Westerbeke 65A-FOUR, 26.0 EDER, 33 EDE, 28.5 EDE, 25.5KW EDE Service Manual

..,,'

"

}i

";

SERVICE

MANUAL

65A-FOUR MARINE

.,,--.,26.0

AND

-NET

.

GENERATORS

3,28.5

ENGINE

20.0KW

MOBILE/INDUSTRIAL

and

25.5KW

'

EDER

EDE

D-NET

~

.,F

,:IL

ARINE

PUBLICATION #053017

SECOND

GENERATORS

EDITION

APRIL

2009

WESTERBEKE

MYLES

WEBSITE:

CORPORATION.

STANDISH

INDUSTRIAL

WWW.WESTERBEKE.COM

150

JOHN

PARK'

HANCOCK

TAUNTON

MA

ROAD

02780

CALIFORNIA

Exhaust gasoline its

constituents)

the

State cancer, reproductive

Exhaust colorless

gasses

gas.

unconsciousness exposure

can

PROPOSITION

WARNING

gas

from

engines

of

California

birth

defects, harm.

contain

carbon

and

include:

-Dizziness

-Nausea.

-Headache

-

Weakness

IF

YOU

GET

OUT seek until

and

OR

ANYONE

INTO medical it

has

been

Sleepiness

THE

attention.

Inspected

65

diesel

and

(and

some

of

are

known

to

cause

and

other

AWARNING:

carbon

Monoxide

death.

ELSE

FRESH

Shut

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

EXPERIENCE

AIR

IMMEOIATELY. down

and

ANY

the

unit

repaired.

an

odorless

and

of

Carbon

in

Temple{;

Twitching

to

Think

OF

THESE

If

and

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

do

not

restart

A

WARNING should generator.

WESTERBEKE MONOXIDE of

your

obtainable

DECAL

be

fixed

to a bulkhead

also

DETECTORS

vessel.

at

They

your

is

provided

by

near

recommends

in

the

living/sleeping

are

inexpensive

local

marine

Engines & Generators

WESTERBEKE

your

engine

installing

CARBON

quarters

and

easily

store.

and

or

SAFETY

INSTRUCTIONS

ImOOUCTION

Read this

safety

numual

carefuily.

Most

accidents

are

caused

by

failure

to

follow

fundamental

rules

and

precau-

tWns.

Know

when

dangerous

condiJions

exist and

take

the

necessary

precautitJns

to

protect yourself, your

personnel,

and your

machinery.

The

following safety

instructWns

are

in

compliance

with

the American Boat and

Yacht

Council

(ABYC)

standards.

PREVENT

ELECTRIC

SHOCK

A

WARNING:

lID

not

touch

AC

eltN:tricaJ

COIIIIIIetIons

willie

tJIJfIiOtlIs

mnning,

01

wilen

connected

to

sholtJ

"...

LetIIaI

milage

Is

PItJSBIIt

at

tIrtJstJ

connections!

•

Do

not

operate this machinery without electrical

enclosures

and

covers

in

place.

• Shut 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

not

COMect

utility shore power

to

vessel's

AC

circuits, except

through

a ship-to-shore double

throw

tIansfer switch. Damage

to

vessel's

AC

generator

may

result if this procedure

is

not

followed.

• Electrical shock results

from

handling a charged

capaci-

tor.

Discharge capacitor

by

shorting terminals

together.

PREVENT

BURNS -HOT

ENGINE

A

WARNING:

lID

not

touch

hot

BOgin.

palls

01

BIhaust

srsItJm

compoOtlnis. A mnning

engine

gets

,."

"",!

•

Always

check the engine coolant

level

at

the

coolant

recovery

tank.

I A

WARNING:

StBam

can

couse

injury

01

death!

• In case of

an

engine overheat,

allow

the engine

to

cool

before touching the engine or checking

the

coolant.

PREVENT

BURNS -FIRE

A

WARNING:

FiltJ

can

caUBB

injury

01

deathl

• Prevent

flash

fires.

Do

not

smoke

or

permit

flames

or

sparks

to

occur near

the

carburetor,

fuel

line,

filter,

fuel

pump,

or

other potential sources of spilled

fuel

or

fuel

vapors.

Use

a suitable container

to

catch

all

fuel

when

removing

the

fuel

line,

carburetor,

or

fuel

filters.

•

Do

not

operate

with

a Coast

Guard

Approved

flame

arrester

removed.

Backfire

can

cause

severe

injury

or

death.

•

Do

not

operate with

the

air cleanerlsilencer

removed.

Backfire

can

cause severe

injury

or

death.

•

Do

not

smoke

or permit

flames

or sparks

to

occur

near

the

fuel

system.

Keep

the compartment and

the

engine/generator clean

and

free

of debris

to

minimize

the

chances

of

fire.

Wipe

up

all

spilled

fuel

and

engine

oil.

•

Be

aware

- diesel

fuel

will

bum.

PREVENT

BURNS -EXPLOSION

A

WARNING:

Explosions

f~m

fuel

vapors

can

couse

Injury

01

d.atIr!

• Follow re-fueling safety instructions.

Keep

the

vessel's

hatches closed

when

fueling.

Open

and ventilate

cabin

after fueling. Check below

for

fumes/vapor

before

run-

ning

the

blower.

Run

the

blower

for

four

minutes

before

starting your

engine.

•

All

fuel

vapors

are

highly

explosive.

Use

extreme

care

when

handling

and

storing

fuels.

Store

fuel

in a well-ven-

tilated area

away

from

spark-producing equipment

and

out of

the

reach

of children.

•

Do

not

fill

the

fuel

tank(s)

while

the engine

is

running.

•

Shut

off

the

fuel

service

valve

at

the

engine

when

servicing

the

fuel

system.

Take

care

in

catching

any

fuel

that

might

spill.

DO

NOT

allow

any

smoking,

open

flames,

or

other

sources

of

fire

near

the

fuel

system

or

engine

when

servic-

ing.

Ensure proper ventilation exists

when

servicing

the

fuel

system.

•

Do

not

alter or

modify

the

fuel

system.

•

Be

sure

all

fuel

supplies

have

a positive shutoff

valve.

•

Be

certain

fuel

line

fittings

are

adequately tightened

and

free

of

leaks.

•

Make

sure a

fire

extinguisher

is

installed

nearby

and

is

properly maintained.

Be

familiar

with

its

proper

use.

Extinguishers rated

ABC

by

the

NFPA

are

appropriate

for

all

applications encountered

in

this

enviromnent.

~

WESTERBEKE

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

STARTING

A

WARNING:

Accidental

starting

can

cause

injury

111

death!

• Disconnect

the

battery cables before

servicIng

the

engine!

generator.

Remove

the

negative

lead

first

and

reconnect

it

last.

•

Make

certain

all

personnel are clear of

the

engine

before

starting.

•

Make

certain

all

covers,

guards,

and

hatches

are

re-

installed before starting

the

engine.

BATTERY

EXPLOSION

A

WARNING:

Battery

explosion

can

cause

injury

at

death!

•

Do

not smoke or

allow

an

open

flame

near

the

battery

being

serviced. Lead acid batteries emit hydrogen,

a.

highly

explosive

gas,

which

can

be

Igmted

by

electrIcal

arcing

or

by

lit tobacco

prodUCts.

Shut off

all

electrIcal

equipment

in

the

vicinity

to

prevent

electrIcal

arcIng

dur-

ing

servicing.

• Never connect the negative (-) battery cable

to

the

posi-

tive (+) connection terminal of

the

starter solenoid.

Do

not

test

the

battery condition

by

shorting

the

terminals

together.

Sparks could ignite battery

gases

or

fuel

vapors.

Ventilate

any

compartment containing batteries

to

prevent

accumulation of explosive

gases.

To

avoid

sparks,

do

not

disturb

the

battery charger connections

while

the

battery

is

being

charged.

•

Avoid

contacting

the

terminals

with

tools,

etc.,

to

prevent

bums

or sparks that could cause

an

explosion.

Remove

wristwatch, rings,

and

any

other jewelry before

handlIng

the

battery.

•

Always

turn

the

battery charger off before disconnecting

the

battery connections.

Remove

the

negatIve

lead

first

and

reconnect

it

last whenservicing

the

battery.

BATTERY

ACID

A

WARNING:

Sulfuric

acid

in

batteries

can

cause

_

injury

or

death!

•

When

servicing

the

battery or checking

the

electrolyte

level,

wear rubber gloves, a rubber apron,

and

eye

protec-

tion.

Batteries

contain

sulfuric

acid

which

is

destructIve.

If

it

comes

in

contact

with

your

skin,

wash

it

off

at

once

with

water.

Acid

may

splash

on

the

skin

or into

the

eyes

inadvertently

when

removing

electrolyte

caps.

TOXIC

EXHAUST

GASES

A

WARNING:

Carbon

monoxide

(CO)

is a deadly

gas!

• Ensure that

the

exhaust system

is

adequate

to

expel

gases

discharged

from

the

engine.

Check

the

exhaust

system

regularly

for

leaks

and

make

sure

the

exhaust

manifold!

water-injected

elbow

is

securely

attached.

• Be

sure

the

unit

and

its

surroundings

are

well

ventilated.

Run

blowers

when

running

the

generator

set

or

engine.

• Don't

run

the

generator set or engine

unless

the

boat

is

equipped

with

a functioning marine carbon

monoxide

detector that complies

with

ABYCA-24.

Consult your

boat

builder or dealer

for

installation of approved detectors.

• For additional information refer

to

ABYC

T-22

(educational information

on

Carbon Monoxide).

A

WARNING:

Carbon

monoxide

(CO)

is

an

Invisible

odorless

gas.

Inhalation

produces

flu-like

symptoms,

nausea

or

death!

•

Do

not

use

copper tubing

in

diesel

exhaust

systems.

Diesel

fumes

can

rapidly

destroy

copper

tubing

in

exhaust

systems.

Exhaust sulfur causes rapid deterioration of copper

tubing

resulting

in

exhaust/water

leakage.

•

Do

not install exhaust outlet

where

exhaust

can

be

drawn

through

portholes,

vents,

or air conditioners. If

the

engine

exhaust

discharge

outlet

is

near

the

waterline,

water

could

enter

the

exhaust

discharge

outlet

and

close

or

restrict

the

flow

of exhaust.

Avoid

overloading

the

craft.

• Although

diesel

engine exhaust

gases

are

not

as

toxic

as

exhaust

fumes

from

gasoline engines, carbon

monOXIde

gas

is

present

in

diesel exhaust

fumes.

Some of

the

symptoms or

signs

of carbon monoxide inhalation or

poisoning

are:

Vomiting

Dizziness

Headache Nausea

AVOID

MOVING

PARTS

Inability

to

think coherently

Throbbing

in

temples Muscular twitching Weakness

and

sleepiness

A

WARNING:

Rotating

parts

can

cause

injury

or

death!

•

Do

not

service

the

engine while

it

is

running.

If

a

situation

arises

in

which

it

is

absolutely necessary

to

make

operat-

ing

adjustments,

use

extreme

care

to

avoid

touching

mov-

ing

parts

and

hot

exhaust

system

components.

-.,y

WESTERBEKE

Engines & Generators

ii

SAFETY

INSTRUCTIONS

• Do not wear loose clothing

or

jewelry when servicing

equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces

or

bracelets that

could

be

caught in moving parts.

• Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective

places at all times.

•

Do

not check fluid levels

or

the drive belt's tension while

the engine

is

operating.

• Stay clear

of

the drive shaft and the transmission coupling

when the engine is running; hair and clothing can easily

be

caught in these rotating parts.

HAZARDOUS

NOISE

A

WARIIIING:

High

nIl.

IBvels

can

cau.

hBaring

/oss1

• Never operate an engine without its muffler installed.

•

Do

not run an engine with the air intake (silencer)

removed.

•

Do

not run engines for long periods with their enclosures

open.

A

WARIIIING:

Do

not

WIlde

In

machlnory

whsn

YIIU

arB

mtmI1IIIt

lIT

physicallt

IncapacltalBd

by

fatiguBI

OPERATORS

MANUAL

Many

of

the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

ENGINE

INSTAllATIONS

Preparations

to

install an engine should begin with a thor-

ough examination

of

the American

Boat

and Yacht Council's

(ABYC) standards. These standards are a combination

of

sources including the USCG and the NFPA. Sections

of

the

ABYC

standards

of

particular interest are:

H-2 Ventilation P-I Exhaust systems P-4 Inboard engines E-9

DC

Electrical systems

All installations must comply with the Federal Code

of

Regulations (FCR).

ABYC,

NFPA

AND

USCG

PUBLICATIONS

FOR

INSTALLING

DIESEL

ENGINES

Read the following ABYC, NFPA and USCG publications

for safety codes and standards. Follow their

recommenda-

tions when installing your engine.

ABYC

(American Boat and Yacht Council)

"Safety Standards for Small Craft" Order

from:

ABYC

15

East 26th Street

New

York,

NY

10010

NFPA

(National Fire Protection Association)

"Fire Protection Standard for Motor Craft" Order

from:

National

Fire

Protection

Association

II

Tracy Drive Avon Industrial Park Avon,

MA

02322

USCG

(United States Coast Guard)

"USCG

33CFR183"

Order from:

U.S. Government Printing Office Washington, D.C. 20404

-..v:

WESJERBEKE

EngInes & Generstors

iii

TABLE

OF

CONTENTS

Testing

for

Overhaul.

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

2

Valves ..........................................................

.41

Engine Compression ...................................... 2 Rocker Arm ................................................ .4 3

Engine

Troubleshooting

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

3 Timing Gear/Crankshaft .............................. 44

General

Description

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

8

Camshaft ..................................................... .45

Cylinder Block ............................................... 8

Idler Gear ................................................... ..46

Half Floating Head Cover ............................. 8

Balancing Shaft .......................................... .47

Cylinder Head ................................................ 8

Piston/Connecting Rod ............................... .48

Piston and Piston Rings ................................. 9 Crankshaft. ................................................... 50

Dynamic Balancer ......................................... 9 Crankpin ......................................................

51

Governor ......................................................

10

Cylinder .......................................................

53

Disassembly

Procedures

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

..

11

Oil Pump ...................................................... 53

Generator .....................................................

11

Servicing

S

·fi

t·

peci

ca

Ions

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

55

Radiator Models ..........................................

II

Engine

Adjustments

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

61

Propulsion Engines ......................................

II

I'

. T' .

nJectton Immg ..........................................

61

Preparation for Disassembly ........................

11

Valve Clearance ........................................... 62

Remove Interior Components ......................

II

Oil Pressure/Oil Change .............................. 63

Remote

Stop/Start Panel ............................

lla

Fuel

System

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

64

Assembly

Procedures

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

.

12

Injectors .......................................................

65

Surface Preparation .....................................

12

Injection Pump ............................................. 65

Gasket Information ......................................

12

Glow Plugs .................................................. 65

Engine

Assembly

Instructions

......

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

13

Raw

Water

Pump

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

66

Heat Exchanger ...........................................

13

Wiring

Diagram

(#52952)

EDE

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

67

Marine Transmissions ..................................

13

Wiring

Diagram

(#54469)

EDER

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

67a

Radiators ......................................................

13

Wiring

Diagram

(#31944)

65A·Four

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

67b

Engine Tuning .............................................

13

Specifications·

65A·Four

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

68

Disassembly/Assembly

(Engine)

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

14

Specifications·

33Kw

EOE

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

68a

Cylinder Head and Valves ...........................

14

Specifications·

28.5Kw

EDER

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

68b

Cylinder Head Gasket .................................

16

Generator

Specifications

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

69

Governor Housing Assembly ......................

18

Torque

Specifications

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

70

Injection Pump .............................................

19

Special

Tools

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

72

Thermostat ...................................................

20

Generator

Information

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

83

Injection Nozzle ........................................... 20

Terminal

Board

Connections

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

84

Fuel Camshaft and Governor Weight.. ........ 23

Electronic

Regulator

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

85

Injection Pump Assembly ............................ 24

Generator

Servicing

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

87

Water Pump/Oil Cooler ............................... 26

Generator

Troubleshooting

(Chart)

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

88

Gear Case ..................................................... 27

EDE

Testing

the

Voltage

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

89

Oil Screw and Strainer ................................ 29

Internal

Wiring

Schematic

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

91

Piston and Connecting Rod ......................... 29

Changing

Hertz

and

Voltage

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

92

Flywheel and Crankshaft.. ...........................

31

AC

Output

Configurations

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

92

Flywheel Housing ........................................ 32

Generator

Parts

Breakdown

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

93

Crankshaft. ................................................... 33

Metric

Equivalent

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

95

Starter

Motor

Service

......

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

34

Metric

Conversion

Chart

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

96

Alternator

Service

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

3 7

Index

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

97

Servicing

(Engine)

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

.40

Cylinder Head ............................................. .40

~

WESTERBEKE

Engines & Generators

1

TESTING

FOR

OVERHAUL

HOW

TO

DETERMINE

ENGINE

OVERHAUL

PERIOD

.

