJ(#14) in the pumphousing. Push the impeller side seal into the housing. Rotate the pump and install the spacer (14) against the seal face. Push the bearing side seal into the housing from the bearing side.

NOTE:

The seals flat suiface that have printing and

numbers face toward eaxh other.

of

the cover gasket

you are going

to

reuse

water until the pump is

dry,

the gasket will shrink

it,

MODELS

3. Support the pump housing at the impeller side. Apply a of

small amount to the impeller shaft (#8). Carefully install the shaft rotating it through the seals until the bearings contact the housing from the bearing end. will push this shaft and bearing assembly into the pump housing by applying pressure against the outer bearing race. Push the assembly into the housing until the bearings seat fully in the housing. Install the circlip (#3).

4.

Position the cam (#6) in the housing and secure it place with the screw (#4) and sealing washer (#5).

NOTE:

Use a small amount

can

suiface and screw threads. Remove any excess from

the impeller housing.

5. Apply a light film housing for the impeller.

NOTE:

Just coat the suiface, do not overapply. Install the impeller with the drive screw mating in the slot drive shaft.

6.

Install the cover gasket (#11), cover( #9, #12) and secure

with the six cover screws·

KEY

NO.

1-1 1-2 1-3

2 3 4

5 6 7

8 9 10

11 12 13

14 15

glycerin to the seals (#7) inner lips and

Use a pushing tool that

of

Permatex

of

glycerin to the inner surface

PARTS

LIST

PART

NUMBER

033636

034457 034466

034464 033044 034462

033037 034456 033043

034460 034440

034459 034461 034463

048013 038679

AND

PART

NAME

PUMP

(COMPLETE)

HOUSIN.G

(PUMP

KIT

(MAJOR

BEARING RING

(RETAINING)

SCREW WASHER

CAM SEAL

SHAFT KIT

(IMPELLER-SCREW-GASKET)

SCREW GASKET

COVER SCREW

WATER SPACER

BODY)

REPAIR)

(PUMP

HOUSING

(IMPELLER-INCLUDED

(IMPELLER

(IMPELLER)

(IMPELLER

SEAL

#1

on the inner

TO

COVER)

of

QUANTITY

CAM)

IN

N0.9)

in

the

2

2 1

1

6

2. Install shaft (#8) into bearings. Support the bearings (#2) at their center race. Push the shaft into the bearings,

pushing at the impeller drive slot end using the base

the drive slot. Push the shaft through both

bearings, flush against each other so that the flat sided

end

of

the shaft extends beyond the second bearing center

race by

11

GASKET

Lubricate

19/32" (15mm),

at

ass~~mbtv.

12

1132"

9IMPEllER

(.5mm).

of

the

8

1-2

PUMP

HOUSING

Clean

and

repaint

housing.

Check

tor

cracks.

WHEN

ASSEMBLING:

GLYCERIN COVER

0-RING,

TO

THE

ANO

INSIDE

APPLY A THIN

OF

THE

COVER,

IMPELLER

COAT

OF THE

35

RAW

(FROM

WATER

MARCH

PUMP

2004

PRODUCTION

(PN.48080)

AND

ON)

Disassembly

1. Remove the six screws and lock washers, and the sealing 0-ring.

NOTE:

Inspect the impeller

Inspect the

0-ring

for

re-use.

cracks

or

stiffness

and

replace

if necessary.

2. Remove the impeller key.

3. Remove the lock nut and withdraw the drive gear from the pump shaft and remove the key. [Insert a metal rod

0.19" in diameter thru the hole in the shaft to prevent it from turning while removing the lock nut].

4. Using snap pliers, remove the snap ring.

5. Press out the shaft and bearing assembly from the pump housing. Using an arbor press, support the bearings inner race and press the shaft out

of

the bearings.

6. Remove the 0-rings from the shaft.

7. Remove the shaft seal from the housing.[Note the seal face position in the housing so as to re-install the new seal correctly].

8. Remove the cam screw and sealing washer and withdraw the cam from the housing.

9. Inspect the shaft support bushing in the pump cover. Replace

if

worn.

INSPECTION

Inspect all parts for wear and corrosion. recommended that 0-rings, -gaskets, and seals be replaced.

It

is also

REASSEMBLY

Reassemble the pump in the reverse order.

of

Apply a small amount

petroleum jelly on the lip shaft seal and on the shaft itself when installing the shaft/bearing assembly into the pump housing.

When installing the pump cam inside the housing, apply a

of

small amount

Permatex # 1 to the inner surface

and to the securing screw threads. Remove any excess.

PARTS

LIST

KEY

NO.

2

3

4

5

6

7 8

9

10

11

12 13

14 15

16 17 18

PART

0480809 049172 049170

048500 033458 049171

0302575 048253 034463

048359 033041 033037

046662 048254 049169

034464 033045 033044

NUMBER

AND

PART

RAW

WATER SHAFT IMPELLER

IMPELLER CAM WEAR

SPRING IMPELLER

IMPELLER D-RING CAM

COVER

PLATE

DOWEL

SEAL

COVER

WASHER

CAM

SCREW

SPRING

SEAL

LIP

SEAL

BALL

BEARING RETAINING RETAINING

NAME

PUMP

KIT

(O·RING & GLYCERIN)

WASHER

SCREW

COVER

D-RING

INTERNAL EXTERNAL

RING

of

the

of

the cam

QUANTITY

1

6

2

WHEN

ASSEMBLING:

GLYCERIN COVER

0-RING,

TO

THE

AND

INSIDE

APPLY A THIN

OF

THE

COVER,

IMPELLER

COAT

OF THE

EXPLODED

REPAIR

FROM

VIEW

PARTS

ARE

YOUR

WESTERBEKE

AVAILABLE

DEALER

ALTERNATOR

TESTING

DESCRIPTION

The

charging system consists of regulator, cuit the ulator back

#14

an

engine

DC

wiring

breaker and a battery with connecting cables. Because of

use

of integrated circuits (IC's)

is

very

compact

of

the

alternator.

#10

RED

PURPLE

EARLY

MODEL

35AMP

ALTERNATOR

and

=

GROUND

an

alternator with a

harness, a mounted

the

electronic

is

mounted internally or

CURRENT 50 ALTERNATOR

MODEL

AMP

voltage

~~~~~~#10

TROUBLESHOOTING

A

WARNING:

bot.

Do

not

This

troubleshooting section

exists

with determined best

to

have

The

alternator charging circuit charges the starting battery

and

the service

or

a battery selector switch

to

isolate the batteries

along

with

the

starting

battery

service

battery

A

WARNING~

that

everyone

sheaves

A

DC applications. isolate before made

and

WARNING:

and

AC

DC

pertonning

without

A

failed

alternator

touch

until

the

alternator

is

the charging circuit or with the alternator.

that the alternator or voltage regulator

a qualified technician check it

battery.

service

but

charging circuit

belts

An isolator with a diode, a solenoid,

is

usually mounted in the circuit

so

the

service battery

battery.

If

not

the

service

and

Before

starting

is

clear

of

moving

during

test

Multimeters

circuits

and

are

Always

AC

converters DC

proper

often

mixed

disconnect

testing.

knowledge

can

has

to

determine

the

alternator

battery,

the problem

not

with.the

the

engine

parts!

Keep

procedures.

and

DC

Circuits:

together

shore

power

and

shut

down

No

AC

tests

of

AC

circuits.

become

cooled

if

a problem

is

out.

is

not discharged

is

charging

alternator.

make

away

in

marine

cords,

generators

should

voltage

DC

cir-

on

the

very

down.

If

it

bad,

the

is

in

certain

from

be

reg-

is

it

the

is

Testing

1.

2.

3.

the

Alternator

Start

the Engine.

After a

The voltage should

If

a. Turn off the

b.

c.

d.

few

minutes of running measure

tery

voltage at

set on

DC

the alternator is working. Tum

TESTING

BATTERY -ALTERNATOR

{ENGINE

RED

B+

OUTPUT

To

starter

the starting battery voltage remains around after the engine problem exists with

Ensure that the battery terminals and

connections

A

charging

switch

If

a battery selector switch

ensure that it

Turn

Check the battery voltage.

condition the reading should

the

battery terminals

volts.

be

THE

STARTING

RUNNING)

motor

is

started and run

the

engine. are

tight and clean.

CAUTION:

when

on

the ignition switch,

circuit,

the

is

on

To

never

engine

the correct setting.

increasing

alternator or

Inspect all wiring and connections.

avoid

damage

shut

is

but

If

cmJ

0

TESTING ALTERNATOR {IGNITION

THE

VOLTAGE

ON -ENGINE

COM

OFF)

the

starting

using

a multi-meter

toward to

off

14

Step

4.

MULTIMETER

for a few

the

charging circuit.

the

to

the

engine

volts.

If

12

volts

minutes, a

engine ground

battery

running!

in the charging circuit,

do

not

start

the

engine.

your

battery

is

in

good

be

12

to

13

volts.

MULTIMffiR

bat-

it

is,

37

ALTERNATOR

TESTING

e. Now check the voltage between the alternator output

terminal (B+) and ground. voltage at the alternator should be the same as the tery, or

if

an isolator is in the circuit the alternator voltage will be zero. between the alternator connections - look for an opening in the charging

cuit

STARTING

TESTING BATTERY • ALTERNATOR (ENGINE

If

BAmRY

ALTERNATOR

11IE

STARTING

RUNNING}

If

the circuit is good, the

bat-

not, a problem exists in the circuit

and

the battery. Check all the

cir-

MULTIMETER

..c::~--1

£ Start the engine again. Check the voltage between the

alternator output and ground. The voltage reading for a properly operating alternator

If

should be between 13.5 and 14.5 volts. tor is overable service shop.

NOTE:

a voltmeter

present

showed only battery voltage

If

12

the

Before

at

volts

wiring

or

under-charging, have it repaired at a reli-

removing

to

ensure

the

EXC terminal

are

not present at

looking

the alternator for

that

12

if

at

the

for breaks

volts DC excitation is

the

EXC

and

your alterna-

repair,

use

previous test

B output

poor connections.

terminal.

terminal,

trace

ENGINE GROUND

Alternator

4. Check the voltage should have a voltage between engine is running. battery charging circuit. Troubleshoot the service chargina circuit by checking the wiring and connections, the

MULTIMETER

A

charging

Megger}.

ALTERNATOR

When

and inspected. The housing can and the alternator terminal studs should be cleaned with a wire brush. Make certain those studs are tight. Also clean the

wiring connections that connect Tum

the rotor pulley by hand. It should tum smoothly.

Depending on when the alternator was last serviced, the

brushes

send

it

is

Working

of

the service battery. This battery

13

and

14

volts when the

If

not, there is a problem in the service

ba~ery

sole~oid,

CAUTION:

isolator, battery switch and the battery itself.

CKQ)

0

COM