Cause

of

Low

Compression

Generally, the time at which

an

engine should be overhauled

is determined

by

various conditions such

as

lowered engine

power output, decreased compression pressure,

and

increased

fuel

and

oil

consumption. The lowered engine power output

is not necessarily due

to

trouble with the engine itself, but

is

sometimes caused

by

injector nozzle wear or injection pump

wear.

The decrease in compression pressure

is

caused

by

many

factors. It is, therefore, necessary

to

determine a cause

or causes

on

the

basis

of

data produced

by

periodic

inspection and maintenance.

Oil analysis on a seasonal basis

is a good means of monitoring engine internal

wear.

When

caused

by

worn

cylinders or piston rings,

the

following

symptoms will occur:

1 Low engine power output

2 Increased fuel consumption

3 Increased oil consumption

4

Hard

engine starting

5 Noisy engine operation

These symptoms often appear together. Symptoms 2

and

4 can result also from excessive fuel injection, improper injection timing,

and

wear

of

the injectors. They are caused

also by defective electrical devices such

as

the battery,

alternator, starter

and

glow plugs. Therefore it is desirable

to

judge the optimum engine overhaul time

by

the

lowered

compression pressure caused

by

worn cylinders and pistons plus increased oil consumption. Satisfactory combustion is obtained only under sufficient compression pressure. If

an engine lacks compression pressure, incomplete combustion of fuel will take place even

if

other parts of the engine are

operating properly.

To

determine

the

period of engine

overhaul,

it

is

important

to

measure the engine compression

pressure regularly. At the same time,

the

engine speed

at

which the measurement

of

compression pressure

is

made should be checked because the compression pressure varies with engine rpm. The engine rpm

can

be measured at the

front end of the crankshaft.

OVERHAUL

CONDITIONS

Compression pressure tends

to

increase a little

in a new

engine until piston rings and valve seats have been broken

in. Thereafter, it decreases gradually with the progress of wear of these parts.

When decrease

of

compression pressure reaches the repair

limit, the engine must

be

overhauled.

The engine requires overhaul when oil consumption

is

high,

blowby evident, and compression valves are

at

minimum or

below.

ENGINE

COMPRESSION

Check the compression pressure.

To

do

this warm

the

engine,

remove all fuel injectors,or glow plugs, disconnect the

fuel

shut-off solenoid wire,

and

install a compression adapter

in

the injector hole or glow plug hole

..

Connect a compression

tester on the adapter

and

crank the engine with

the

starter motor until the pressure reaches a maximum value. Repeat this process for

each

cylinder. Look for cylinders

with

dramatically lower compression than the average of

the

others.

COMPRESSION

PRESSURE

(Faclary

Spec.)

at

250

RPM

626

PSI

44

Kgl/cm'

4.32

MPa

ALLOWABLE

LIMIT

al250

RPM

472

PSI

33.2

Kgl/cm'

3.26

MPa

If

a weak cylinder is flanked

by

healthy cylinders, the

problem

is

either valve or piston-related. Check the valve

elearances for the weak cylinder, adjust

as

needed, and test

again.

If

the cylinder

is

still

low,

apply a small amount of

oil

into the cylinder

to

seal the rings, and repeat the test. If

the

compression comes up, the rings are

faulty.

Abnormally high readings on all cylinders indicate heavy carbon accumulation, a condition that might be accompanied by high pressures and noise.

NOTE:

In case

of

severe vibrations and detonation noise, the

cause may be fuel injector problems, see

FUEL INJECTORS.

Poor

fuel quality, contaminants and loss

of

po

sitive fuel

pressure to the injection pump will result

in

faults.

TESTING

ENGINE

COMPRESSION

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

34.3

to

39.2

N·m

Nozzle holder

3.5

to

4.0

kgf·m

25.3

to

2B.9

ft-Ibs

t9.6

to

24.5

N·m

Tightening torque

Over1low pipe nut

2.0

to

2.5

kgf·m

14.5

to

tB.t

ft·lbs

49.0

to

6B.6

N·m

Nozzle holder assembly

5.0

to

7.0

kgl·m

36.2

to

50.6

ft·lbs

Engines & Generators

2

ENGINE

TROUBLESHOOTING

The following troubleshooting chart describes certain problems relating and the recommendations to overcome these problems.This chart may overhaul.

HARO

PROBLEM

STARTING

LOW

CRANKING

1.

Engine

oil

2.

Run·down

3.

Worn

battery.

4.

Battery

5.

Defective

6.

Defective

OEFECTIVE

1.

Air

trapped

2.

Clogged

3.

Low

injection

4.

Inadequate

5.

Injection

6.

Injection

MAIN

ENGINE

1.

low

compression.

a.

Incorrect

b.

Inadequate

c.

Valve

d.

Broken

e.

Compression

f.

Piston

g.

Worn

2.

Burnt

glow

3.

Faulty

glow

4.

Incorrect

5.

Governor

PROBABLE

SPEEO

viscosily

battery.

terminals

loosely starter. main

drive

INJECTION

in

fuel

passage.

fuel

filter.

pressure.

spray.

pump

delivering

too

early.

TROUBLES

valve

contact

stem

seized.

valve

spring.

leaks

ring

seized.

piston

ring

plug.

plug

operation.

governor

lever

spring

out

CAUSE

too

high.

connected.

section.

SYSTEM

insufficient

clearance.

of

valve

through

and

cylinder.

position.

of

POSITION

fuel.

seat.

cylinder

head

gasket.

to

engine service, the probable causes of these problems,

be

of assistance in determining the need

VERIFICATION/REMEOY

1.

Replace

engine

oil

with

less

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

6.

Check

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

2.

Replace

3.

Correct

4.

Set

5.

Correct

terminals

clutch

air

or

injection

or

injection

a.

Adjust

b.

Lap

c.

Replace

d.

Replace

•.

Replace

f.

Replace

g.

Overhaul

lever

battery.

or

replace

from

replace

valve

valve.

glow

lead

wire

to

starting

spring

for

fuel

valve valve gasket.

piston

engine.

plug.

and

correct

starter.

disengagement.

system.

filter.

pressure.

nozzle.

injection

pump.

timing.

clearance.

and

valve

spring.

and

piston

connection.

position.

viscous

cables.

guide.

ring.

for

oil.

an

engine

LOW

OUTPUT

LOW

COMPRESSION

INJECTION

1.

2.

3. INSUFFICIENT

1.

2.

3. INSUFFICIENT

1.

SYSTEM Incorrect Insufficient Low

injection

Airtrapped Clogged

filter.

Contaminated

Clogged

aireleaner.

injection

injection.

pressure.

FUEL

in fuel

fuel

INTAKE

OUT

OF

timing.

system.

tank.

AIR

~

ADJUSTMENT

WESTERBEKE

Engines & Generators

3

See

1.

2.

3.

1.

2.

3.

1.

HARD

Adjust Repair Check

Check Clean Clean

Clean

STARTING

injection or

replace

injection

and

retighten

or

replace

tank.

or

replace

timing.

injection

nozzle

connector.

filter.

air

cleaner.

and

pump.

adjust

pressure.

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

PROBABLE

CAUSE

VERIFICATION/REMEOY

LOW

OUTPUT

(c.nI.)

OVERHEATING

1.

Low

coolant

level.

1.

Add

coolant.

2.

Loose

V·belt.

2.

Adjust

or

replace

V·belt.

3.

Incorrect

injection

timing.

3.

Adjust

injection

timing.

4.

low

engine

oil

level.

6.

Add

engine

oil.

EXCESSIVE

OIL OIL

LEAKAGE

CONSUMPTION

1.

Defective

oil

seals.

1.

Replace

oil

seals.

2.

Broken

gear

case

gasket.

2.

Replace

gasket.

3.

loose

gear

case

attaching

bolts.

3.

Retig

hten

bolts.

4.

Loose

drain

plug.

4.

Retighten

plug.

5.

Loose·oil

pipe

connector.

5.

Retighten

oil

connections.

6.

Broken

rocker

cover

gasket.

6.

Replace

gasket.

7.

Loose

rocker

cover

attaching

bolts.

7.

Relighten

attaching

bolts.

OIL

LEVEL

RISING

1.

Incorrectly

positioned

piston

ring

gaps.

1.

Correct

ring

gap

positions.

2.

Displaced

or

twisted

connecting

rod.

2.

Replace

connecting

rod.

3.

Worn

piston

ring.

3.

Replace

ring.

4.

Worn

piston

or

cylinder.

4.

Replace

piston

and

rebore

cylinder.

OIL

LEVEL

FALLING

1.

Oelective

stem

seal.

1.

Replace

stem

seal.

2.

Worn

valve

and

valve

guide.

4.

Replace a valve

and

valve

guide.

EXCESSIVE

FUEL

ENGINE

BODY

TROUBLES

CONSUMPTION

1.

Noisy

knocking.

1.

See

KNOCKING.

2.

Smoky

exhaust.

2.

See

SMOKY

EXHAUSr

3.

Moving

parts

nearly

seized

or

excessively

worn.

3.

Repair

or

replace.

4.

Poor

compression.

4.

See

LOW

COMPRESSION;

HARO

STARTING.

5.

Improper

valve

timing.

5.

Adjust.

6.

Improper

valve

clearance.

6.Adjust.

INSUFFICIENT

INTAKE

AIR

1.

Air

intake

obstructed.

1.

Remove

obstruction.

NOZZLE

TROUBLES

1.

Seized

nozzle.

1.

Replace.

2.

Worn

nozzle.

2.

Replace.

IMPROPER

FUEL

Replace

with

proper

fuel.

FUEL

LEAKS

Find

fuel

leaks.

SMOKY

EXHAUST

WHITISH

OR

PURPLISH

1.

Excessive

engine

oil.

1.

Correct

oil

level.

2.

Excessive

rise

of

oil

into

combustion

chamber.

a.

Poor

piston

contact.

••

Check.

b.

Seized

piston

ring.

b.

Replace

or

clean.

c.

Excessive

piston-to-cylinder

clearance.

c.

Replace

or

correct.

(contmued)

Engines & Generators

4

ENGINE

TROUBLESHOOTING

PROBLEM

SMOKY

EXHAUST

ABNORMAL OR

NOISE

(cant.,

SOUND

WHITISH

3.

4. BLACKISH

1.

2.

3. CRANKSHAFT

1.

2.

3. CONNECTING

1.

2.

3.

OR

d.

Worn

e.

Low

f.

Excessive

Injection

timing

Insufficient

OR

Engine

body

a.

Poor

b.

Improper

Insufficient

Improper

Badly

worn

Badly

worn

Melted

bearing.

Worn

connecting

Worn

crankpin.

Bent

connecting

PURPLISH valve

engine

compression.

intake

fuel.

AND bearing.

crankshaft.

ROO

PROBABLE

stem

oil

viscosity.

oil

pressure.

is

too

DARK

GRAYISH

troubles.

valve

air

MAIN

AND

rod

rod.

CAUSE

(cant.,

and

valve

guide.

late.

clearance.

(air

cleaner

clogged).

BEARING

CONNECTING

big

end

bearing.

ROD

BEARING

3.

Adjust.

4.

See

2.

Clean

3.

Replace

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

VERIFICATION/REMEDY

d.

Replace.

e.

Replace.

I.

Correct.

LOW

COMPRESSION;

a.

See

LOW

COMPRESSION;

b.

Adjust.

air

cleaner.

with

proper

fuel.

bearing

and

crankshaft.

bearing

and

check

bearing.

crankshaft.

bend

or

replace.

grind

HARD

STARTING.

HARD

crankshaft.

lubrication

STARTING.

system.

ROUGH

OPERATION

PISTON.

PISTON

1.

Worn

cylinder.

2.

Worn

piston

3.

Piston

seized.

4.

Piston

seized

VALVE

MECHANISM

1.

Worn

camshaft.

2.

EXcessive

3.

Worn

timing

INJECTION

1.

2.

GOVERNING

1.

2.

PUMP

Uneven

injection.

Inadequate

SYSTEM

Governor

Fatigued

lever

governor

PIN.

AND

pin.

and

ring

valve

clearance.

gear.

SYSTEM

injection

nozzle

malfunctioning.

spring.

PISTON

worn

spray.

RING

or

damaged.

1.

Rebare

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

1.

Adjust

4.

Replace

1.

Check

2.

Replace.

cylinder

piston. piston

piston

injection

governor

to

oversize

and

or

replace

nozzle.

shaft

rebore

rings.

and

replace

cylinder.

parts.

correct

piston.

operation.

(continued)

"MJI"

WESTERBEKE

Engines & Generators

5

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMlmNT EKHAUST

OVERHEATING

SOUND

ENGINE

KNOCKS

1.

Main

engine

a.Overheated

b.Carbon

2.

Too

early

3.

Too

high

4.

Improper

KNOCKING

1.

Poor

compression.

2.

Injection

3.

Improper

a.

Poor

b.

Poor

c.

After-injection

d.

Nozzle

1.

Fuellilter

2.

Fuel

pipe

3.

Water

mixed

1.

V-belt

slackening

2.

Damaged

3.

Lack

of

coolant.

4.

Low

oil

level

5.

Knocking.

6.

Moving

parts

7.

Defective

PROBABLE

WITHOUT

troubles.

cylinder.

deposits

injection

timing.

injection

pressure.

luel.

WITH

DARK

pump

malfunctioning.

nozzle.

spray. chattering.

drip.

needle

valve

clogged.

sucks

air.

in

fuel

or

water

pump.

or

poor

seized

thermostat.

MUCH

in

cylinder.

SMOKE

seized.

slippery

oil

quality.

or

damaged.

CAUSE

SMOKE

with

oil.

a.

See

b.

Clean.

2.

Correct.

3.

Correct.

4.

Replace

1.

See

LOW

2.

AdjusVRepair.

a.

Clean

b.

Repair

c.

Repair

d.

Replace.

1.

Clean

or

2.

Retighten

3.

Replace

fuel.

1.

Adjust,

replace

2.

Replace.

3.

Add.

4.

Add

or

change.

5.

See

KNOCKING.

6.

Replace.

7.

Replace.

VERIFICATION/REMEOY

OVERHEATING;

with

proper

COMPRESSION;

or

replace

or

replace

or

replace

replace.

pipe

jOints

or

fuel.

nozzle.

or

clean.

LOW

OUTPUT.

HARD

replace

STARTING.

pipe.

LOW

OIL

HIGH

OIL

RAW

WATER

FUEL

MIXING

LUBE

OIL

WATER LUBE

OIL

PRESSURE

IN

CYLINDERS

WITH

MIXING

WITH

1.

Worn

2.

Relief

3.

Clogged

4.

Diesel

1.

Wrong

2.

Relief

1.

Fail

1.

Injection

2.

Injection

3.

Deficient

1.

Delective

2.

Cylinder

Bearings. valve

mallunction.

oil

cooler.

dilution

type

of

valve

defective

of

syphon

pump

pump's

nozzle

head

block/cylinder

of

the

oil.

valve

or

broken.

plunger

injection.

gasket.

exhaust

is

worn.

head

flawed.

system

1.

Engine

overhaul

replace

bearings.

2.

Overhaul

oil

pump.

3.

Repair.

4.

Injection

pump

repair.

1.

Replace.

2.

Replace.

..

1.

Clean

1.

Rebuild,

2.

Replace.

3.

Replace

1.

Replace.

2.

Replace.

out,

inspect

replace.

nozzle

exhaust

system,

replace.

(continued)

Engines & Generators

6

ENGINE

TROUBLESHOOTING

Problem

Probable

Cause

Veriftcatlon/Remedy

Exhaust

smoking

problems

1.

Blue

smoke.

1.

Incorrect

grade

of

engine

oil.

1a.

Crankcase

is

overfilled

with

engine

oil

(oil

is

blowing

out

through

the

exhaust).

2.

White

smoke.

2.

Engine

is

running

cold.

28.

Faulty

injector

or

incorrect

injector

timing.

3.

Black

smoke.

3.

Improper

grade

of

fuel.

3a.

Fuel

burn

incomplete

due

to

high

back

pressure

in

exhaust

or

insufficient air

for

proper

combustion

(Check

for

restrictions

in

exhaust

system;

check

air

intake.).

3b.lmproperly

timed

injectors

or

valves

or

poor

compression.

3 •.

lack

of

air -check

air

intake

and

air

filter.

Check

for

proper

ventilation.

3d.

Overload.

LCD

QISPLAYS

No

LCD

Display

1.

Check

battery.

1.

Battery

on.

2.

20

amp

breaker

off.

2.

Turn

breaker

on.

Oil

Pressure

1.

Oil

level

low/oil

leak.

1.

Check

oil

level,

add

oil

and

repair

leaks.

2.

Lack

of

oil

pressure

2.

Test

oil

pressure.

If

OK,

test

oil

pressure

sendor,

inspect

oil

filter,

inspect

oil

pump.

3.

Ground

connection.

3.

Check

ground

connection.

4.

Faulty

control

module.

4.

Inspect

all

the

plug

connections/replace.

Coolant

Temperature

1.

Check

system

coolant

level.

1.

Add

coolant.

Check

for

leaks.

2.

Check

water

pump

drive

belt.

2.

Adjust

belt

tension,

replace

belt.

3.

Faulty

Temp

sensor.

3.

Check

sensor/replace.

4.

Ground

Connection.

4.

Check

ground

circuit.

5.