SERVICE

BAmRY

circuit

You

can

When

perfonning

do

not

damage

TESnNG BATTERY

use a high

the

alternator

THE

tests

on

voltage

(ENGINE

the

tester

diodes.

SERVICE

RUNNING)

altemator

(i.e.

INSPECTION

rebuilding the engine. The alternator should be cleaned

be

wiped off with a solvent

to

the wiring harness.

may

need replacing.

to a service shop for testing and overhaul.

If

the alternator is at all suspect,

38

STARTER

MOTOR

TESTING

DESCRIPTION

The

starter can be roughly divided into the following sections:

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an arma-

ture

torque, preventing

• A switch section (solenoid) which is operated when actuating the overrunning clutch through a lever and which supplies load current to the motor.

The starter is a new type, small, light-weight and is called a

high-speed internal-reduction starter. The pinion shaft is separate from the ion shaft. A reduction shaft and a pinion shaft. exposed outside the starter so that the pinion smoothly without becoming fouled with dust and grease. The motor shaft is supported at both ends on ball bearings. The lever mechanism, switch and overrunning clutch inner circuit are identical to conventional ones.

ADJUSTMENT

If

any abnormality is found by the following tests, the starter

should be disassembled and repaired.

Pinion

1.

Connect a battery (12V) between the starter and the starter body, and the pinion drive should rotate out and stop.

A

CAUTION:

seconds

2.

Lightly push the pinion back and measure the return stroke (called pinion gap).

If

the pinion gap is not within the standard range, (0.5 to

3.

2.0 mm), adjust it of

shims on the solenoid.

number

motor

AND

Gap

Inspection

Never

continuously.

of

shims increases.

motor

overrun after starting.

shaft; the pinion slides only on the pin-

gear

is installed between the motor

The

pinion sliding part is not

may

slide

REPAIR

terminalS

apply

by

increasing

battery

The

voltage

or

gap is decreased as the

for

over

10

decreasing the number

No-Load

1.

2.

Test

Connect as illustrated.

When the starter must run smoothly (at the current semble

the ammeter, voltmeter, and battery

the switch is closed, the pinion must protrude and

3000 rpm

or

starter speed is

the starter and repair it.

out

of

specification, disas-

or

e

~----------------------1

A

CAUTION:

tighten type

staffer

that

of a starter in

contact

Use

every

tenninal

which

direct-drive

rotation

with

at

the

thick

wires

securely.

makes a rotating

type

starter.

the

pinion

gear

SOLENOID

Perform satisfactory, replace the solenoid assembly.

1.

the

following tests.

Inspect the solenoid for continuity between terminals (+)and(-)

and

M between terminals between terminals the body.

and between terminals

the body. There should

If

any test result is not

S and M. Continuity will S and the body and terminal M and

~TnRY

as

much

as

This

is a solenoid

sound

When

detecting

tip,

be

careful

when

it

protrudes.

Sand

the body and

be

no continuity found

possible

louder

not

to

the starter

more).

than

to

be

found

If

and

shift·

come

PINION

GAP

39

MULTIMETER

NOTE:

Disconnect

2.

Connect and M for (-). Have a switch in the + lead and close it. The

pinion drive should extend fully out.

A

CAUTION:

than

10

seconds

the

wire

from terminal

a battery to the solenoid's terminal S for ( +)

Do

not

apply

battery

when

testing

the

M.

current

solenoid.

for

more

STARTER

MOTOR

REPAIR

STARTER

INSPECTION

Solenoid

Inspect the solenoid for continuity between terminals S and M and between tenninals S and body. No continuity should be

found between S and M. Continuity should be found

between S and the body and M and the body.

CONTINUITY

Inspecting

1.

Check the armature with a growler tester. circuited, replace the armature. Also check for insulation

between insulated, replace the armature.

The

the commutator and its shaft.

CHECK

Armature

Hit's

short

If

poorly

ARMATURE

CHECK

"-

Brush

and

Brush

1.

Check the brushes. replace the brushes.

Holder

Inspection

If

worn out beyond the service

BRUSHES

Brush

Height Standard Limit

2.

Check the brush spring tension. A weak or defective

spring will cause excessive brush wear; replace the

springs

17

mm

6

mm

if

suspect.

(0.669

(0.2363

in) in)

limit,

2.

Measure the commutator O.D. and the depth Repair or replace it check the commutator outside surface for dirtiness and roughness. crocus cloth.

COMMUTATOR

If

D.O.

if

the service limit is exceeded. Also

rough, polish the commutator with fine

Commutator

Standard Limit

of

Outside

1.523

-0.039

undercut.

Diameter

in

(38.7

in

(·1.0

mm)

BRUSH

HOLDER

ASSEMBLY~

3. Check for insulation between the positive brush holder

and holder base. assembly. Also check the brush holders for proper staking.

C>..l,;)"""'~'

If

poorly insulated, replace the holder

Engines & Generators

40

STARTER

MOTOR

TESTING

AITRACTION

3.

HOLDING

DISASSEMBLY

1.

2. Loosen the two screws fastening the solenoid. Remove

3. Remove the two long through bolts and two screws

4. With the brushes pulled away from the armature,

5. Remove the cover, pry the snap ring out, and remove

6.

TEST

Holding

terminal the pinion fully. The pinion must remain at that position

even

test.

With a battery connected to the solenoid

S ( +) and to the starter body, manually pull out

when

released from holding with your hand.

TEST

(Typical)

Disconnect the wire from the solenoid terminal M (-).

the solenoid assembly.

fastening the brush holder. Remove the rear bracket.

remove the yoke and brush holder assembly. Then pull the armature out.

the washer.

Unsc~w

same time, the washers for the pinion shaft end play

adjustment will come off.

the bolts and remove the center bracket. At the

4. Return

7. Pull out the reduction gear lever and lever spring from the

8.

9.

test:

With a battery connected

to

minal M (-) and pinion fully. The pinion must return to its original position when released from holding by hand.

front bracket. On the pinion side, pry the snap ring out, and pull out the

pinion and pinion shaft. At

each end a bearing puller. It is impossible ing press-fitted in the front bracket. worn off, replace the front bracket assembly.

the starter body, manually pull out the

RETURN

of

the arfnature, remove the ball bearing with

TEST

to

the solenoid ter-

to

replace the ball bear-

If

that bearing has

STARTER

PINION

MOTOR

41

""-.ADJUSTING

SHIMS

NOTE:

Inspect,

(if

necessary) commutator, etc.

See

the

clean

replace

solenoid,

following

arul

the

brush,

armature,

pages.

STARTER

MOTOR

REPAIR

Field

Coil

Inspection

1.

Check for insulation between one end (brush) coil and yoke.

2.

Check for continuity between both ends (brushes) of

the coil

3. Check the poles and coil for tightness.

FIW

COIL

TEST

STARTER

ADJUSTMENT

AND

REASSEMBLY

of

the

Greasing.

2. apply grease

a. Armature shaft gear and reduction gear. b. All bearings. c. Bearing shaft washers and snap rings. d. Bearing sleeves.

e. Pinion.

f. Sliding portion

A

CAUTION:.

tenninals,

3.

After reassembly, check by conducting a no-load

test again.

SNAP

Whenever the starter has been overhauled,

to

the following parts:

of

lever.

Never

smear

the

starter

brushes,

RING

or

commutator

GEAR

with

fitting

grease.

surface,

A

CAUTION:

starter

old

paint. depends cient

size

and

fully

Reassemble the starter assembly disassembly, making sure

1.

Pinion

to

gap) washer between the center bracket and the reduction gear.

a. Fit the pinion shaft, reduction gear washer and snap

ring to the center bracket.

b. Measure end play by moving the pinion shaft in the

axial direction. increase the number

Before

installing.

flange

and

mounting

and

rust.

Starter

on

the quality of

and

grade

between

tighten

shaft end play adjustment. Set the end play (thrust

between 0.5 to 2 mrn by inserting an adjusting

to

the

tenninal.

of

If

the end play exceeds 0.5 mm,

of

thoroughly

surfaces.

perfonnance

the

wiring.

the

battery

in

the reverse order

the following:

adjusting washers inserted.

clean

remove

largely

Use

wire

and

all oil,

of suffi-

starter

the

of

PINION

SHAFT

END

PLAY

l""fiV'fWESTERBEKE

Engines & Generators

42

TRANSMISSION

For Transmission Service and Maintenance, refer to your Transmission manual or WESTERBEKES 12C/12D Operators Manual. To re-build a transmission, contact an

authorized Transmission Service Center.

HURTWZF Marine Transmission

ZF

Industries Marine US Headquarters

SW

42"d

3131 Fort Lauderdale, Tel: 954-581-4040 Website: www.zf-marine.com

BW/JS

Westerbeke Corporation

150 John Hancock Road Taunton, Tel: 508-823-7677 Website: www. westerbeke.com

NOTE:

pressure test the oil cooler and replace the coolant hoses. Inspect and lubricate the gear shift linkage

change the transmission fluid.

Street

FL

33312

Marine Transmissions

MA

02780

If

the transmission is not being re-built, it should be visually inspected. Flush out and

and

the propeller shaft coupling. Clean and repaint the transmission and

PRM Marine Transmissions

Newage Transmission Limited Barlow Road Coventry CV2 2LD England Tel: +44 (0) 24 7661 1845 Website: www.newage-pnn.co.uk

43

12C

AND

120

TWO

ENGINE

SPECIFICATIONS

Engine

Type

Governor Valve

Mechanism Combustion Bore & Stroke Piston Firing Direction Maximum Compression Compression Valve

Valve (engine

Dimensions

Inclination

Dry Fuel

Idle Cruise

Starting Battery Starting Starter DC Cold Alternator Regulator

Chamber

Displacement

Order

of

Rotation

Torque

Seat

Angle

Clearance

cold)

Weight

Consumption

Speed