Faulty

control

module.

5.

Check

plug

connectionslreplace.

Exhaust

Temperature

1.

Check

sea

water

flow.

1.

Inspect

thru

hull

fitling,

hose

and

strainer.

Correct

as

needed,

2.

Faulty

exhaust

temp

switch.

2.

TesVreplace.

3.

Ground

Connection.

3.

Check

ground

circuit.

4.

Faulty

control

module.

4.

Check

plug

connections.

5.

Sea

water

pump.

5.

Inspect

impeller/replace.

Battery

Voltage

1.

Check

alternator

drive

belt.

1.

Adjust

tension/replace

if

worn.

2.

Check

charge

voltage.

2.

Check

excitation.

replace/repair

alternator

3.

Check

battery

connections.

3.

Check + and -cables

from

battery

to

engine.

4.

Faulty

control

module.

4.

Check

plug

connectionslreplace.

Generator

Voltage

1.

Check

AC

voltage

output.

1.

Adjust

voltageitroubleshoot

generator

for

cause.

2.

Faulty

control

module.

2.

Check

plug

connectionslreplace.

Generator

Frequency

1.

Check

engine

speed.

1.

Adjust.

2.

Check

fuel

supply.

2.

Inspect

filters/replace

filters.

Test

fuel

pump

operation.

3.

Amperage

load.

3.

Check

load

with

amprobe.

LED

Display

-

1.

Compartment

ambient

temperature

1.

Ventilate

compartment.

edges

tum

pink.

too

high.

-.¥

WESTERBEKE

Engines & Generators

7

I

GENERAL

CYLINDER BLOCK

This engine employs separate type crankcases the crankcase 1 with combustion parts and the crankcase 2 which supports the crankcase 1 and reduces noise.

Since it is a hanger type, you can

and disassemble it. The cylinder is a linerless

ble type which enables good cooling operation, less strain and good abrasion resistance.

easily assem-

HALF-FLOATING HEAD COVER

DESCRIPTION

The rubber packing cover 0.5 arrangement

. cylinder head.

mm

or

helps

is

so

off

reduce

RUBBER PACKING

fitting

the

in

to

maintain

cylinder head. This

noise

coming

the

from

CYLINDER

HEAD

head

the

COVER

U---OIL

PAN

CYLINDER HEAD

This engine employs a three valve system: two

inlet valves and double ports, and one exhaust valve which produces good inlet inertia to improve combustion efficiency and efficiency. combustion chamber with grooves.

Besides the employs the forced cooling method between valves to eliminate heat distortion, thus enabling durable

It

also employs a new unique

multiple injection

conventional cross port system, it

and reliable configuration.

volumetric

En'glnes & Generators

8

GENERAL

DESCRIPTION

PISTON

This engine employs the E-TVCS VERSION-II

so

that top bustion efficiency than the conventional

The profile and the offset optimized the heat

Three rings are installed piston. The top ring is made get It

is against heavy load. At the Sliding part, a special piston ring which is conformable to the

cylinder wall is employed. The second ring is chrome-plated on the

is

an undercut ring to prevent the holding

The oil ring (3) has chamfered contact faces

and an expander ring, which increase the

pressure

wall.

Several help heat dissipate and to prevent scuffing.

AND

PISTON

the improved combustion surface at the

of

the piston enables more complete com-

to

reduce piston slap. The oil

small end

load of the piston.

more reliability than the chrome plated ring.

a keystone type ring to provide durability

of

the connecting rod reduces the

of

the oil ring against the cylinder

grooves are cut

RINGS

models.

of

the piston are

jet

at

in

grooves

of

nitrizing steel to

peripheral surface and it

on

the topland to

in

the

of

oil.

TOP

RING

~~~G

OILRING

DEPRESSION

I I \

r;

I \ -

~

....

;:.

PISTON

~~~_77GROOVES

DYNAMIC

Engines are sure to vibrate due to the

reciprocation cylinder engines are much less prone to cause vibration than four

any engine has many moving parts to its pistons and cannot be from vibration.

The balanced weight second inertia mentioned above and reduce

vibration.

BALANCER

of

the pistons. theoretically, three

cylinder engines. However,

four

cylinder engine is fitted with

on

the crankcase to absorb the

in

addition

completely free

PISTON

TOPLAND

BALANCER

SHAFT

-.v

WESTERBEKE

Engines &

Generators

9

GENERAL

GOVERNOR

This

mechanism maintains engine speed at a constant provides engine speed by rate.

This controls the fuel injection rate at all speed ranges (from utilizing the balance between the flyweight's centrifugal

A

is independent

rotates providing better response to delivering greater engine output.

level even under fluctuating loads and stable idling and regulates maximum

controlling the fuel injection

engine uses a mechanical governor that

idling to maximum speed)

force and spring tension.

governor

at

shaft for monitoring engine speed

of

the injection pump shaft and

twice the speed

of

conventional types,

load fluctuation and

by

DESCRIPTION

SPRING

(6)';~~~~Q\;;;;~-.T'J'!:="'5---

SPEEO

CONTROL--ttt+~r

LEVER

FORK

LEVER 1 (7)

IDLE

ADJUSTING

BOLT-'Oll~::h;",,<

FORK

2

LEVER

GOVERNOR

SPRING

(4)

At

Start

The

stop

solenoid (energized to run type) is

powered to

release the stop lever.

As no centrifugal force is applied to the

flyweight

(1), low tension

of

the start spring (2)

. permits the control rack to move to the starting

position, start

At

Idling

Turn

supplying the amount

the

engine.

the

speed control lever (3) clockwise to

of

fuel required to

idle the engine. It tensions the governor spring

(4) to

pull

the

fork lever

2.

When the fork lever 2 is pulled, it moves the torque spring pin (6) and fork direction

of

the arrow A to restrain the weight.

lever 1 (7)

in

the

In combination with the start spring tension, it is

balanced with the centrifugal force

flywheel

• At rated speed with full load and overload

As

speed to high

weight

to maintain idling.

the speed control lever

speed,

the governor spring tension

is

changed

increases to compress the torque spring fork lever 1

The fork lever 2

limiting bolt

When the engine

speed decreases

weight decreases. fork lever 1

The control fuel supply centrifugal force of

in

the

to

keep

in

the

rack

to

increase

direction

moves

rated

rotation

is

overloaded,

and

the

Then

the torque

direction

moves

in

the

output.

the

flywheel weight

of

the

arrow

until it

reaches

and

centrifugal force of flywheel

of

arrow

the

direction that increases

It

is

of

the

from

the

middle

and

move

A.

the

output

rated

output.

the

engine rotating

spring

moves

A.

balanced with the

to

produce low-

the

speed output (torque output).

the

NO·LOAD ROTATION

OUTPUT

TORQUE

SPEEO

LIMITING

BOLT

CONTROL

• To stop engine When

tension

of

the

the the stop lever the

To

lever

arrow B

stop to

the

which

the

left.

FLYWEIGH1l1

LEVER

stop

solenoid

moves

)

131-H\+l

solenoid

is

the control

stops

engine

manually,

/ll-l.l..>..w.J--

is

released,

the

engine.

turned

the

rack

move

off,

the

rod

extrudes

in

the

direction

the

external stop

CONTROL

RACK

spring

and

of

'9Y'

WESTERBEKE

Engines & Generators

10

DISASSEMBLY

PROCECURES

GENERATOR

Unplug side the

photo or mark all connections

Remove intake elbow

Drain the engine

Carefully support from

Additional generator information will be found

GENERATOR

and

disconnect

and inside of the control box

control box off the

the

air hose between

box.

Separate the exhaust hose

and

disconnect the fuel supply

the engine.

section of this manual.

oil

and

the

electrical connections

AC

generator end.

the

coolant from the engine.

then unbolt

to

allow

to

ensure proper

the

control

at

and

the

generator backend

COOLANT

19MM

for

NOTE:

box

the water injected

return lines.

HEX

on

the out-

the

removal of

Properly

reconnecting.

and

the

engine

in

the

DRAIN

PLUG

PROPULSION

Unplug

transmission

Detach from the engine.

NOTE:

the

Label any

ENGINE

instrument panel wiring harness. Drain

fluid

and

oil

cooler hoses

lines,

the transmission

and

hoses or cables

oil

cooler hoses.

unholt the transmission

as

you

separate

the

them.

TRANSMISSION

If

the

transmission inspected. Flush out and pressure test the replace the coolant hoses. Inspect

linkage

the transmission and change the transmission fluid. For

units contact the transmission manufacturer for the location

and

transmission service

Operator's

DAMPER

BOLTS

is

not being rebuilt,

and

the

propeller shaft coupling. Clean

and

maintenance refer to the

mannal,

To

rebuild a transmission

it

should

oil

cooler

lubricate

be

the

gear shift

and

visually

and

repaint

of

RADIATOR

Drain the coolant using of

the brackets and lower the mounting frames. Remove the radiator and

Remove the DC charging alternator. Remove the four bolts securing and

remove the

remove

MODELS

the

radiator. Unbolt the radiator from

set

aside for servicing.

the

fan

to

the fresh water pump pulley

fan

and pulley. Unbolt the

it.

petcock found at

the

side support

fan

guard

the

base

and

''''',"<I'T

PLATE BROKEN

PREPlUtAil(IN

• Clean

• Do not remove

• When disconnecting sensor wires, label and

• Perform disassembly

•

• Pay attention

or

disassembly.

Keep disassembled parts necessary.

from intrusion of dust and dirt.

Parts

must

which

they

parts

must

its

component,

reproduced

parts for their positions or directions. Put on marks, if necessary,

FOR

DISASSEMBLY

wash

the

engine exterior.

or

disassemble the parts that require

in

a proper order using proper

in

order. Apply

Take

special care

be

restored

were

removed

be

set

aside

so

that

at

assembly.

to

marks on assemblies, components

to

aid assembly.

to

their

at

disassembly.

separately

the

same

to

keep

respective

in

groups,

combination

the

"u<DAMPER

FOR

SPRINGS

tape

oil

when

fuel system parts

components

This

means

each

or

set

WEAR

the

from

that

marked

can

be

and

AND

no

ends.

tools.

all

for

DISASSEMBLY/ASSEMBLY

RADIATOR

~

WESTERBEKE

Engines & Geners/ors

11

• Carefully check each part or component for faulty condition during removal or cleaning. The part

tell you how

it

acted

or

what

was

abnormal about

any

sign of

will

it

more

DISASSEMBLY

PROCEDURES

REMOVE

With the transmission/generator/radiator separated from the engine. begin the following step by step procedure to disassemble the exterior parts.

NOTE:

1.

Remove Label the wires

2 Witb the hoses disconnected, remove the thermostat

housing sender

3. Remove

(Generators

4.

Remove hreaker/pre-heat solenoid mounting

Remove

S.

Remove bracket. Make note

6. Remove engIne Hywheel

7. Remove the engIne mounted

complete with its

WATER

Generators

8. Remove

one end removed

EXTERIOR

Mount the engine securely

the

start

and

housing gasket, leaving the

and

switch in place if applicable.

the

magnetic pick-up from the bell housing

COMPONENTS

on

motor, drive belt,

and

cables.

only).

the

Hywheel

the

engIne

the

oU

the

transmission

PUMP for parts breakdown.

heD

housing

back

plate.

filter,

oU

cooler,

of

the hose arrangements.

damper

(Marine

Engines).

adapter

mounting plate. See

raw

only)

the

engine

of

each hose connected to the part being

(Marine

heat

Engines

exchanger.

and

Generators

a suitable engine

and

the alternator.

temperature

and

the circuit

bracket

oU

hoses

and

mounting

plate from the

water

pump,

(Marine

If

Engines

possible. leave

only)

.

stand.

RAW

and

9.

Remove the exhaust components from the exhaust manifold

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

lower surface of the manifold. Clean

and

cracks

b) Remove the exhaust nipples, elbows

the manifold.

c)

Remove the water connectors from the ends of the

manifold. Be arrangement

d) Examine

and

e) Flush

passage. Set aside

10. Remove the coolant circulating pump. Refer

COOlANT PUMP ASSEMBLY.

11.

Remove the manifold.

Prepare

12.

defects. Replace as needed.

sure

to note the

of

each for

aU

parts

for defects, corrosion

replace as needed.

out

the coolant recovery tank

to

re-instaD on the boat.

air

intake silencer

to disassemble the main engine.

proper

and

inspect for

and

plugs from

location

alignment.

and

clear its hose

the intake

and

wear

to

....

WESTERBEKE

Engines & Generators

11a

ASSEMBLY

PROCEDURES

GENERAl

Surface

Thoroughly remove application Check is

to greases and surfaces. remains

INFORMATION

Preparation

surfaces

to

ensure

that

be

applied

Do

in

foreign

not

the

bolt

is

forget

ASSEMBLY

•

Wash

all

parts,

etc.

with cleaning solvent

• Always you

job.

•

Use

of

• Be sure

torques

•

When

must be installed.

use

tools

understand

only

good

oil, grease or sealant

to

use

are

specified.

the

engine

all

substances deposited

using

a gasket scraper

the

surfaces

flat.

Make sure that there

substances deposited

to

holes.

except

for

that

are

how

to

quality lubricants. Be

a torque

is

assembled,

remove

oil

and

in

good

use

them

to

parts

wrench

to

which

the

seals,

dry

condition

before performing

as

to

tighten

new

on

the

gasket

or

wire

brush.

the

silicone

are

no

on

the

old

sealant

O-rings, rubber sheets,

them

with

and

sure

to

apply a coat

specified.

parts

gaskets

and

gasket

oils,

application

that

air

pressure. be

sure

any

for

which

O-rings

INTERNAL

When

reassembling external or internal

them

so

which

force

that

SNAP

the

is

applied.

sharp

RING.

PLACE AGAINST aFFORCE

edge

GREASE

THE

faces

EXTERNAL

SHARP

EDGE

DIRECTION

snap

against

the

SNAP

rings,

position

direction

RING

from

Be

aware

of

these

common

problems

assembly.

Insufticlent Lubrication.

reciprocating parts, lightly except those fasteners should high-tech equivalent.

Reversed

all

thermostats

Mechanical damage. torque sequences and Exceptions fasteners. latter-mcker shaft fasteners should

small increments, especially head assembly,

that

penetrate into

be

orientation. Most

are

asymmetrical.

are

torque-to-yield bolts

The former

working

gaskets,

they

should

Heavily oil

sealed

with

gaskets,

Run

fasteners

in

three steps-I/Z,

are

torqued

from

might

be

positioned

head

the Pennatex

the center

also

that

can

oil

sliding

bolts

and

water jacket.

No. Z or

many

down

in

2/3,

and

rocker

as

indicated.

be

brought

bolts

be

damaged during

with

great

occur during

and

other

fasteners,

These

the

bolt

washers,

approved

and

111

arm

shaft

The

down

out.

care.

and

torque.

in

very

Gaskets,

GASKET

The silicone gaskets RTV it

is gasket. Too be the

a joint, break while observing

The vulcanization gram) moisture

both

INFORMATION

engine

has

several

100.

To

ensure that

necessary

thin a bead

squeezed out of location causing blocking

fluid

gasket

applicator/tube.

engine

Bead

feed

it

is

in

to

size,

lines.

necessary

material

(RTV)

the

atmospheric

oil

and

areas

where

are

used

such

as

LOCTITE

the

gasket

observe

could

some

precaution

continuity and location

cause

leaks

and

To

eliminate

to

apply

the

used

type

The

coolant assemblies.

correct

in

the

and

RTV

air

the

bead

engine

is

supplied hardens

and

gasket

form-in-place

fully

possibility

can

598

serves

when

are

too

thick a bead

or

evenly

size.

is a room

in a 140z

as

it

reacts

be

used

RTV

or

GE

its

purpose,

applying

very

important.

narrowing of

of

leaks

without a

temperature

(400

with

for

sealing

the

could

from

the

Engines & Generators

12

ENGINE

ASSEMBLY

INSTRUCTIONS

ALTERNATOR

When rebuilding the engine. the alternator should be cleaned and inspected. The housing can be wiped

and the alternator tenninal studs should be cleaned with a

wire brush. Make certain the studs are tight and clean the

wiring

connections that connect to the wiring harness.

Thrn the rotor pulley by hand.

Depending on when the alternator was last serviced. the brushes may need replacing. send it to a service shop for testing and overhaul. or refer the more detailed alternator section in this manual.

HEAT

EXCHANGER

Install the heat exchanger. replace the heat exchanger zinc

and attach new hoses with new clamps to the cooling system.

Refer to the

INSPECTION

off

with a solvent

It

should turn smoothly.

If

the alternator is at all suspect.

to

(MARINE

COOllNG SECTION in this manual for HEAT

ENGINES/GENERATORS)

EXCHANGER service.

MARINE

1. Assemble Ibe

2. Re-install

MOlE:

Drive require oil coolers.

pressure tested and repainted at engine overhaul.

transmission oil cooler hases should also ReJer

TRANSMISSION

damper

Ibe

marine

correct

amount

of

(MARINE

plate

transmission

fluid. Do

to

not

the

Some transmissions. such as the Borg

Oil

coolers should be

to

the text on HEAT EXCHANGERS.