.Battery

Capacity

Aid

Motor

No-Load

Current

Cranking

SPECIFICATIONS

Diesel, cooled, 12

Mechanical, Overhead Swirl

2.99 x 2.76

38.75

1 - 2

Clockwise,

30 Ratio Pressure

23:1

398

Intake

Exhaust

Intake

Exhaust

Height:

Width:

Length:

Continuous

Temporary

228

0.8

at

1000-1200

2000 -2500

ELECTRICAL

12

600 -800

Glow

12

100

Current

125

12

Internal

four-cycle,

vertical

Hp @ 3000

chamber

cubic

when

lb-ft

(4.15

psi

(28

45•

0.010

19.75

17.22 25

inches

25•

lbs

(1

03.4

us

gph

3000

rpm

Volt,

(-)

CCA

plugs,

Volt,

1.2

Amps

at

Amps

at

Volt

DC,

50

regulator,

two-cylinder,

in-line.

rpm

maximum

centrifugal

inches

kg/em')

inches

inches ( 437

14

(3.0

(approximate) rpm rpm

type

(76 x 70

(0.635

viewed

kg-m)

at

(0.25)

inches

(501.65)

(635)

• (not

to

kgs)

lph)

weight

from

2200

280

(0.25)

.3)

exceed

SYSTEM

negative

ground

(Cold

Cranking

sheathed

type

Kw,

solenoid,

actuator

11.5

VoiJs

(3000

10

Volts

(805

Amps

built

into

fresh

type

mm)

liters)

the

front.

rpm

30

min.)

Amps)

rpm,

min)

alternator

water-

shift

min)

General

Operating (engine

Oil

Oil (Pn.#036920)

Sump (including

General Fuel

Injection

Engine (Spill

Injection Nozzle Air Air

(engine Lift

(~N

General

Operating Fresh

(PN# Raw

(measured discharge elbow)

System (Fresh

JS PRM

BW7

Oil

hot)

Grade

Filter

Capacity

filter)

Pump

Timing

Timing)

Pressure

cleaner Flow

combustion)

Pump

#039275)

Temperature

Water

037015)

Water

033636)

Water

into

Capacity

Water)

Model

80

Pressure

Pump

Flow before

ZF

Propeller

Rotation

Propeller

Shaft

LUBRICATION

Pressure with

external

15-45

API

Specification

SAE

15W-40

Full

flow,

3.0

U.S.

FUEL

Open

flow, No.2 In-line 19• ± 1•

Static 1991

psi Th

rattle Metal 34

cfm

12

voltDC

COOLING

Fresh controlled

170

-190• F (77-

Centrifugal

Positive mechanically-driven

11.1

US

exhaust

2.9

US

TRANSMISSIONS

2.05:1

reduction

2.0:1

reduction

2.05:1

reduction

2.04:1

reduction

Right

hand

turning -Standard

3/4"

diameter

SYSTEM

type

by

Trochoid

pressure

psi

(1.0-3.1

CF,

(all

season).

paper

element,

qts

(2.8

liters)

SYSTEM

self-bleeding

diesel

(cetane

plunger

type

BTDC

(140

kg/cm2)

type

screen

type-cleanable

(0.96

cmm)

lift

capacity

SYSTEM

water-cooled

with

heat

type,

metal

displacement,

gmp

(421pm)

qts

(2.71iters)

(See

Transmission

(minimum)

pump,

valve

relie·f

kg/em')

CF-4,

CG-4,

spin

on

rating

of

45

(BOSCH)

of

5'

(1.5

block,

thermostatically-

exchanger

sa·

C)

impeller,

rubber

at

3000

pages)

Transmission

gear-driven,

CH-4

or

higher)

mm)

wet

belt-driven

impeller,

rpm-approx.

Cl-4

44

,------

1

SEE

NOTE

2

I I

1~1

I

.J

+iu:D_

~-==-

ll.A.I.I.EJl..l

WIRING

#39144

5I

DIAGRAM

114

18

f'NK

,--

•10

RED

1--------------------------------J

<

- -

ADMIRAL PANEL

I

CAPTAIN

~

-

PANEL

KEYSWJTCH

L--------++--:=:==.-':~{~~~

I

1 I I B B L

I

___________________

--

~

__!

~-~

BL

~

-------------

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START

SOL

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I

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~

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~~·:

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BAT

,._

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IGN

PREHEAT

-

SOL

1

STARHR

M

-

Al

--

T[RNATOR

t

s~N~ER

w.r

SENDER

w.

SWITCH

\ l

ADMIRAL PANEL

TACHOMEHR

WIRING

- -

LIFT

PUMP

p

CURRENT T

11-4[111

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SOL

·-

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j 12c zoe -·

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I

THIS

STARTER.

SHUT

ENGINE

2

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DISCONNECT WITH A CONTINUOUS RATING SWITCH

J.

THE THE

4

1114LT.

!STARTING

lr

USING

=

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46

12C/12D

TWO

SERVICE

DATA I STANDARDS

AND

LIMITS

Component

COMPRESSION I TIMING

Cylinder

Compression

·Pressure Difference

Cylinders Fuel Injection

on Spill

Injector

CYLINDER

Bottom

Valve

(Intake & Exhaust)

Valve

(Intake & Exhaust)

Valve

(Intake & Exhaust)

Valve

Valve (Intake & Exhaust)

between

(max)

Injection

liming

compression

liming

(static)

Spray

HEAD

Surface

Guide

1.0

Seat

Angle

Seat

Width

Seat

Sinkage

Clearance

...........

...........................

Order

-12C/D

at

BTDC

stroke

.....................

Pressure

..............

Distortion

................................

...................................

..................

.....................................................

...........................

VAlVES

Valve

Head

Diameter

(lntake)

Valve

Head

Diameter

(Exhaust)

Overall

Length

...................................

Stem

O.D

..........................................

Stem

to

Guide

Clearance

Stem

to

Guide

Clearance

Valve

Contact

Width

................................. 3 ..................................

Valve

Face

Angle

....................................

Valve

Head

(Margin

·,.

Valve

Head

(from

cylinder

Valve

Spring Free Preload/Installed

........................................

Squareness

TIMING

Thickness

Width)

Sinkage

Length

GEARS

......................

........................

head

to

bottom

..............................

Length

..............................................

Specified

Value I Standard

inches(mm) inches(mm)

398.16

psi

at

280

rpm

(28

kg/em')

35.55

(2.5

kg/em')

Two

.........

1-

2

19° ± 1.5

1990

psi±

(140 ± 10.0

........

within

0.002

0.260

(6.6)

.45°

0.051 -0.071

O.o10

(0.25)

.........

1.051

(26.7)

......

0.972

(24.7)

3.701

(94)

0.260

(6.6)

(Intake)

.............................................

(Exhaust)

..........................................

.45°

0.039

(1.0)

O.o19

1.595 ( 40.5) lbs/1.398

kg/35.5mm)

(14.84

kg/28mm)

2°

(0.5)

face)

....

13.095 (5.94

32.7161bs/1.102

................

psi

............................

140.0

Kg/cm2)

(0.05)

..................

(1.3 -1.8)

......................................

............

-0.039

Cold

..............

:·

.........

........................

......................

in

......................

in

......................

Repair

355.5

(25

kg/em')

19°

0.004

(-1mm)

1.051

0.972

1.3 -1.8

0.019

0.591

1.54 7 (39.3)

-15%

Limit

---

psi

± 2

(0.1)

Service

(26.7) (24.7)

(0.5)

(1.5)

3°

Limit

Component

ROCKER

CYLINDER

ARM

Interior

Diameter

Rocker

Arm

to

BlOCK

Camshaft

Hole

Front...

.........................................

No.2

..........................................

No. 3 ..........................................

Rear

............................................

BORE

Specified

...............................

Shaft

Clearance

Diameter

.

Bore

Size

........................................

Oversize

Finish

ToleranceO -0.001 Cylindricity Gasket

Surface

PISTON

Type Materiai Outside Clearance Oversize

Protrusion Block

PISTON

Type

Outside

................................................

Piston Piston

Rod Press-fit

PISTON

Number Compression

Ring

............................ : ...

Fitting/

...........................

Distortion

.................................................

.........................................

Diameter

(Skirt

End)

to

Cylinder

......

0.0028-

...... : .................................

From

Cylinder

Top

Surface

(See

..........................................

Diameter.

to

Piston

to

Connecting

Clearance

Load

.............

RINGS

of

Rings

No. 1 ......................

No. 2 ............................................

Oil

Compression Compression

Oil

(2)

(1)

......................

Sid~

Clearance

...............................

Gap

(All

Rings)

................

note

on

..................

Clearance

2204.6 ± 1102.31bs

(See

note

Chrome

No. 1 ......................................................................

No. 2 ......

.0.001 -0.002

...........

Value I Standard

lnches(mm)

0.047

(12)

................................................

1.654

(42) , ..

Ball

1.339

(34)

1.299

(33)

1.299

(33)

2.992

(76mm)

(0-0.03)

within

0.0004

within

0.0020

Solid

Type

Aiuminum

..........

2.992

(76)

0.0079(0.071 -0.084)

0.01,

0.02.

(0.25,

0.50,

0.035

(0.9)

Semi-floating

0.709

(18)

0.825

on

0.002 -0.004

0.006-

Early

(21)

Late

.................................................

plated,

semi-keystone

Tapered

plated

with

0.016

Bearing

....................

for

each

oversize (0.01) (0.05)

................

Alloy

0.03

0.75)

Type

Models

(1000 ± 500

Coil

expander

(0.05 -0.09) (0.03 -0.07)

(0.15-

0.40)

........

kg)

type

.........

..........

................

Repair

limit

inches(mm)

-0.008

(-0.2)

Hole

+0.008(+0.2)

0.004

(0.1)

0.001

(0.3)

0.003

(0.08)

0.3

.0.008

(0.2)

0.008

(0.2)

(1.5)

Backlash

between

gears

in

Mesh

0.0003-

0.0005(0.01 -0.14)

Idler

Gear

between

Bushing -Clearance

Bushing

and

Shaft

0.001

-0

01

0(0.03 -0.07)

..........

0.012(0.3)

0.0078(0.2)

Engines & Generators

47

12C/12D

TWO

SERVICE

DATA I STANDARDS

AND

LIMITS

Component

--------------------------

CONNECTING

Type Oil

Clearance

Under

____________________

CONNECTING

Type

Bend Big

End

ROD

BEARING

..................................

....................

Size

...............................

ROD

........................................

and

Twist..

........................

Thrust

Clearance

CRANKSHAFT

Type

.......................................

Bend