ENGINES)

flywheel.

and

overfill.

be

inspected.

fill with the

Warner

Velvet

cleaned,

The

RADIATORS

The

radiator, cleaned. flushed, and pressure tested can be

assembled to the generator mounting rails. The fan can be

assembled to the engine.

ENGINE

After re-assembly, the unit must be test run. This will ensure

that the engine/generator operates to its specifications. Fill the engine cooling system with an antifreeze mixture and the engine oil sump with lube oil CH4

1.

2.

3.

4.

5.

6.

7.

8.

Refer These Specifications. and Raw

TUNING

or

CI4

Mount fuel, elecrtical, required.

Pre-lube solenoid/actuator allow

Start pressure,

Allow temperature adjust

Check Correct

Propulsion Load

full

After

fasteners are

protect

the

engine idle speed

unit

test

load

tight

as

to

the following pages for details

sections

Water

OPERATION

SEA 15-40.

unit

on a test

exhaust

the

unit

if

not

and

oil

pump

to

unit

and

monitor

water

temperature,

unit

to come

and

check the engine speed. (Propulsion-

for

any

leakage

as

needed.

Check

the

test,

and

needed.

also Torque

Pump.

fuJI

unit

in

gradual

stop

unit

electrical connections to

secure.

Check

include:

Diagrams.

API specifications

stand

aud

make

and

coolant connections

already

intermittently

prime

up

no

done

the oil passages.

for

proper

DC

charge, etc.

to

normal

for

smoothest operation).

of

oil, fuel

load

rpm.

steps

114, 112,

an

allow to rest.

wire hose challing

of

Wiring

Diagrams,

Starter

Motor.

of

CF,

CG4.

the

needed

as

or

disable

crank

operation

operating

or

make

the

the unit to

coolant.

3/4

and

Check

sure

and

like oil

all

they

sub-assemblies.

Engine

Alternator

fuel

Engine

Inspect the engines flexible mounts. Replace any that show signs

complete overhaul. all four should be replaced.

Mounts

of

wear, rust, or splits in the rubber isolators.

In

a

Engines & Generators

13

DISASSEMBLY

I

ASSEMBLY

Cylinder Head and Valves

Cylinder Head Cover and Nozzle Holder

1.

Remove the injection pipes

2.

Remove the glow plugs.

3.

Remove the nozzle holder assembly

4.

Remove the heat seal.

5.

Remove the head cover.

(When reassembling)

• Check to.

see

that the cylinder head cover gasket is not

defective.

•

Be

sure to replace the heat seal.

• TIghten the head cover mounting bolts to specified torque.

• Mount the return fuel check valve with the I mark in the direction

Tightening

of

flow back to the taok. t

Cylinder head cover

mounting

Injection

nut

torque

NOlzle holder assembly 5.0 to 7.0 kgf·m

Overflow pipe assembly retaining nut

Glow Plug 2.0 to 2.5 kgf-m

Nozzle Heat Seal Service Removal Procedure

•

IMPORTANT

•

Use a plug bigger

1.

Drive screw driver lightly into

(phillips) screwdriver

than

the

heat seal hole (Approx. 6 mm, 1/4 in.).

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat seal out together with the injection nozzle gasket. . If the heat seal drops, repeat the above procedure. Hmit seal (4) and injection nozzle gasket injection nozzle is removed for cleaning or for service.

screw

pipe

(1)

and

overflow pipes.

(4)

and copper gaskets.

6.9 to 11.3

0.7

5.1

retaining

the

(3)

22.6 to 36.3 N·m

2.3 to 3.7 kgf·m

16.6 to 26.8

49.0

36.2

19.6 to 24.5

2.0

14.5

19.6 to 24.5 N·m

14.5 to

that

has

heat seal hole.

must be changed when the

N·m

to

1.15 kgf·m

to 8.32 It-Ibs

It-Ibs

to 68.6 N·m

to

50.6 It-Ibs N·m

to 2.5 kgf·m

to

18.1

It-Ibs

18.1

It-Ibs

a dia.

which

is

COPPER

GASKETS

HEAT

o

GLOW

NOZZLE

SEAL

HEAD

COVER

_",IN,JEClrION

PIPE

LIFTING

CAUTION:

ENGINES OUT THE

ASSEMBLED

EYE

IF

THERE

LIFTING

THIS

STUO.

BOTTOM

BOLT.

THRU

IS

REASON

EYE,

00

SIMPLY

THE

STUD

THE

WATER

TO

NOT

ATTEMPT

REMOVE

THE

IS

PERMANENTLY

JACKET.

REMOVE

Engines & Generators

TO

NUT

THE

TAKE

AND

14

PHilLIPS

INJECTION NOZZLE

GASKET

=:r.:3::s..\..L=-

HEAT

SEAL

(3)

(4)

DISASSEMBLY

I

ASSEMBLY

Rocker Arm

1. Remove

2. Remove

3. Detach the bridge arm. (When

When putting the push

• their

•

IMPORTANT

•

After valve

Tightening torque 5.0 to 5.7 kgf·m

.

Cyfinder Head and Tappet

1.

Loosen the hose clamp and remove the by-pass hose

2.

Disconnect the fuel pipe

3.

Remove ttie

4. Remove the cylinder head screw remove the cylinder head.

5.

Remove the cylinder

6.

Remove the tappets from the crank case.

(When

• Replace

• Before installing the tappets apply engine oil thinly around them.

• When mounting the gasket, set it care not to mount it

•

The cylinder head should

• Take care for handling the gasket not to damage

• Install the cylinder

• Tighten the cylinder (18) aiter applying engine

•

Be Clearance".

• It

is not necessary

running the engine for

•

IMPORTANT

• When replace the piston, piston pin bush, connecting rod

or thickness "Selecting

•

NOTE

• Mark

interchanging.

Tightening torque 10.0 to 11.0 kgf·m

and

Push

Rod

the

rocker arm

the

push rods.

reassembling)

ends are properly engaged with the

reassembling the rocker arm, be sure

clearance.

Rocker screw

IN. / EX.

reassembling)

the head gasket

sure

to

adjust the valve clearance.

crankpin

the

bearing, select the cylinder head gasket

to

meet with the top clearance refer

Cylinder

cylinder

Cylinder head mounting

screw

(1)

as

a unit.

rods

onto

the tappets, check

arm

bracket

(3)

first

Manifold.

head

gasket.

with

a new

reversely.

be

free of scratches

head.

head

screw gradually

oil.

to

retighten the cylinder head screw aiter

30

minutes.

Head Gasket" .

number

to

49.0 to 55.9

36.2 to 41.2 ft-Ibs

and

then the

in

the order

one.

to

the knock

the tappets to prevent

98.1 to

72.3 to 79.6 It-Ibs

tappet

to

N·m

fuel

filter.

of

(18)

and

it.

in

the orderof

See

107.9

N·m

to

see if

recess .

adjust the

to

(1),

and

hole.

Take

dust.

(1)

the "Valve

to

the

to

-L---V:li

.

014

018

.

no no

17

0

010

o-clo..

0013

06.

o

0

05

CYLINDER

PUSH

RODS

TAPPET

03

02

00

d 0 0

0

04

HEAD

TIGHTENING SEQUENCE

07

8

0

Om

00

0

-

-0

012

_

0/

......

15

16

..

Engines & Generators

15

DISASSEMBLY

Selecting Cylinder Head Gasket

• Replacing

1.

Make sure to note the notch (a), (b) or (c) of cylinder head

gasket.

Replace the same notch (a), (b) or (c)

2. head gasket.

•

Selecting

• Select the cylinder head gasket thickness top

clearance when replacing the piston, piston pin bush,

connecting rod or crankpin bearing.

1. Measure the piston head's protrusion or recessing from the crankcase

four pistons) using the dial Select the suitable cylinder head gasket refer

2. below.

Notch

01 Cylinder Head

Gasket

2 notches (a) 0.0354 in. 0.0315 in. ·0.0028 to

1 notch

(b) 0.0394 in. 0.0354 in. +0.0020 to

wnhout notch

(c)

~

1.

Remove the valve cap compressing the (3).

(When

• Install the intake valve spring with downward (at the head side).

• Wash the valve stem and valve guide hole, and apply engine oil sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a

the

Cylinder

the

Cylinder

cylinder face 4 spots

Thickness of cylinder

head gasket crankcase cylinder

Before

tightening tightening

0.90mm

1.00mm

1.05mm

0.0413 in.

reassembling)

After

0.80mm

0.90mm

0.95 mm +0.20

0.0374 in. +0.0059 to

valve spring

head Gasket

as

the original cylinder

Head Gasket

to

per

each piston (average

!Jauge

(1)

plastic hammer.

as shown.

Piston

Head's

recessing from (average of 4 pistons)

V3300·E2B

·0.07

to ·0.27

+0.049

mm

+0.0019 in.

+0.050

to

+0.149

mm

+0.0058 in. ·0.0020 in.

+0.150 to

mm

+0.0078 in.

and the valve spring collets (2)

(4)

with the valve spring retaine;

its

small-pitch end

meet with the

to

protrusion

the

V3300·T·E2B

·0.151mm

·0.0110 to

·0.0059 in.

·0.15 to

·0.051 mm

·0.0059 to

-0.0510

·0.0019 to

a

in.

I

the table

or

level

of

face.

to

Dmm

ASSEMBLY

of

PROTRUSION RECESS

II

.

I-

@(~

(2)

(1)...-"~(3)

~(7)~(4)

~ ~

J1 J1

...__-:::O..,;,-"'l!Th,...

(a) 2 Notches

(b) 1

Notch

(c)

Without

Flywheel

MEASURING

SPOTS

Notch

Side

PISTON

, .

@@

,

f-::~

(1)

Valve Cap

.

(2)

Valve Spring Collet

(3)

Valve Spring Retainer

(4)

Valve Spring

(5)

Valve Stem Seal

(6)

Valve

(7) Arm Bridge

Engines & Generators

16

t

(10)

INSTALL PITCH

END

WITH

DOWN

LARGE

SMALL

PITCH

DISASSEMBLY

I

ASSEMBLY

7. Slide off the governor connecting injection pump

8. For convenient sake, temporarily hook the start spring rack pin

9. Remove the governor housing mounting screws.

10.

Detach the governor housing assembly (8) from the injection pump unit.

(When reassembling)

• When reassembling the inside parts, put the oil part

slightly.

After sliding on the governor connecting

•

tighten the nut with the specified torque with using the jig for

keeping the governor connecting

Replacing Injection

After tightening the

•

• Check the movement of control rack of injection pump assembly by the stop lever .

•

NOTE

• When installing the governor housing assembly to the injection pump unit, When linking the governor connecting rod to the rack pin

• of injection pump, use the jig for keeping the governor connecting rod

be stuck, and causes

may or hunting of governor.

Pump Assembly.)

Tightening

torque

assembly.

hole of the governor connecting rod.

Pump

Assembly).

nut,

hook the start spring on the rack pin.

be careful not to damage O.ring.

horizontal. Otherwise the control rack

to

Governor

mounting

Anti-rotation

housing

screw

nut

rod

(7) from the rack pin of

on

the

on

each inside

roa

to the rack pin,

rod

horizontal. (See the

be difficult to start the engine

(See the Replacing Injection

9.B

to

11.3

N·m

1.00

to

1.15 kgf·m

7.23

to

B.32 ft·lbs

2.B

to

4.0

N·m

0.29

to

0.41

kgf·m

2.1

to

3.0 ft·lbs

GOVERNOR CONNECTING ROD

(7)

GOVERNOR HOUSING

ASSEMBLY

(81

~;o-===ffFt':~-Hr--RACK

(51

1...".,'1

GOVERNOR

/

CONNECTING

ROD

(71

Engines & Generators

17

'%;))

~0f~~~

O·RING

CONNECTING

START

SPRING

ROD

(6)

(7)

DISASSEMBLY

4.

Temporarily tighten the injection pump gear mounting nut hand.

5.

Fix the injection pump unit mounting nut to the specified torque.

S.

Take off the fuel plugs (1) for plugging.

7.

Loose the injection pump unit mounting nuts

the injection timing.

8. Moving the injection pump unit clockwise (viewed from gear case side), align the injection timing marks pump unit and

9.

Tighten the injection pump unit mounting nut

specified torque.

10.

Reconnect replace

gear

11.

Remove

12. Check the injection timing. (See the "Injection Timing".)

13.lf the injection timing is to (12) again.

TIghtening torque

the

cover

the flywheel lock.

cam

on

the

the lubricating oil pipe (3) and

injection pump

of

the injection pump unit.

Injection mounting

Injection

mounting

and

tighten the injection pump gear

shaft lock screws

gear

case.

unit

not

within the specification, repeat

pump

gear

nut

pump

unit

nut

(2)

(S)

support and the

73.6 to 83.4

7.5 to 8.5 kgf·m

54.2 to

6t.5

17.7 to 20.6 N'm t.8

to

2.1

13.0 to 15.2 h-Ibs

kgf·m

and

(4)

on

N·m

h-Ibs

the

I

ASSEMBLY

by

tighten the

for aligning

injection

(4)

to the

(7)

INJECTION GEAR

---""-'

,....-<,----.~_...,.,..,.u"'1

PUMP

(5)

Governor Housing Assembly

1. Remove the injection pump unit from the engine. (See the "Injection Pump Unit".)

2.

Remove the governor lubricating pipe.

3. Remove the stop solenoid

4. Detach the sight cover

5.

Unhook the start spring pump assembly.

S.

Remove the nut.

..

(3)

from the injection pump unit.

(4)

from the rack

(5)

of injection

.NOTE

• Be careful

not

to

drop

the

nut

inside.

Engines & Generators

18

~~~

~~J.I.-:;\~

Jm}ctfil~:m=~TIIMINGIMARKS

r--T~(ji'tl-MnolNTlINn

NUTS

(6

(4

DISASSEMBLY

I

ASSEMBLY

Injection

(Removing the fuel injection

1.

2.

•

IMPORTANT

•

NOTE

• When the already existing align marks align with each

3.

4.

5.

•

NOTE

• Never overtighten the lock screws when they have come

• Use

6.

•

NOTE

• Be careful

7.

8.

9.

Injection Pump Unit

(Reassembling the fuel injection pump unit)

1.

Pump

Unit

pump

Detach gearcase. Place the

look

marking pen tooth of the gears in mesh

other, there

Unscrew Tighten contact with the not

Tighten the lower

into contact with

into contact with the cam shaft. Otherwise the injection pump unit

recommended for best constructed as shown in figure (a). loosen specific gear puller, take

Disconnect Loosen Remove injection pump unit.

Place

the

gear cover for

the

piston

compression

for

the align mark on the idle .gear

the

move

any

of

a socket set screw (dog point type) in

the

piston

compression

of

stroke.

or

the like, put

idle gear. This helps to reassemble these

later .

is

no need

two

plugs

upper

fuel

longer.

fuel

the

itself may get damaged.

injection

not

to

drop

the

lubricating

three injection pump unit mounting

injection pump unit support

of

the

stroke.

the

4th

cylinder

Lock the flywheel

to

put

(1)

off

cam

shaft lock screw

cam

shaft.

cam

shaft lock screw

fuel

cam

results. Such screw can be

pump

gear mounting

out

the gear

the key.

oil

pipe.

4th

cylinder

Lock the flywheel

fuel injection

an

the injection pump

shaft .

unit)

pump

unit

from

at

the

top

dead

center

in

place .

2.

Using a white

align mark on the engaged

another align mark.

unit.

until

it

comes

Make

sure the

(5)

at

the

.

(6)

top

cam

(2)

nut.

and

dead

in

shaft

until

Using

take

place.

does

it

comes

out

center

into

the

in

SUPPORT

in

~~~lF~U~~~~17t17):::""'PLUGS(l)

(a)

-

~~~----

--1--

B

c

D

A M8 x Pilch 1.25

5 mm dia. (0. I

B

4 mm (0.157 in.)

C

D 45 mm (1.772 in.)

E

10

mm

(0.39

97

in. dia.)

in.)

: Conspicuously Painted

2.

Place the injection position.

pump gear

3.

install the injection

•

NOTE

• When installing the injection pump unit to the injection pump injection pump gear.

Make

(5)

gear, make sure that the key

sure

and

pump

of

aligning

the

idle

pump

gear

unit

to

(5)

back into

the

align marks

2.

the injection

is

fit in the keyway

~

the

gear

case

of

the

injection

pump

gear

(5)

.

of

WESTERBEKE

Engines & Generators

19

DISASSEMBLY

I

ASSEMBLY

Thermostat

Thermostat Assembly

1.

Remove

the

thermostat cover mounting

screws,

and

remove

the

thermostat

cover.

2.

Remove

the

thermostat

assembly.

(When reassembling)

• Apply a liquid gasket (Three

Bond

1215

or

equivalent) only at

the thermostat cover side

of

the gasket.

•

Install

the

thermostai

with

its

bleed

hole

facing

towards

the

discharge

opening

of

the

thermostat

housing.

Re-Assemble

and

Test

THERMOSTAT

(~

~J

THERMOSTAT

HOUSING

COVER

Turn

the

cover

back

into

place

and

tighten

the

three

screws.

Do

nol

over-tightenl

Tighten

the

hose

clamp

and

close

the

drains.

Top

off

the

coolant

and

run

the

engine.

CHeck

for

normal

temperature

and

for

any

leaks

around

the

thermostat

assembly

.

TEMPERATURE· SENSOR

Injection Nozzle

Nozzle Holder

.

THERMOSTAT

ASSEMBLY

SENSOR

1.

Secure

the

nozzle retaining

nut

(7)

with a vise.

2.

Remove

thehozzle holder

(1),

and

take

out

parts inside.

(When reassembling)

• Assemble

the

nozzle

in

clean

fuel

oil.

• Install

the

push

rod

(4),

noting

its

direction.

• After assembling

the

nozzle,

be

sure

to

adjust

the

fuel

injection

pressure.

34.3 to 39.2

N·m

Nozzle

holder

3.5 to 4.0 kgf·m

25.3 to 28.9 «·Ibs

NOZZLE HOLDER

ADJUSTING

ROO

(4)

PIECE

t-::(.....--NOZZLE

PIECE

t9.6

to 24.5

N·m

Tightening

torque

Overflow

pipe

nut

2.0

to

2.5 kgf·m

14.5 to 18.1

«·Ibs

NUT

(7)

49.0 to 68.6

N·m

Nozzle

holder

assembly

5.0 to 7.0 kgf·m

36.2 to 50.6 «·Ibs

Engines & Generators

20

DISASSEMBLY

Governor Fork Lever Assembly

1. Pull off the governor fork lever shaft (Dia.: 4 mm,

2.

Unhook the governor spring (3) side.

3. Remove the governor fork housing (5).

(When reassembling)

• After reassembling the governor housing assembly, check the movement control lever and the stop lever.

•

NOTE

• When assembling the inside parts, put the oil on each Inside part slightly.

•

Be careful not

Boost

Arms

1. Remove the boost actuator (1).

2. Remove the

3. Remove the boost arms (3) and the boost spring (4) from the

(fi).

Tightening

torque

Pitch:

of

III equipped Boost Compensator)

cir-clip (2).

0.7 mm, Length: more than 25

lever assembly from the governor

the governor fork lever assembly, the speed

to

deform the start spring.

Boost

actuator 4.0

(1)

with the extra screw

at

the governor fork lever (4)

39.2

to

45.1

N·m

to

4.6 kgf·m

28.9

to

33.3 ft-Ibs

I

ASSEMBLY

mm).

GOVERNOR

()

(

(4)

\\~

."::J::-

__

IIOOiHACTUATOR

I ·,ClIP

'~~::r==a~f:~lli::=

(5)

__

BOIOST

nr--Rnln<T

ARMS

SPRING

(1)

(2)

3)

(4)

(5)

HOUSING

GOVERNOR

SPRING

(5)

,----FORK

t

GOVERNOR

LEVER

FORK LEVER

SHAFT

r~

I

(4)

.

~

WESTERBEKE

Engines & Generators

21

REMOVING ARMS

AND

THE

C/R-CLIP

SPRING

BOOST

DISASSEMBLY

1.

Remove the speed contra) lever (1) and the return spring.

2.

Remove the governor lever assembly (3) from the governor housing.

3. Remove the start spring

Stop Lever

1. Remove the stop lever (1) and the return spring.

2.

Remove the stop lever shaft.

'RETURN SPEED LEVER

CONTROL

(1)

SPRING

(4) and the stop spring.

I

ASSEMBLY

SPEED LEVER

CONTROL

(1)

=

b

STOP

SPRING

~

WESTERBEICE

Engines & Generators

22

DISASSEMBLY

I

ASSEMBLY

Fuel Camshaft and Governor Weight

1.

Separate the governor housing assembly from the injection

pump unit.

2.

Remove the governor sleeve.

3.

Remove the injection pump assembly.

4.

Remove the cover.

5.

Remove the fuel camshaft lock screws.

6.

Fix

the fuel camshaft with open end wrench

(See the "Injection Pump Unit".)

(4),

and

remove

the governor weight mounting nut and the governor weight (5).

7.

Loosen the fuel camshaft stopper mounting screws and remove the fuel camshaft stopper (6).

8.

Pull out the fuel camshaft

9.

After removing the bearing's cir-clip

(7)

and bearings

(8)

together.

(9),

press out the

bearings .

•

NOTE

• Do not use the fuel camshaft lock bolts, when removing the governor weight mounting nut. Otherwise, the bolts

or

injection pump housing might get damage.

(When

reassembling)

lock

• Press the bearings into the fuel camshaft.

• Set the cir-clip at the gear side's bearing.

• Install the fuel camshaft and bearings to the injection pump housing.

• Attach the fuel camshaft stopper and tighten the

fuel

camshaft

stopper mounting screws with the specified torque.

• Attach the governor weight

to

the fuel camshaft and tighten the

governor weight mounting nut with specified torque.

Tigntening

torque

Injection

mounting

Injection

mounting

pump

screw

pump

nut

23.510 27.5

2.4

10

17.4 to 20.3

17.71020.6 I.B

10

13.01015.2

2.B

2.1

N·m

kgf·m

ft-Ibs

N·m

kgf·m

ft-Ibs

--------

COVER

BEARINGS

B

~

WESTERBEKE

Engines & Generators

23

GOVERNOR WEIGHT

(5)

DISASSEMBLY/ASSEMBLY

Fuel Camshaft

and

Governor Weight (Continued)

(When reassembling)

•

Fix

the

fuel

camshaft with lock bolts

camshaft

(10)

is

upward.

• Install the injection pump assembly housing.

• Attach

the

O-ring

and

the cover

mounting screws.

• Install the governor sleeve

• Check the movement

•

NOTE

• Be careful

not

to

damage the O-ring.

• Be careful the direction

•

When part

Tightening torque

Replacing .Injection

• The Injection

reassembling

slightly.

Fuel camshaft stopper

mounting screw

Governor weight

mounting nut

Pump

pump

to

of

the governor sleeve .

of

inner

Assembly IIf necessary)

can be replaced

whatever position.

,.

1. Disconnect all injection pipes.

2.

Disconnect the fuel pipe

3.

Disconnect the connector

remove the stop

solenoid.

4. Detach the sight cover

5.

Unhook the starter spring

(5)

(2)

(3)

from

(6),

as

the

key

way of fuel

to

the injection pump

and

tighten the cover

the

fuel

camshaft.

the governor sleeve.

parts,

and

fuel overflow pipe.

oil

each

to

9.3 N·m

7.9

0.80

to

0.95 kgf·m

5.8

to

6.9 n-Ibs

to

72.6

62.8

6.4

to

46.3

with

N·m

7.4 kgf·m

to

53.5 n·lbs

the crankshaft in

from the stop solenoid. Then

the injection pump

and

remove the control

unit.

rod

nut.

~./Jii;~_;FUEL

CAMSHAFT

KEY

WAY

(10)

6.

Slide off the governor connecting injection pump assembly.

7.

Remove the injection pump mounting screws

take out the injection pump assembly .

• NOTE

• Be careful

•

Be

careful

• When taking not

to

not

to

drop

the anti-rotation nut.

not

to

deform the start spring.

out

the injection pump assembly,

hit

it against the governor connecting rod.

(When reassembling)

• Install the

new

injection pump according

procedure.

rod

(7)

from the

~

rock

of

and

nuts,

and

be

careful

to

the installing

WESTERBEKE

Engines & Generators

24

CONNECTING

-'-----------CONNECTING

ROD

(7)~~-lm""'1

STARTER

SPRING

(6)

~GOVERNOR

ROD

(7)

DISASSEMBLY

Installing Procedure of Injection Pump Assembly

1.

Install the fuel injection pump assembly (1) in its unit

see

N·m

kgf·m

of

if the fuel

to

the start

hook the governor connecting rod to the rack pin injection pump assembly.

2.

Place the service jig

fuel injection pump unit.

the

3.

Make sure the permanent magnet at the tip of the service jig is

(3)

in

the stop solenoid mounting hole of

attracted to the governor connecting rod (4). To do this, turn the jig a

little clockwise and counterclockwise and look into the fuel injection pump unit sight hole to see if the governor connecting

4.

Slightly tighten the anti-rotation nut of the governor connecting

rod

(4)

moves right and left accordingly.

rod.

5.

Holding down the service jig (3) by hand, tighten up the anti-

(5)

to

rotation nut

6.

Hook the start spring

the specified torque.

(6)

to the rack

pin.

Installing Procedure (Continued I

1.

Move the stop lever

(1)

and visually check

to injection pump control rack comes smoothly back position by the counter force of the start spring.

2.

If the control rack fails to move back smoothly, remove the

nut,

start spring and the anti-rotation

take the above steps

from 2 of the former page again.

3.

Finally fit the sight cover and the stop solenoid back into place.

2.8 to 4.0

Tightening

torque

Anti-rotation

Injection mounting

nut

pump

screw

pump

nut

0.29 to 0.41 kgf·m

2.1

to 3.0 ft·lbs

23.5 to 27.5

2.4 to 2.8 kgf·m

17.4 to 20.3 ft-Ibs

17.7 to 20.6

1.8 to

2.1

to 15.2 ft·lbs

13.0

I

ASSEMBLY

(2),

and

the fuel

JIG

CONNECTING

(4)

SLIDING POINT

)

Engines & Generators

25

START

RACK

SPRING

(5)

DISASSEMBLY

I

ASSEMBLY

Alternator Drive Pulley

1.

Lock

the

flywheel

in place.

2.

Remove

the

crankshaft

screw.

3.

Draw

out

the

drive

pulley.

(When reassembling)

255.0

to

274.6

N·m

Tightening

torque

Crankshaft

screw

26.0

to

28.0 kgf·m

188.1

to

202.5 ft·lbs

Alternator Drive Fan Pulley

RADIATOR

MODELS

1.

Lock

the flywheel

in

place.

2. Remove the crankshaft

screw.

3. Draw out the drive

fan

pulley.

Water

Pump and Oil Cooler

Water Pump

1. Remove the pipe band and the water

pipe_

2.

Remove the water pump

..

(When reassembling)

• When mounting the water pump, take

care

not to forget

mounting the

O-ring and not to let it out of position.

Oil Cooler

1. Remove the water pipe.

2.

Remove the oil filter cartridge (2) and the oil cooler joint screw.

3.

Remove the oil

cooler.

39.2

to

44.1

N·m

Tightening

torque

Oil

cooler

joint

screw

4.0

to

4.5 kgf·m

28.9

to

32.5 ft·lbs

COOLER

OIL

FILTER

(2)

Englne~

& Generators

26

WATER

PIPE

ORIVE

PULLEY

CRANKSHAFT SCREW

/,0'//-<1>.

-WATER

PUMP

DISASSEMBLY/ASSEMBLY

Gear Case

Gear Case Cover

1.

Remove the gear case cover.

(When reassembling)

• Confirm that the liquid gasket coating surface dust and

oil in order to maintain sealing effect.

• Carefully apply the adhesive evenly. Refer to the illustration .

•

NOTE

• When mounting the adhesive-applied parts, take care to

fit

them

to

the mating parts.

• Assemble the adhesive-applied parts within ten minutes.

• Apply a liquid gasket (Three Bond 12170) to the gear case cover.

23.5

2.4

17.4

Tightening torque

Gear

case

mounting screw

cover

Relief Valve

1.

Remove the relief valve retaining screw.

2.

Remove the relief valve (2), the spring (3) and the packing.

Tightening torque

Relief valve retaining

screw

68.6

7.0

50.6

to

27.5

to

2.8

to

20.3 h-Ibs

to

78.4

to

B.O

to

57.9 h-Ibs

is

free

N·m

kgf·m

N·m

kgf·m

of

water,

,/,LIUIUIU

GASKET

Idle Gear and Camshaft

1.

Remove three set screws of the idle gear and draw out the idle

gear

1,

2.

Remove two set screws of the camshaft stopper

the camshaft.

(When reassembling)

• Set the crankshaft at the top dead center of cylinder and the camshaft key to the top position and align the marks of

Refer

idle gear 1

to

the illustration .

a.nd

idle gear 2

• Mount the injection pump gear

case.

CamShaft

Tightening torque

Idle

screw

set screw

gear mounting

and

No.

to

assemble them.

(1)

after installing the gear

23.5

to

27.5

N·m

2.4

to

2.8

17.4

23.5

2.4

17.4

kgf·m

to

20.3 h-Ibs

to

27.5

N·m

to

2.8

kgf·m

to

20.3 «-Ibs

"""

WESTERBEKE

Engines & Generators

27

draw out

1 and 4

INJECTION

PUMP

GEAR

(1)

~ ~VALVE

!-SPRING

~PACKING

§-RETAINING

..-i...-IDLE

CRANK

'GEAR

RELIEF

SCREW

GEAR

(2)

(3)

(1)

DISASSEMBLY

Idle Gear 1 and Idle Gear 2 (For Balancer Modell

1.

Remove the idle gear mounting screws.

2. Draw out the idle gear (2) and (3).

(When

• When install the idle gear

reassembling)

(2)

and

(3),

cylinder piston at the top dead center align all mating marks gears, set the idle gear last.

on

each gear

be

sure

in

compression then,

to

assemble the

to

place the 4th

I

ASSEMBLY

o

MOUNTING

SCREWS

tifTling

CAMSHAFT

Tightening

torque

Idle

screw

gear

mounting

23.5 to 27.5

2.4 to 2.8 kgf·m

17.4 to 20.3 ft·lbs

N·m

~

Camshaft and Balancer Shaft (For Balancer Model)

1.

Remove the camshaft set screws and draw out the camshaft.

2.

Remove the balancer shaft 1 set screws and draw out the

balancer shaft

3.

Remove the balancer shaft 2 set screws and draw out the

balancer shaft

(When

reassembling)

• When. install the balancer shaft 1 and 4th

cylinder piston at the top dead center

1.

2.

2,

be sure to place the

in

compression then,

align all mating marks on each gear to assemble the timing

gears, set the

Tightening

torque

idle gear last.

Camshaft

Balancer

set

shaft

screw

set

screw

23.5 to 27.5

2.4 to 2.8 kgf·m

17.4 to 20.3 ft·lbs

23.5 to 27.5

2.4 to 2.8 kgf·m

17.4 to 20.3 It·lbs

N·m

CRANK GEAR

BALANCER

SHAFT

1

BALANCER

2

v

o

Plate (Gear Case)

1.

Remove the three plate mounting screws. Detach the plate.

(When

reassembling)

• Apply Three Bond 12170 adhesive or equivalent over the shaded zones

sandwiched between the crankcase and Be sure to fix the O-rings.

•

Tightening

LIQUID

GASKET

torque

on

both sides of the gasket that will be

plate.

Plate

mounting

screw

23.5 to 27.5

2.4

to

17.4 to 20.3 ft·lbs

LIQUID

GASKET

N·m

2.8

kgf·m

I!ngfnes & Generators

o

GEAR CASE PLATE

28

DISASSEMBLY/ASSEMBLY

Oil Pan and Oil Strainer

the

1. Unscrew

2.

Unscrew

strainer

oil pan mounting screws and remove the oil

the oil strainer mounting screw, and remove the oil

(2).

(When reassembling)

• Install

• Apply liquid shown.

• Confirm dust

• Carefully apply the adhesive evenly .

• NOTE

the

oil strainer, using care not to

gasket (Three Bond 1217D) to the oil pan

that

the liquid gasket coating surface is free of water,

and oil in

order

to maintain sealing effect.

damage

the.

• When mounting the adhesive-applied parts, take care

fit

them

to

the mating parts.

• Assemble the adhesive-applied parts within ten minutes.

• To avoid uneven tightening, tighten mounting screws

diagonal order from the center.

• After cleaning the oil strainer, install it.

• Attach the

the

oil pan with

air

suction side.

its

central drain plug facing toward

pan.

O·ring.

as

to

in

OIL

STRAINER

OIL

LIQUID GASKET

PAN

o

PISTON AND CONNECTING Connecting

1.

Remove cap. Remove

2.

Rod

Cap

the

connecting rod screws (1) from connecting rod

the connecting rod caps.

(When reassembling)

• Align

•

• Fit

Tightening torque

the

marks (a) with each other. (Face the marks toward

the

injection pump.)

Apply

engine oil to the connecting rod screws and lightly screw

it in

by

hand, then tighten it to the specified torque.

If

the

connecting rod screw won't be screwed

clean

the

threads.

If

the

connecting rod screw is still hard to screw in, replace

When

marks

to

toward the

using

the

existing crank pin bearing again, put tally

on

the crank pin bearing and the connecting rod

keep

their positioning.

the

crank pin bearing in the connecting rod, and the non-grooved side toward

cap.

Connecting

rod

ROD

place:

screw 8.0

its centrally groove side

78.5

57.9

to

8.5

to

in

83.4

N·m

kgf·m

61.5 ft-Ibs

smoothly,

it.

in

order

CONNECTING ROD

SCREWS

(1)

WRENCH

•

~

WESTERBEKE

Engines & Generators

29

ALIGN

(a)

DISASSEMBLY

I

ASSEMBLY

Pistons

1.

Turn the flywheel and set a piston

to

the top dead center.

2. Pull out the piston upward by lightly tapping it

from

the

bottom

of the crankcase with the grip of a hammer.

(When reassembling)

• Before inserting the piston into the cylinder, apply enough engine oil to the cylinder.

• When inserting the piston into the cylinder, face

the

mark

on

the connecting rod

to

the injection pump .

•

IMPORTANT

• Do

not

change

the

combination

of

cylinder and piston.

Make

sure

of

the

position

of

each

piston

by

marking. For

example,

mark

"1"

on

the

No.1

position.

• When

inserting

the

piston

into

the cylinder, place the gap

of

the

compression

ring 1

on

the

opposite side

of

the

combustion

chamber and stagger the gaps

of

the

compression

ring

2 and

oil

ring marking a right angle

from

the

gap

of

the

compression ring 1.

•

Carefully

insert

the.

pistons

using

a piston ring

compressor

(1). Otherwise,

their

chrome-plated section

may

be

scratched, causing

trouble

inside the liner.

Piston Ring

and

Connecting

Rod

1.

Remove the piston rings using a piston ring tool.

2.

Put the

fan

shaped concave

(8)

on

the piston

as

shown.

3.

Remove the piston

(1),

and

separate the connecting

rod

(7)

from

the

piston.

(When reassembling)

• Be sure to fix the crankpin bearing and the connecting

rod

are

same I.D. colors.

• When. installing the ring, assemble the rings sa that the manufacture's mark

(12)

near the gap faces the top of the

piston.

• When installing

the

oil

ring onto the piston, place the expander

joint (10)

on

the

opposite side of the oil ring

gap.

• Apply engine

oil

to

the piston

pin.

• When installing the piston

pin,

immerse the piston

in

80°C

(176

of)

oil

for

10

to 15 minutes and insert the piston

to the

piston.

(6)

(A)

(8)

Second

Rlnl!l

(C)

011

Ring Gap

(D)

Piston

Pin Hole

,

CONCAVE

(e)

(a) 0.79 red. (45 j

(B)~

• Assemble

the

piston to the connecting rod with

the

aligning the

(A)

Connecting Rod

1.0.

Color:

/

direction of

the

fan

shaped concave

(8)

of piston head and the Blue

or

without

color 0

mark

(9)

of

connecting

rod.

(B) Crankpin Bearing

1.0.

Color:

'

• The end faces of the oil ring

are

plated with hard chrome.

In

Blue

or

without

cOlor~-

Oil

RING

putting the piston into

the

cylinder,

be

careful not to get the

oil

.

/GAP

ring scratched by the cylinder.

Use

the piston ring fitter to

~~r:n~~

y -

tighten up the oil ring.

If

the ring's planting is scratched, it may

~

t t

k

th

I

· d

II

. . t

bl

MARK

THE

SAME

NUMBER

ON

ge

s uc

on e cy

In

er

wa

,causing a serious

rou

e.

THE

CONNECTING

ROD

AS

THE

.

PISTON

SO

AS

NOT

TO

CHANGE

THE

COMBINATION

-..y:

WESTERBEKE

. Engines & Generators

30

MTGS.

MAR

(12)

DISASSEMBLY

I

ASSEMBLY

Flywheel and Crankshaft

Flywheel

1.

Install the flywheel lock not turn .

•

NOTE

•

Do

not

use an impact wench. Serious damage will occur.

2. Detach

3. Remove the flywheel.

the

flywheel

(When reassembling)

• Apply ergine

oil

to

the

• Before fitting the flywheel oil, dust and other foreign substances

• The flywheel

and

the

position. Make sure they

Tightening torque

Flywheel

Bearing Case Cover

•

NOTE

• Before disassembling, check the side clearance

crankshaft. Also check

1.

Remove the bearing

2.

Screw two removed screws into

case cover

to

remove

(When reassembling)

•

IMPORTANT

• In case installing install

of

replacing the oil seal, use caution when

the seal in the bearing case cover as not to

it

tilted. The seal should

• Confirm that the liquid gasket coating surface is free

•

water, Apply

dust

and oil

liquid gasket (Three Bond 12170) to the bearing

case cover as shown.

• Before installing the bearing case cover I assembly,

lube the seal and be careful not to damage the

seal while installing the assembly.

Install position

the bearing case cover I oil seal assembly to

the casting mark "UP" on

• Tighten the bearing case cover mounting screws with

even force on the diagonal

•

NOTE

• When mounting the adhesive-applied parts, take care to

fit

them to the mating parts.

• Assemble the adhesive-applied parts within ten minutes.

Tightening torque

Bearing mounting

so

that the flywheel does

screws.

flywheel

crankshaft

screw

case

screws.

and

the

crankshaft together, wipe

off

their

are

fitting together

are

tightly fit

it

during reassembly.

over

mounting screws.

and

98.110 107.9

10.0 to 1 t

72.3 to 79.6 «-Ibs

the

screw

drive

hole

mating

the

N·m

.0

kgf·m

(3)

it.

be

flush with the cover.

in

order to maintain sealing effect.

it

upward.

line .

case

screw

cove'r

23.5 to 27.5

2.4 to 2.8 kgf·m

17.4 to 20.3 «-Ibs

N·m

faces.

in

just

bolts.

of

bearing

oil

one

seal

of

TOP

MARK

UP

TWO

SCREW

HOLES

(3)

LIQUID GASKET

Engines & Generators

31

DISASSEMBLY

I

ASSEMBLY

Flywheel Housing

1.

Remove

the

flywheel housing.

(When

reassembling)

•

Tighten

the

flywheel housing mounting screws with

even

force

on

the diagonal line.

• Make sure

the

crank cases 1

and

2 are clean. Install them

in

position, referring

to

the flywheel housing's contoured face.

Flywheel housing

77.5

to

90.2

N·m

Tightening torque

mounting screw

7.9

to

9.2

kgf·m

57.1

to

66.5 «·Ibs

Crankcase 2

1.

Remove the crankcase 2.

(When reassembling)

•

IMPORTANT

• Make sure

the

crankcase 1 and 2 are clean.

•

Apply

liquid

gasket (Three

Bond

12170)

to

the crankcase

2

as

shown.

•

Tighten

the crankcase 2

mounting

screws

with

even

force

on

the

diagonal line.

•

Confirm

that the

liquid

gasket coating surface is free

of

water,

dust

and oil

in

order

to maintain sealing effect.

• Carefully

apply

the

adhesive evenly.

•

NOTE

• When

mounting

the

adhesive-applied parts, take care to

fit

them

to the mating parts.

• Assemble the adhesive-applied parts

within

ten minutes.

Crankcase 2 mounting

Tightening torque

screw

Crankcase 1 and Crankcase 2

(When

reassembling)

49.0

to

55.9

N·m

5.0

to

5.7 kgf·m

36.2

to

41.2 «·Ibs

• Match the crankcase 1

and

2,

referring

to

the

flywheel

housing's contoured face.

• Tighten the crankcase 2 mounting screws loosely.

• Tighten

up

the jig to the specified torque same

as

the

flywheel

housing screw. This helps

to

minimize

the

level difference

between

the

crankcase 1

and

the

crankcase 2 (at

the

flywheel

side). Possible gap must

be

0.05

mm

(0.0020

in.)

or smaller.

Crankcase 2 mounting

49.0

to

55.9

N·m

5.0

to

5.7 kgf·m

screw

36.2

to

41.3 It·lbs

Tightening torque

Flywheel housing

77.5

to

90.2

N·m

7.9

to

9.2

kgf·m

mounting screw

57.1

to

66.5 ft·lbs

~

WESTERBEKE

Engines & Generators

32

[/0

0

0 0

°

SIT

'1

/~

~

o

Sil

}(r9J

~

1=

'fA,-

0

f-

°

fir

1\

l=

•

0

0 0

~

co:,":::>

,

~

CRANKCASE

2

,0

0

0"l

;J

\..

/

\..0

~

,

~]

0

)(,

f-n

0

1-

U~

-

b

)

0

0 0

Jf~

)(

~-'O\_.

0

i5'J

.<.J J

CRANKCASE

1

GAP

FLYWHEEL HOUSING

DISASSEMBLY

I

ASSEMBLY

Crankshaft

1.

Remove the main bearing case.

2.

Remove the crankshaft.

(When

reassembling)

• Reassemble

the main bearing case having the same number as the one engraved on the crankcase, and set the casting mark

"F

/ W SIDE"

on

the main bearing case facing towards

the

flywheel side.

• Reassemble the thrust bearing (2), with the oil groove facing outside, into both side of the fourth main bearing case.

•

Apply

oil to the main bearing case screws and tighten them

to

the specified torque .

Main

bearing

case

137.3 to 147.1

N·m

Tightening

torque

14.0 to 15.0 kgf·m

screw

101.3 to 108.5 «-Ibs

/:

~:a;;t~~~~~;:~;2:,-)FOURTH

MAIN

,

EARING

CASE

THRUST

BEARING

(2)

~

--.v-

WESTERBEKE

Engines & Generators

33

1\

.;..;:.!---CRANKCASE 2

JIG

~CRANKCASEI

(21

STARTER

MOTOR

SERVICE

Disassembling

1.

Disconnect the solenoid switch.

2.

Remove the two through screws 9 ) and the

two

brush

rear end frame (13) and the brush holder.

3.

Disconnect

(11). Remove also the

{he armature.

4.

Remove the set

planetary

5.

Take out the shaft assembly. Take note of the

position

•

IMPORTANT

•

Before

yoke

and

• Take

•

NOTE

• Do

(When

•

note setup Apply

and

Apply grease (DENSO.CO. indicated

bolt.

grease

ball

not

damage

reassembling)

Motor

holder lock screws. take out the

the armature

of

gears and another packing.

of

the lever.

disconnecting the yoke,

the

front bracket.

of

the

to

.

in

the

packings (8), the four

positions

the gears, bearings, shaft's sliding part

to

the brush and commutator.

illiJstration.

(10)

ball (7) from the tip

and the yoke

of

the set

No.

50

put

or equivalent)

tally marks on the

of

GEAR

ASSEMBLY~

packings and the

to

the

..

parts

_.-?

Gear Front Bracket Solenoid

Overrunning Clutch

Internal Gear

Planetary Gear Sail

SOLENOID

SWITCH

rl'-\ll.'I'I''''-""''

FRONT BRACKET

Switch

'~~~.':,~:~

fi~\i~

ARMATURE

FOUR PLANETARY GEARS

(10)

Set of Packings Through Screw Armature

Yoke

Brush

Holder

Rear End Frame

BAL~(7)

Commutator and Mica

1.

Check the contact face the

commutator

2. Measure the commutator several points.

3.

If

the minimum

armature.

4.

If

the

difference

correct the commutator

5.

Measure the mica undercut.

6.

If the undercut saw blade and chamfer

Commutator

Mica

0.0.

undercut

with

emery paper

0.0.

is

of

the

is

less

than

Factory spec.

Allowable limit

Factory spec.

Allowable limit

less

of

the

commutator for

if

it

0.0.

with

an

than

the

allowable

O.D.'s exceeds

on a lathe

the

segment edges.

to

the

allowable limit, correct

wear,

and

is

slightly

outside micrometer

factory specification.

32mm

1.2598

31.4

1.2362

0.50

0.0197

0.20

0.0079 in.

worn.

limit,

replace

the

allowable limit,

in.

mm

in.

to

0.80

mm

to

0.0315

mm

in.

it

grind

with

at

the

a

SEGMENT~OEPTH

CORRECT

~

INCORRECT

~MICA

OF

.;

-

MICA

-..yo"

WESTERBEKE

Engines & Generators

34

STARTER

MOTOR

SERVICE

Brush Wear

1.

If

the contact face of the brush is dirty or dusty,

clean

it with

emery paper.

2.

Measure the brush length (A) with vernier calipers.

3.

If the length is less than

the

allowable limit, replace

the

yoke

assembly and brush holder.

Factory

spec.

18.0mm

0.7086 in.

Brush

length

CA)

Allowable

limit

t t.O

mm

0.433t in.

Armature Coil

1.

Check the continuity across the commutator

and

armature coil

core with an ohmmeter.

2.

If it conducts, replace the armature.

3.

Check the continuity across the segments of the commutator

with an ohmmeter.

4.

If it does not conduct, replace the armature.

Commutator

Infinity

Resistance

Armature

coil

core

Commutator

segment

OQ

Overrunning Clutch

1.

Inspect the pinion for wear or damage.

2.

If there is any defect, replace the overrunning clutch assembly.

3.

Check that the pinion turns freely and smoothly

in

the

overrunning direction

and

does not siip

in

the

cranking

direction.

4.

If the pinion slips or does not rotate

in

the

both directions,

replace the overrunning clutch assembly.

Brush Holder

1.

Check the continuity across the brush holder

and

the

holder

support with an ohmmeter.

2.

lfit

conducts, replace the brush holder.

Resistance

Brush

holder

-Holder

support

Infinity

Engines & Generators

35

A

BRUSH

lENGTil

INSPECTING THE ARMATURE COIL

INSPECTING

THE OVERRUNING CLUTCH

STARTER

MOTOR

SERVICE

Field Coil

1.

Check the continuity across the lead (1) and brush (2) with

an

ohmmeter.

2.

If

it does not conduct, replace the yoke assembly.

3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

4.

If it conducts, replace the yoke assembly.

Resistance

Lead (1) • Brush (2)

o

~l

Brush (2) • Yoke (3)

1nfinity

Bearing

1. Check the bearing for smooth rotation.

2.

If it does not rotate smoothly, replace it.

SlalQr

1. Measure the resistance across each lead of the stator coil with an ohmmeter.

2.

If the measurement

is

not within factory specification, replace

it.

3. Check the continuity across each stator coil lead and core with an ohmmeter.

4.

If infinity is not indicated, replace it.

I

Resistance

I

Factory

spec,

I

Less

than

1.0

n

Engines & Generators

36

DESCRIPTION

The stator is rectifier package converts the battery charging

Power alternator

package contained These alternators produce a rated output of

rated output

!pm at

alternators are

range of

connected

AC

to the regulator

is

provided

is

achieved

an

ambient temperature of 75'F (23.8'C). The

designed

-40'

to

a three-phase,

which

contains generated and

accessories,

and

by

the

in

the

alternator.

at

approximately 6000 alternator

to

operate

212'F (-40'

in

the

field

to

six

the

stator

field

diode

lOO'C).

full-wave

diodes.

to a DC

of

the

(or

in

an

ambient temperature

INSPECnDN

When

rebuilding

and

inspected. The housing

and

the alternator

wire

brush.

wiring connections that connect

Thm

the rotor

Make

pulley

the

engine,

temninal certain

by

the

alternator

can

be

studs should

the

studs

to

hand.

It

should tum

wiped

are

tight

the

wiring

be

ALTERNATOR

bridge

The bridge

output

for

integral regulator

diode trio)

50

or

51

amps.

should

be

cleaned

off

with

a solvent

cleaned

with

and

clean

harness.

smoothly.

a

the

SERVICE

FRONT

BRACKET

(1)

60

AMP

ALTERNATOR

CASE

REFER

TO DIAGRAM MANUAL WIRING

CONNECnONS

GROUND

THE

WIRING

IN

THIS

FOR

ALL

REAR

BRACKET

(2)

DISASSEMBLE

Front Bracket

1. Remove the 4 screws.

2.

Separate the fron! bracket (1) and the rear bracket

each other .

•

IMPORTANT

•

Put

a tally

reassembling

Pulley

1.

Hold the rotor (base of the claw) using a M24 box wrench.

Tightening torque Pulley nul 5.95

Rotor

1.

Remove the 4 screws and detach the bearing retainer.

2. Temporarily install the nut rotor.

Brush

1.

When the rotor is detached, the 2 brushes are found out of the shaft hole.

ALTERNATOR

line

on

the

front

them

later.

on

bracket

the pulley screw, and detach the

and

the

rear bracket

in

a vise. Loosen the lock nut

58.3

to

78.9

to

8.05 kgf·m

to

58.2 ft·lbs

43.0

N·m

(2)

to

stretch

from

for

--

-

--

-

REMOVE 4 SCREWS

0-

00-

MOUNTING SCREWS

Engin'!.s & Generators

37

TWO

BRUSHES

ALTERNATOR

Reassembling the Brush

1.

Fit the brush with

when viewed from front.

•

IMPORTANT

• Be

sure

to

keep the 2 brushes deep Otherwise into

position.

• Use a 4 Using

• popping

2. Match the tally line

section.

the

mm

a pin-pointed (2 mm) punch, keep the brushes

out.

3. Tighten the 4 screws, and draw out the pin-pointed punch out

of the brush holder.

Bearing at

1. Lightly secure the rotor (1) with a vise

remove the bearing

Slip Ring Side

rotor

hex.

its

sliding face

and the rear section can

wrench

to

of

the front section with that

(2) with a

push

puller.

in

the

in

the brushes

clockwise direction

the

brush

to

prevent damage. and

not

into

of

holder.

be

filted

place.

from

the rear

SERVICE

TWO

BRUSHES

PUNCH

WRENCH

Bearing

1. Check the bearing for smooth rotation.

2. If

it

does not rotate smoothly, replace it.

SIatQr

1.

Measure the resistance across each lead an ohmmeter.

2. If the measurement

it.

3.

Check the continuity aoross each stator coil lead and core with an ohmmeter.

4.

If infinity is not indicated, replace

I

Resistance

is

not within factory specification, replace

it.

I Factory

spec.

of

the stator coil with

I Less than 1.0

(l

ROTOR

BEARING

(2)

MA7CHI!IG

TALLY

LINES

THE

Engines & Generstors

CHECKING CONTINUITY

38

ALTERNATOR

BQlQr

1.

Measure

ohmmeter.

2.

If the resistance

3.

Check the continuity across the slip ring and core with ohmmeter.

4.

If infinity

I

Resistance

Slip Rino

1.

Check the slip ring for score.

2.

If scored, correct with

3.

Measure the

4.

If the measurement is less than the allowable limit, replace il.

Slip ring D.D.

Brush

Wear

1.

Measure the brush length with vernier calipers.

2.

If

the

3.

Make sure that the brush moves smoothly.

4.

If

the

Brush length

the

resistance across

is

not the factory specification, replace

is

not indicated, replace

I

Factory

spec.

an

emery paper or

0.0.

of slip ring with vernier calipers.

Factory

spec.

Allowable

limit

it.

the

slip rings with

12.8

to

3.3

on

a lathe.

22.7

mm

0.894

in.

22.1

mm

0.870 in.

(l

measurement is less than allowable limit, replace il.

brush is defective, replace il.

Factory

spec.

Allowable

limit

18.5 mm

0.728 in.

5.0mm

0.1.97

in.

TESTING

an

it.

an

MEASURING SLIP

RINGS

MEASURING

BRUSH

LENGTH

Rectifier

1.

Check the continuity across ohmmeter.

2.

The rectifier is normal if one direction

IC

Regulator

1.

Check the continuity across

terminal of

2.

The

IC

does not conduct

and

does not conduct

IC

regulator with

regulator is normal if the conducts

in

the reverse direction.

B

E

the

each

diode

the

an

ohmmeter.

diode of rectifier with

in

the rectifier conducts

in

the reverse direction.

"B" terminal

in

...v:

and

the

one

direction

WESTERBEKE

Engines & Generators

an

in

"F"

and

CHECKING

CONTINUITY

B

8

TERMINAL

39

-

SERVICING

Cylinder Head

Too Clearance

1.

Remove the cylinder head (remove the cylinder head gasket

completely).

2.

Bring the piston to its top dead center fasten 1.5 mm dia. 5 to

7

mm

long fuse wires to 3 to 4 spots on the piston top with

grease so

as

to avoid the intake and exhaust valves and the

combustion chamber ports.

3. Bring the piston to its middle position, install the cylinder head,

and tighten the

cylinder head screw to specification. (Head

gasket must be changed to new one).

4. Turn the crank shaft until the piston exceeds its top dead

center.

5.

Remove the cylinder head, and measure squeezed fuse wires

for thickness.

6.

If

the

measurement is not within the specified value, check the

oil

clearance

of

the crankpin journal and the piston pin.

0.72

to

0.90

mm

Factory

0.0283

to

0.0354 in.

Top clearance

spec.

Cylinder

head

mounting

98.1

to

107.9

N·m

Tightening

torque

10.0

to

11.0

kgf·m

screw

72.3

to

79.6 ft·lbs

Cylinder Head Surface Flatness

1.

Clean the cylinder head surface.

2.

Place a straightedge on the cylinder head's four sides (A), (B), (C)

and

(D) and two diagonal (E) and (F) as shown

in

the figure. Measure the clearance with a

feeler gauge.

3.

If the measurement exceeds the allowable limit, correct it with a surface grinder.

• IMPORTANT

•

Do

not

place

the

straightedge

on

the

combustion

chamber.

•

Be

sure

to

check

the

valve

recessing

after

correcting.

Cylinder

head

surface

flatness

Cylinder Head Flaw

Allowable limit

0.05 mm

0.0020 in.

1.

Prepare an air spray red check.(Code No. 07909·31371).

2.

Clean the surface of the cylinder head with the detergent (2).

3.

Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.

4. Wash away the red permeative

liquid on the cylinder head

surface with the detergent (2).

5.

Spray the cylinder head surface with the white developer (3).

6.

If

flawed, it can be identified

as

red marks.'

~~~WESTERBEKE

Engines & Generators

40

3EEABAB1P056A

A

E

F

c o

B

Ilil!mll

IDi

s:m:r

illIl:IJIl

Ac-AA

Ie-AS

A!i;f

8

~

SERVICING

Valve Recessing

1.

Clean the cylinder head, the valve face and

2. Insert the valve into the valve guide.

3.

Measure the valve recessing with a depth gauge. If the measurement exceeds the allowable limit, replace the

4. valve.

If

it still exceeds the allowable limit after replacing the valve,

replace the

Valve recessing

Valve Lapping

1.

Apply compound evenly to the valve lapping surface.

2.

Insert the valve into the valve guide. Lap the valve onto its seat with a

3.

After lapping the valve, wash the compound away and apply

oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check the seated rate.

•

IMPORTANT

cylinder head.

Factory Intake o mm (0 in.)

spec. valve (recessing)

Factory Exhaust

spec. valve

Allowable (recessing)

limit

valve flapper or screwdriver.

If it is 'Iess than

70

%, repeat valve lapping again.

0.4 mm (0.0157 in.)

seat

(Protrusion)

0.2

mm

(0.0079 in.)

(Protrusion)

0.'5

mm

(recessing)

0.05

(0.0059 in.)

mm

(0.00t9

to

,

in.)

• When valve lapping is performed, be sure to check the valve recessing and adjust the valve clearance after

assembling the valve.

DEPTH

GAUGE

,*-.l-U))

CYLINDER

HEAD

SURFACE

~~~(A~)~~~~\~i

CYLINDER

(A) Recessing

(8)

HEAD

(8)

Protrusion

SURFACE

..

(

.....

,

Clearance between Valve Stem and Valve Guide

1.

Remove carbon from

2.

Measure the valve stem

3.

Measure the valve guide 1.0. of the cylinder head

wear part gauge.

calculate the clearance.

And

4.

If the clearance exceeds the allowable limit, replace the

valves. guide.

Valve stem

Valve guide

as

shown

If it still exceeds the allowable limit, replace the valve

0.0.

1.0.

the

valve guide section.

0.0.

with an outside micrometer.

with

a small hole

Intake

Factory

spec.

Factory

spec.

valve Exhaust

valve

Intake

valve

Exhaust

valve

at

the most

6.960

to

6.975

mm

0.2740

to

0.2746 in.

7.960

to

7.975 mm

0.3134

to 0.3140 in.

7.030

to

7.045 mm

0.2768

to

0.2774 in.

8.015

to 8.030 mm

0.3155 to 0.3161 in.

Engines & Generators

0

+

Clearance between

valve stem

and

guide

CORRECT

D.D.

Factory

spec.

Allowable limit

~.J

INCORRECT

Intake

valve Exhaust

valve

0

0.055

0.0022

0.040

0.0016

0.1

0.0039 in.

INCORRECT

to

0.085 mm

to

0.0033 in.

to

0.070 mm

to

0.0028 in.

mm

41

SERVICING

Replacing Valve Guide

(When

removing)

1.

Using a valve guide replacing tool, press out the used valve

guide.

(When

installing)

1.

Clean a new valve guide, and apply engine oil

to

it.

2.

Using a valve guide replacing tool, press

in

a new valve guide

until it is

flush with the cylinder head as shown.

3. Ream

precisely the I.D. of the valve guide

to

the specified

dimension .

•

IMPORTANT

•

Do

not

hit

the

valve

guide

with a hammer,

etc.

during

replacement.

(AI

When ,emoving

Correcting Valve and Valve Seat

•

NOTE

(8) When Inslalling

•

Before

correcting

the

valve and seat,

check

the

valve

stem

and

the

1.0.

of

valve

guide

section,

and repair them

if

necessary.

•

After

correcting

the

valve seat,

be

sure

to

check

the

valve

recessing.

1)

Correcting

Valve

1.

Correct the valve with a valve refacer.

2)

Correcting

Valve Seat

1.

Slightly correct the seat surface with a 1.047

rad

(60

0)

(intake

valve)

or

0.785 rad (45

0)

(exhaust valve) seat cutter (Code

No.

07909-33102) .

2.

Resurface the seat surface with a 0.523 rad (30

')

valve seat

cutter to intake

valve seat and with a 0.262

rad

(15

')

valve

seat cutter to exhaust valve seat so that the width is close

to

specified valve seat width (2.12

mm,

0.0835 in.).

3. After resurfacing the seat, inspect for .even

valve seating, apply a thin film of compound between the valve face and valve seat, and fit them with valve lapping tool.

4.

Check the valve seating with prussian blue. The valve seating surface

should show good contact ali the way around.

(a) Identical Dimensions

(bl

Valve Seal Wldlh

(c)

0.523 rad (30 • )

or

0.262 rad (15 • )

(d)

0.262

rad

(15 ' )

or

0.523 rad (30 • )

(e)

0.785

,ad

(45

• )

or

1.047

,ad

(60 • )

(A)

Check Conlacl (8) Correcl Seal Wldlh (C)

Check Conlacl

A

f5

~

L

"~M

. ..l

VALVE GUIDE

~

:;

-

J

(A) (8)

REMOVING

INSTALLING

RESURFACING

Engines & Generators

42

'-

SERVICING

Free Length and Tilt of Valve Spring

1.

Measure the free length measurement is

2.

Put the spring

less than the allowable limit, replace it.

on

a surface plate, place a square

of the spring, and check to see if the entire side is contact with

the square. Rotate the spring and measure the maximum (8).

If the measurement exceeds the allowable limit, replace.

3.

Check the entire surface of the spring for scratches. Replace it, if any.

Factory

spec.

Free length (A)

Allowable

limit

, Till

(B)

, Allowable limil

(A)

with vernier calipers. If the

on

Intake valve

Exhaust

valve

Intake

valve Exhaust

valve

35.1

to

35.6 mm

1.3819 to 1.4016 in.

41.7 to 42.2 mm

1.6417tol.6614in.

34.6 mm

1.3622 in.

41.2 mm

1.6220 in.

1.0

mm

,

~.039

in.

the side

VALVE

SPRING

TESTER

VALVE

SPRING

Valve Spring Setting Load

1.

Place the valve spring length it

2.

Read the compression load

3.

If

the

Setting load 1 Selling

length

is

actually compressed

measurement is less than the allowable limit, replace it.

on

Factory spec.

Allowable

limit

a tester and compress it to the same

in

the engine.

on

the gauge.

Intake

valve

Exhaust

valve

Intake

valve

Exhaust valve

63.547 N 131.5 mm

6.48 kg1/31.5 mm

14.2561bs 11.2401 in.

117.6 N

135

mm

12.0

kgfl35

26.4

Ibs 11.3780

45.864 N 131.5 mm

4.68 kg! 131.5 mm

10.2961bs

100.0 N 135 mm

10.2

kgl/35

22.51bs 11.3780 in.

mm

in.

11.2401 in.

mm

Oil Clearance between Rocker Arm Shaft and Bearing

1.

Measure the rocker arm bearing

I.

O.

with an inside

micrometer.

2.

Measure the rocker arm shaft micrometer, and then

3.

If the clearance exceeds the allowable limit, replace the rocker

arm and measure the

calculate the oil clearance.

oil clearance again. If it still exceeds the

0.0.

with

an

allowable limit, replace also the rocker arm shaft.

Oil arm

ROC'Ker

Rocker

outside

clearance

shaft

and

arm

of

rocker

bearing

shaft

0.0.

1.0.

for

shaft

MEASURING

Factory

spec.

Allowable

Factory

spec.

Factory

spec.

THE

.=,

MEASURING ROCKER

ARM

limit

SHAFTS

THE

1.0.

0.016

to

0.045 mm

0.00063 to 0.00177 in.

0.15

mm

0.0059 in.

15.97310 15.984 mm

0.6289

10

0.6293 in.

16.0001016.018 mm

0.6299

10

0.6306 in.

0.0.

OIL

CLEARANCE

-..v:

WESTERBEKE

Engines & Generators

43

SERVICING

Pysh Rod Alignment

1. Place the push rod

2. Measure the push

3. If the measurement exceeds the allowable limit, replace the push rod.

Push

rod

alignment

Qj! Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet Q.D. with

2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance.

3.

If

the oil clearance exceeds the allowable limit

damaged, replace the tappet.

Oil

clearance

tappet

bore

Tappet

Tappat guide bore

and

tappet guide

0.0.

between

1.0.

on

V blocks.

rod

alignment.

Allowable

Factory

Allowable

Factory

spec.

limit

spec.

limit

spec.

0.25mm

0.0098 in.

an

outside micrometer.

0.020 to 0.062 mm

0.0008 to 0.0024 in.

0.07mm

0.0028 in.

23.959 to 23.980 mm

0.9433 to 0.94t

24.000 to 24.02t mm

0.9449 to 0.9457 in.

or

the tappet

tin.

is

MEASURING PUSH ROD ALIGNMENT

MEASURING TAPPET

000

00

~:O~

00

0

.,

,.-

0

,....,

00

0

00

C

00

,--, ,..

Timing

Gear

and

Camshaft

Timing Gear Backlash

1. Set a dial indicator (lever type) with its tip

2. Move the gear to measure the

backlash, holding its mating

on

the gear tooth.

gear.

3.

If the backlash exceeds the allowable limit, check the

clearance

4.

If the oil clearance isn't proper, replace the gear.

Backlash crank

gear

t

Backlash gear 1 and

Backlash

gear 1

and

of

between

and

idle

between

cam

gear

between

idle

gear 2

the shafts and the gear.

Factory

spec.

gear

Allowable

Factory

idle

Allowable

Factory

idle

Allowable

limit

spec.

limit

spec.

limit

0.049 to

O.OOt

9 to 0.0076 in.

0.22

mm

0.0087 in.

0.049 to

0.00t9

to 0.0074 in.

0.22

rnm

0.0087 in.

0.044 to O.OOt

7 to 0.0073 in.

0.22

mm

0.0087 in.

O. t 93

O.

t89

O. t 85

mm

oil

Backlash gear 2 and

pump

Backlash

geal

and

1

Backlash gear 1 and

gear 2

~-

between

gear

between

balancer

between

injection

balancer

idle

cam

gear

idle

Factory

Allowable

Factory

spec.

Allowable

Factory

spec.

Allowable

spec.

limit

0.044 to 0.177 mm O.OOt

7 to 0.0070 in.

0.22

mm

0.0087 in.

0.047 to

O.OOt

O.22mm

0.0087 in.

0.044 to 0.183 mm

0.0017 to 0.0072 in.

0.22mm

0.0087 in.

0.t82

8 to 0.0072 in.

mm

Engines & Generators

44

SERVICING

Idle Gear Side Clearance

1.

Set a dial indicator with its tip

2.

Measure the side clearance

front and rear.

3.

If the measurement exceeds the allowable limit, replace the

idle gear collar.

Factory

Idle

gear

side

clearance

Allowable

spec.

limit

on

the idle gear.

by

moving the idle gear

0.15 to 0.30

0.0059 to 0.0118

0.9

rnm

0.0354 in.

mm

in.

to

the

DIAL

INDICATOR

Camshaft Alignment

1.

Support the camshaft with V block on the surface plate and set

a

dial indicator with its tip

on

the intermediate journal at right

angle.

2. Rotate the camshaft on the V blocks and get the misalignment of

(half

If the misalignment exceeds the allowable limit, replace the

3.

the measuremeni).

camshaft.

Camshaft

alignment

Allowable

limit

0.01 mm

0.00039

in.

Camshaft Side Clearance

1.

Set

a dial indicator with its tip

2. Measure the side

clearance by moving the cam gear to the

on

the camshaft.

front and rear.

3. If the measurement exceeds the allowable limit, replace the camshaft stopper.

End play of camshaft

Factory

spec.

Allowable

limit

0.07 to 0.22

0.0028 to 0.0087

0.30 mm

0.0118 in.

mm

in.

MEASURING GEAR SIDE CLEARANCE

Cam Height 1

..

Measure the height of the cam at its highest point with outside micrometer.

2.

If the measurement is less than the allowable limit, replace the camshaft.

Intake

Factory

spec.

Intake

and

exhaust

heighl

cam

Allowable

limit

valve Exhaust

valve Intake

valve Exhaust

valve

37.63 mm

1.4815 in.

38.96mm

1.5338 in.

37.13 mm

1.4618 in.

38.46

mm

1.5141 in.

~

an

WESTERBEKE

Engines & Generators

45

CAMSHAFT ALIGNMENT

MEASURING CAM HEIGHT

SERVICING

Oil

Clearance of Camshaft Journal

1.

Measure

the

camshaft journal

0.0.

with

an

outside

micrometer.

2.

Measure

the

cylinder block bore

1.0.

for camshaft with

an

inside micrometer.

3.

If

the

oil

clearance exceeds the allowable limit, replace the

camshaft.

Factory

spec.

0.050 to 0.091 mm

Oil

clearance

of

0.00t97

to 0.00358 in.

camshaft

journal

0.15

mm

Allowable

limit

0.0059 in.

Camshaft

journal

0.0.

Factory

spec.

45.934 to 45.950 mm

1.8084 to 1.8091 in.

Camshaft

bearing

I.D.

Factory

spec.

46.000 to 46.025 mm

1.81

I 0 to 1.8120 in.

Oil Clearance between Idle Gear Shaft

1,

2 and Idle Gear

1,

2

Bushing

1.

Measure the idle gear shaft

0.0.

with

an

outside micrometer.

2.

Measure the idle gear bushing

1.0.

with

an

inside micrometer,

and calculate the oil clearance.

3.

If the.

oil

clearance exceeds the allowable limit, replace the

bushing.

Clearance

between

idle

Factory

spec.

gear

1,

2

shaft

and

idle

gear

1,

2

bushing

Allowable

limit

Idle

gear

1, 2 bushing

Factory

spec.

1.0.

Idle gear " 2 shaft D.D.

Factory

spec.

Replacing Idle Gear Bushing

(When removing)

0.050 to 0.091 mm

0.0020 to 0.0036 in.

0.10 mm

0.0039

in.

45.025 to 45.050 mm

1.7726 to 1.7736 in.

44.959 to 44.975 mm

1.7700 to 1.7707 in.

1. Using

an

idle gear bushing replacing tool, press out

the

used

bushing.

(When installing)

1.

Clean a new idle gear bushing and idle gear bore,

and

apply

engine

oil

to them.

2.

Using

an

idle gear bushing replacing tool, press

in

a new

bushing (service parts)

to

the

specified dimension.

~

WESTERBEKE

Engines & Genera/ors

46

MEASURING

THE

CYLINDER BORE

1.0.

o

REMOVING

•

INSTALLING

REPLACING THE IDLER

GEAR

BUSHING

SERVICING

Balancer-shaft Side Clearance

1.

Set a dial indicator with tip

on

the balancer shaft.

2. Measure the side clearance

by

moving the balancer shaft to

the front and rear.

3.

If the measurement exceeds the allowable limit, replace the balancer shaft.

Factory

spec.

0.070 to 0.220 mm

End play

of

balancer

0.0028 to 0.0087 in.

shaft

0.3

mm

Allowable

limit

0.0118 in.

Balancer-shaft Alignment

1. Support the balancer shaft with V blocks

on

the surface plate

and

set

a dial indicator with its tip on the intermediate journal

at high angle.

2. Rotate the balancer shaft

on

the V block and get the

misalignment (half of the measurement).

3.

If the misalignment exceeds the allowable limit, replace the

balancer

shalt.

Balancer

shaft

a1lgnmenl

Allowable

Jimil

Oil Clearance of Balancer-shaft Journal

O.02mm

0.0008

in.

1. Measure the balancer

~h.aft

journal

0.0.

with

an

outside

micrometer.

2. Measure the

cylinder block bore

1.0.

(A), (8) for balancer shaft

with an inside micrometer.

3.

If

the clearance exceeds the allowable limit, replace the

balancer shaft.

Factory

spec.

0.070 to 0.159.mm

Oil

clearance

of

0.0028 to 0.0063 in.

bah;lncer·shaft

journal

O.2mm

Allowable

limit

0.0079 in.

Balancer-shaft

journal

Factory

spec.

50.92 to 50.94 mm

0.0.

2.0047 to 2.0055 in.

Balancer-shaft

bearing

Factory

spec.

51.01 to 51.08 mm

J.D.

2.0083

10

2.0110 in.

BALANCER

SHAFT

O""-~

\

1)=

~

OJ

L\\

~

MEASURING THE SIDE CLEARANCE

BALANCER

SHAFT

ALIGNMENT

,-

o -

INSPECTING THE

----------l

BALANCER SHAFT

ALIGNMENT

CYLINDER

BLOCK

BORE

BALANCER

SHAFT

JOURNAL

..•

---

./

/-----,

..

....

WESTERBEKE

Engines & Generators

47

--c-J

MEASURING tHE BALANCER SHAFT

JOURNAL

SERVICING

Piston and Connecting Rod

Piston Pin Bore I.D.

1.

Measure the piston vertical directions with a cylinder gauge.

2.

If

the

measurement exceeds the allowable limit, replace the

piston.

Piston

bore

I.D.

Clearance between Piston Ring and Groove

1.

Remove carbon from the ring grooves.

2.

Measure the clearance between the ring and the groove with a

feeler gauge or depth gauge.

3.

If

the

clearance exceeds allowable limit, replace the ring since

compression

4.

If the clearance still exceeds the allowable limit after replacing

leak and oil shortage result.

the ring, replace the piston.

Factory spec.

Allowable limit

bore I.D.

Factory

spec.

Allowable

Compression

Oil

Compression

Oil

limit

ring

in

both the horizontal and

30.000 to 30.013

1.1811 to 1.1816

30.05

mm

1.1831 in.

0.093 to 0.120 mm

2

0.0037 to 0.0047 in.

0.020

to

0.060 mm

0.0008 tq 0.0023 in.

0.20 mm

2

0.0079 in.

0.15 mm

0.0059 In.

mm in.

MEASURING

I

PISTON

BORE

TOP

RING

(A)

PISTON

BORE

a

FACTORY SPECIFICATION

Factory

(A) Top

specification:

Ring

(Key

8

Store

Type)

I More than 0.2 mm

0.0079 in.

(B) 2nd,

011

Ring

Piston Ring Gap

1.

Insert the piston ring into the lower part of the liner (the least worn out part) with the piston.

2.

Measure the ring gap with a feeler gauge.

3.

If the gap exceeds the allowable limit, replace the piston ring.

Compression

Oil

ring

1 . 2

Factory

spec.

Allowable

Factory

spec.

Allowable

limit

0.30 to 0.45 O.Ot

18 to 0.0177 in.

1.25

0.0492

0.25 to 0.45

0.0098 to 0.0177 in.

1.25

0.0492

...v

mm

in.

mm

in.

WESTERBEKE

Engines & Generators

MEASURING THE PISTON RING CLEARANCE

PISTON

RING

MEASURING THE RING GAP

GAP

48

SERVICING

Oil Clearance between Piston

and Small

End

Bushing

1.

Measure the

0.0.

of the piston

where it contacts the

bushing with

an

outside micrometer.

2.

Measure the

1.0.

of the piston pin bushing

at

the connecting

rod

small end with a cylinder gauge.

Calculate the oil clearance.

3.

If the clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston

pin.

Factory

spec.

0.020

to

0.040

mm

Oil clearance between

0.0008

to

0.0016

in.

piston pin

and

small

end

bushing

Allowable limit

O.15mm

0.0059

in.

MEASURING

THE

PISTON

When Removing "

Installing

Piston pin

0.0.

Factory spec.

Small end bushing 1.0. Factory

spec.

Replacing Small End Bushing

(When removing)

30.006 to

30.011

mm

1.1813to 1.1815

in.

30.031

to

30.046

mm

1.1823

to

1.1829

in.

1. Press out the used bushing using a small end bushing replacing tool.

(When installing)

1. Clean a new small end bushing and bore, and apply engine oil to them.

2.

Insert a new bushing onto the tool and press-fit it with a press so that the seam (1) of bushing position

as

shown

until it is flush with the connecting

rod.

Connecting

Rod

Alignment

•

NOTE

• Since the

1.0.

of

the connecting rod small end bushing is the basis of this check, check the bushing for wear beforehand.

1.

Remove the piston pin

in

the connecting rod.

2.

Install the piston pin

in

the connecting

rod.

3. Install the connecting

rod

on

the connecting

rod

alignment tool

(Code

No.

07909-31661).

4. Put a gauge over the piston pin, and move it against the face plate.

5.

If

the gauge does not fit squarely against the face plate,

measure the space between the pin of the gauge and the face

plate.

6. If the measurement exceeds the allowable limit, replace the connecting

rod.

Connecting rod alignment

Allowable limit

O.05mm

0.0020

in

.

.....

WESTERBEKE

Engines & Generators

49

REPLACING

THE

SMALL

END

BUSHING

0.26 'ad (15

')

(e)

(1) Seam

ALIGNING

THE

CONNECTING

ROD

Crankshaft

SERVICING

Crankshaft Side Clearance

1.

Set a dial indicator with its tip

on

the end of the crankshaft.

2.

Measure the side clearance by moving the crankshaft

to

the

front and rear.

3.

If the measurement exceeds the allowable limit, replace the thrust bearings.

4.

If the same size bearing

is

useless because of the crankshaft

journal wear, replace it with

an

oversize one referring

to

the

table and figure.

Factory

spec.

0.15 to 0.31

mm

Crankshaft

side

.0.0059 to 0.0122

in.

clearance

0.50mm

Allowable

limit

0.0197 in.

(Reference)

• Oversize dimensions of crankshaft journal

Oversize

O.2mm O.4mm

0.008

in.

0.016 in.

Dimension

A

29.20 to 29.25 mm 29.40

to

29.45

mm

1.1496101.1515 in. 1.1574 to 1.1594

in.

Dimension

B

169.1

to 169.15

mm

169.2 to 169.25

mm

6.6575 to 6.6594

In.

6.6614 to 6.6634

in.

Dimension

C

2.8

to

3.2

mm

radius

2.8

to

3.2

mm

radius

,

0.1102 to 0.1260 in. radius 0.1102

to

0.1260

in.

radius

(O.B-S)

The

crankshaft

journal

must

be

fine-finished

to

higher

than

V'ilVV

Crankshaft Alignment

1.

Support the crankshaft with V block on the surface plate and

set a

dial indicator with its tip

on

the intermediate journal at

right

angle.

2.

Rotate the crankshaft

on

the V block and get the misalignment

(half

of

the measurement).

3.

If the misalignment exceeds the allowable limit, replace the

crankshaft.

Crankshaft

alignment

Allowable

limit

0.02mm

0.00079

in

.

...v:

WESTERBEKE

Engines & Generators

50

CRANKSHAFT

SIDE

CLEARANCE

DIAL INDICATOR

CRANKSHAFT JOURNAL DIMENSIONS

o

CRANKSHAFT

JOURNAL

•

~

/

CRANKSHAFT

SERVICING

Oil Clearance between Crankpin and Crankpin Bearing

1.

Clean

the

crankpin

2.

Put a strip of plastigage

and

crankpin bearing.

on

the

center of the crankpin.

3. Install the connecting

screws to

the

specified torque, and remove the

4. Measure the amount

rod

cap and tighten the connecting

of

the

flattening with

the

scale,

cap

again.

and

rod

get

the oil clearance.

5. If the oil clearance exceeds the allowable limit, replace the

crankpin bearing.

6. If the same size bearing

wear, replace it with

•

NOTE

•

Never

•

Be rod

Crankpin

Oil clearance between

crankpin and crankpln

bearing

insert

sure

not

screws

0.0.

the

plastigage

to

move

are tightened.

Factory spec.

Allowable limit

is

useless because of the crankpin

an

undersize one referring

into

the

crankpin oil hole.

the

crankshaft while

52.977

2.0857 to 2.0862

0.018

0.0007

0.20

0.0079 in.

to

mm

the

to

0.051

to

52.990

0.0020

to

the

table .

connecting

mm in.

mm

in.

PlASTIGAGE

CRANKSHAFT

a

B

1.0.

o

COLOR

Oil Clearance between Crankpin (Continued)

•

IMPORTANT

• STD

10

Without 56.00 to

color 2.2047 to

size

To

replace

the

crankpin

connecting

Color

Blue

Connecting

Large-end in. dia.

56.01 to 56.02

2.2051 to 2.2055

crankpin

it

with

bearing has

rod.

rod

mm

56.Q1

mm

2.2051

bearing.

a specific STD service part, make sure

the

Class

L

in.

S

in.

• Undersize dimensions of crankpin

Undersize

Dimension A

Dimension B

Dimension C

The

crankpin must be fintl-fjl'Jished to higher than

O.2mm 0.4

0.008 in.

2.8

to 3.2

mm

radius 2.8

0.1102 to 0.1260

1.0

to

1.5

0.0394 to

52.777 to 52.790

2.077810 2.0783

in.

mm

radius

0.0591

in. radius 0.0394 mm

In.

radius 0.1102 to 0.1260

and

Crankpin Bearing

same

Crankpin bearing

Part code

mm

0.Q16 to

1.0

to 1.5 mm radius

52.577 to 52.590

2.07DO

(0.8·S)

vvvv

ID

color

Center

1.496

0.0589

1.491

0.0587 to 0.0589 in.

in.

3.2

mm

to

0.0591

to 2.0705

wall thick

to

1.501

to

0.0591

to 1.496

radius

in.

mm in.

as

mm

radius

the

in.

CRANKPIN

BEARING

CENTER WAll

THICKNESS

~

WESTERBEKE

Engines & Generators

51

SERVICING

Oil Clearance between Crankshaft Journal and Crankshaft Bearing

1.

Clean the crankshaft journal and crankshaft bearing.

2.

Put a strip of press gauge center

•

IMPORTANT

of

the journal.

• Never insert the press gauge into the oil hole journal.

3.

Install the

main

bearing case and tighten the screws to the

specified torque, and remove the cases again.

4.

Measure the amount

of

oil clearance.

5.

If the clearance exceeds the allowable limit, replace the

crankshaft bearing.

Crankshaft journal

Oil clearance

crankshaft

between

journal

bearing

0.0.

and

Factory

Allowable

(Reference)

• Undersize dimensions

Undersize

Dimension A

Dimension B

Dimension C

The

crankpin must

O.2mm

0.008 in.

2.8

to

3.2

0.1102 to

1 .0

to

1.5

0.0394 to 0.0591 in. radius 0.0394 to 0.0591 In. radius

74.777 to 74.790

2.9440

to

be

fine-finished to higher than

on

the

of

the

the flattening with the scale and get the

74.977

to

74.990

spec.

limit

of

crankshaft journal.

mm

radius

0.1260in.

mm

2.9445 in.

radius 0.1102

radius

mm

(0.8-5)

vvvv

2.9518 to 2.9524 in.

0.018

to 0.062 mm

0.0007

to 0.0024 in.

0.20 mm

0.0079

in.

OAmm

0.016

in.

2.8

to

3.2 to

1.0

to

1.5

74.577

to

2.9361

to

mm

radius

0.1260 in. radius

mm

radius

74.590

mm

2.9366 in.

B

A

CRANKSHAFT

A

c

A

JOURNAL

Replacing Crankshaft Sleeve

1.

Remove the used crankshaft sleeve

puller

set.

2.

Set the sleeve guide

3.

Heat a new sleeve to a temperature between 150 to

(302 to 392

4.

Press fit the sleeve using the auxiliary socket for pushing .

•

NOTE

OF),

(4)

to

the crankshaft.

and fix the sleeve to·the crankshaft

• Mount the sleeve with its largely chamfered surface facing outward.

(1)

using a special-use

as

....

WESTERBEKE

Engines & Genera/ors

52

200°C

shown.

CRANKSHAFT

o

CRANKCASE SLEEVE

(1)

SLEEVE GUIDE

AUXILIARY SOCKET

SERVICING

Cylinder

Cylinder Wear

1.

Measure the

cylinder gauge

with a

2.

Get the difference (Maximum wear) between the maximum and the minimum

3.

If the wear exceeds the allowable limit, bore and oversize dimension. (Refer to

4.

Visually check the cylinder wall for scratches. scratches are found, "Correcting

Cylinder

Bor.

1.0.

Cylinder".)

t.D.

of

the

cylinder at the

to

find the maximum

l.o.'s.

the

cylinder should

Factory

spec.

Allowable limit

six

positions

and

"Correcting

be

98.000

3.8582103.8591

98.15 mm

3.8642

minimum I.O.'s.

hone

Cylinder".)

bored. (Refer

10

98.022 mm

in.

If

to

the

deep

to

A

B

(A) Top

(B) Middle

(C)

Bottom

Correcting Cylinder (Oversize + 0.5

1.

When the cylinder is worn beyond the allowable limit, bore and

hone it

Cylinder t.D. (2)

Maximum

Finishing

2.

Replace the piston and piston rings with oversize (0.5 mm)ones.

(Skirt)

to

the specified dimension.

Factory

wear

Allowable limit

Horn

to

V'lV'l

(0.000047

(a) Right-angled to Piston Pin

(b) Piston Pin Direction

mm)

mm

98.500

3.8780

98.65mm

3.88"9

.uR

max.

in.

/JR max.)

spec.

1.2

to

2.0

to

0.000079

to

98.522 mm

to

3.8788

in.

.NOTE

• When the oversize limit,

replace

the

cylinder

is

worn

block

beyond

with

a new one.

the

a"owable

C

MEASURING CYLINDER WEAR

-

,

:CYLINoER

,BEFORE

CONNECTiON:

, -

--

,

:

, ,

,

..

,

'CYLINDER

OVERSIZE

(1

(2)

1.0.

)

1.0.

,

..

,

r--

,....

'-'

Oil Pump

Rotor Lobe Clearance

1.

Measure the clearance between lobes of the inner rotor

the outer rotor with a feeler gauge.

2.

If the clearance exceeds

pump rotor assernbly.

Clearance inner rotor rotor

between and

outer

Factory