........................................

End

Play

.............................

Journal

0.0

.......................................

O.D

..............................................

Bearing

Oil

Clearance

Under

Size

Rnishing

Journal

Under

Size

....................

Size

....................

MAIN

0.25

0.50

Under

0.25

0.50

BEARING

Specified

Aluminum

0.0009-

0.01,

.Forged

Within

....

0.004 -0.014

Fully

.Within

0.002-

...................

1.6817-

1.6823

1.6719-

1.6724

1.5636-

1.5537

-1.5543

Value I Standard

inches(mm) inches(mm)

with

Black

Metal

0.0020(0.022-

0.02

(0.25,

0.50)

____c

____

____c

1-Beam

0.002

(0.05)

(0.1 -0.35)

Counterbalanced

0.001

(0.03)

0.007

(0.05-

0.175)

1.693

(43)

......................

1.575

(40)

......................

(0.022-

0.052)

(42.715-

(42.465-

1.5642

(39.715(39.465-

0.052)

____

42.730)

42.480)

39.730)

39.480)

Repair

...... 0 006

~---------

-0.006

limit

----~

(0.15)

(-0.15) (-0.15)

Component

INJECTION

Driving Front Lobe Major

PUMP

Method Journai. Height..

Cam

Diameter

......................

........ ; ..........................

---------·~

Specified

CAMSHAFT

.................................

Ball

Bearing

.........................

TAPPET

Outside

Diameter

...............................

Tappet

to

Cylinder

Block

Clearance

PUSH

ROD

Bend

........................................

Fuel

Solenoid

Cut-Off

STARTER

Depth

Height Spring Commutator Pinion

NOT£:

MOTOR

of

Brush

Undercut..

of

Brush

.................................

Pressure

........................

0.0

Shaft

End

T'ae

wrist pin used with the piston and connecting rods

.............................

Play

.Within

Stroke

............

...............

43

......................

has changed. The diameter

from 18mm

Refer

to

21

mm.

to

WESTERBEKES Parts Bulletin #2010-2.

Value I Standard

inches(mm)

Gear

Drive

(Front & Rear)

1.18

(30.0)

........................

1.18

(30)

..............................

0.75

(1

9)

..........................................

0.0118

(0.3)

(10 ± 0.5)

0.019

(0.5)

........................

0.669

(17)

..........................

Lb/in'

(3

Kg/em')

1.523

(38.7)

......................

0.014

(0.5)

of

the wrist pin has been changed

Repair

inches(mm)

0.027 (-0.7)

0.006

0.008

0.236

-0.039

limit

(0.7)

(0.15)

(0.2)

(6)

(-1.0)

Type

..................................

Oil

Clearance

Under

Size

...............................

VAlVE

CAMSHAFT

Driving

Method

Front

Journal

to

Block Lobe

Major (Intake

Oil

Cylinder

Hole

Clearance

Height..

Diameter

and

Exhaust)

Clearance

Aluminum

.............................

.................................

...................................

...................................................................

..................................

of

Cam

.................

..............................................................................

No.

0.01,

with

2:

Flanged

0.02

Gear

Ball

1.078

Black

Metal

(0.25,

Drive

Bearing

(27.37) (27.37)

Metal

0.50)

......................

0.006

0.039

0.039(

0.006

(0.15)

(1.0)

-1.0)

(0.15)

48

NOTE:

STANDARD

Unless

stated otherwise for a specific assembly,

HARDWARE

use

the

following torque values

TORQUES

when

tightening standard

hardware.

Grade

6mm 8mm 1

Omm

1

Omm 12mm 12mm 12mm 13mm 14mm 14mm 16mm 16mm

Grade

6mm

8mm

·1

Omm

10mm 12mm 12mm

12mm

4

bolt bolt

6T

head/nut

head/nut bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt

bolt bolt

bolt

bolt bolt bolt bolt

head/nut head/nut head/nut head/nut

head/nut

head/nut head/nut head/nut head/nut

head/nut head/nut

head/nut head/nut head/nut head/nut head/nut

Pilch

1.25

1.75

1.25

1.75

1

1.5 (ISO)

1.5

1.5 2

1

1.25

1.5 (ISO)

1.5

I

b-It

2.9-5.1

7.2-11.6

13.7-22.4

13.0-21.7

25.3-39.8

21.7-36.2

32.5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

51.4-76.7

4.3-6.5

10.8-15.9

21.7-32.5

19.5-30.4

36.2-57.9

36.2-50.6

34.7-49.2

kg-m

0.4-0.7

1.0-1.6

1.9-3.1

1.8-3.0

3.5-5.5

3.0-5.0

4.5-7.0

5.0-8.0

4.7-7.7

7.5-11.0

7.1-10.6

0.6-0.9

1.5-2.2

3.0-4.5

2.7-4.2

5.0-8.0

5.0-7.0

4.8-6.8

Grade

7T,

8T

6mm

bolt

8mm

bolt

10mm

bolt

10mm

bolt

12mm

bolt

12mm

bolt

12mm

bolt

13mm

bolt

14mm

bolt

14mm

bolt

16mm

bolt

16mm

bolt

Grade 5 Cap

1/4

UNC

1/4

UNF

5/16

UNC

5116

UNF

318

UNC

318

UNF

7/16

UNC

7/16

UNF

112

UNC

112

UNF

and

8.8 head/nut head/nut

head/nut head/nut head/nut head/nut

head/nut

heail/nut head/nut head/nut head/nut

Screw

Pitch

1.25

1.75

1

1.5 (ISO)

1.5

2

1.5

2

I

b-It

5.8-8.7

14.5-21.7

28.9-39.8

26.8-37.6

54.2-75.9

50.6-65.1

43.4-61.5

57.9-86.8

72.3-108.5

68.7-101.3

108.5-166.4

101.3-159.1

9-11 11-13 18-20 21-23 28-33 30-35 44-49 50-55 68-73 73-80

kg-m

0.8-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.5-10.5

7.0-9.0

6.0-8.5

8.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

1.2-1.5

1.5-1.8

2.5-2.8

2.9-3.2

3.7-4.6

4.1-4.8

6.1-6.8

6.9-7.6

9.4-10.1

10.1-11.1

BOLT

DIAMETER

M6

MB M10 M12 M14

PARTS

REQUIRING

Taper

Screw

Taper

Screw

Taper

Screw

Water

Drain

Oil

Pressure

Side

Seal

Bearing

Cap

112"

1/4" 1/8"

Plug

Switch

No.

1

SEAlANT

Thread Thread Thread Thread Thread

Periphery

Contact

portion portion portion portion portion

(Main

surface

BOLT

HEAD

MARK

4 7

0.3-0.5 0.8-1.0

1.0-1.3

1.8-2.5

3.0-4.2 5.5-7.5 9.5-12.0

5.0-7.0

SURFACES

(where (Gear (Cylinder (Cylinder {Cylinder {Cylinder

Bearing

with

to

mount

Gase)

Block Head Block Block Caps

Cylinder

REQUIRING

sealant

right

rear

right right

No. 1 and

Block

1.5-2.2 2.5-3.5

3.0-4.2 5.0-7.0

8.0-11.0

SEAlANT

coated

parts)

side,

pump

cover)

surface)

side,

rear

middle

side

surface) No.

5)

49

portion)

10

1.0-1.3

16.0-

19.0

SEALANT Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Permatex

#6B

Permatex

#68

REMOTE

OIL

FILTER

(OPTIONAL)

PN:040078

REMOTE

INSTALLATION

This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as

an engine room bulkhead.

NOTE:

Refer

to

instructions

APPLY A THIN INSTALLING TIGHTEN

AN

CONTACTS

THE

ENGINE

on

removing

COAT

OF

THIS

KIT.

ADDITIONAL3/4

BASE.

CLEAN

THREAD

TURN

OIL

the

OIL THE

TO

CHANGE

oil

filter.

THE

O·RING

KIT

ON,

THEN

AFTER

THE

in

WHEN

HAND

D-RING

this

manual for

OIL

FILTER

To

install, simply remove the engine oil filter

SET

and

thread on

WESTERBEKE's remote oil filter kit as shown. Always

install this kit with the oil filter facing down

as illustrated.

Contact your WESTERBEKE dealer for more information

NOTE:

Westerbeke

incorrect installation

A

CAUTION:

rectly.

If

pass

valve

from

reaching

failure.

If

immediately

the

in

there

is

not responsible for engine failure

of

the

..

oil

the

and

It

Is

flows

filter

engine

is

no

check

Remote

vital

in

the

assembly

oil

pressure

the

Oil

to

Install

reverse

will

causing

hose

Filter.

the

direction,

prevent

an

internal

reading,

connections.

FASTEN

(SCREWS

oil

lines

the

engine

shutdown

SECURELY

TO A BULKHEAD

ARE

OWNER

due

cor-

the

by-

oil

SUPPLIED)

to

NOTE

THE

''IN"

ON

THE

ADAPTER REMOVED WILL

BE

RECONNECTED

AND

"OUT"

WHEN

FOR

INSTALLATION

MARKiNGS

THE

HOSES

ARE

SO

THEY

CORRECTLY

THE

IN

CONNECTION

MUST

ATTACH CONNECTION REMOTE

OIL

FILTER.

THEOUT MUST

ATTACH CONNECTION REMOTE

OIL

AT

FILTER.

TO

THE

ATTHE

TO

THE

HOSE

OUT

HOSE IN

APPLY A THIN

GASKET

WHEN CONTACTS 3/4

THE

TURN,

COAT

OF

CLEAN

INSTALLING.

BASE,

TIGHTEN

OIL

AFTER

IT

AN

TO

THE

FILTER

THE

FILTER

ADDITIONAL

50

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

METRIC

(mm)

x

.0394

(m)

x

3.281

=

Feet

(km)

x

.0621

CONVERSION

=

Inches

=

Miles

DATA

VOLUME

Cubic

Inches

(in Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints Quarts Gallons (IMP Quarts Gallons

Ounces

Pints

(US

Quarts

Gallons

x

pt)

(US

(IMP

29.573

qt)

MASS-WEIGHT

Ounces Pounds

(oz) (lb)

x

28.35

x

.454

PRESSURE

Pounds Inches Inches Inches Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

3

x

)

(IMP

x

.473

x

gal)

=

In

(psi)

(Hg)

(Hg) (H20) (H20)

(H20)

16.387

pt)

=

x

.568

qt)

x

1.137

gal)

x

qt)

x

1.201

gal)

x

=

Milliliters

=

Liters(L)

.946

=

Liters

x

3.785

=Grams

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

Cubic

Centim~ters

=Liters

4.546

1.201

=Liters

(g)

=

(L)

=

Liters

=

Liters

=US

Quarts

=US

Gallons

x

.034

x

2.113

(L)

x

1.057

(L)

x

.035

=Ounces

(kg)

x

2.205

=

Kilopascals

=

psi

x

2.036

=

Kilopascals

=

Inches

=

psi

x

27.684

Kilopascals

x

1.76

(L)

x.88

(L)

=

Ounces =

Pints

=

.264

=

(kPa)

=

of

Mercury

(kPa)

x

.061

=

IMP

=

x

.22

(US

qt)

(US

Quarts =Gallons

Pounds

x

Hg

(kPa)

=

H20

x

4.026

IMP

=

IMP

x

gal)

.145

x

.2961

x

13.783

=in

pt

qt

.833

x

3

gal

=

.833

=psi

=

H20

IMP

=

Hg =

H20

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Kilometers Miles Kilometers

Per

(Hp)

Hour

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree Degree

Fahrenheit Celsius

0

(

(in-lb)

(ft-lb)

x

1.609

x

.745

(MPG) (Km/L)

US

(MPG)

(Km/L)

(°F) = (°C

C}

=

(°F

x

.113

x

1.356

=Newton

=

Kilometers

=Kilowatts

x

.354

=

x

2.352

x

.425

x

2.352

X

1.8) + 32

-

32) x .56

=

Newton

(Kw)

x

1.34

Kilometers

=

IMP

MPG

=

Kilometers

=

US

MPG

Meters

Per

Hour

=MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-lb

=

ft-lb

=MPH

51

I~?

i·ii#;l

=1#.1Si

6/2012-1164

Westerbeke 12C-TWO, 120D-TWO Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual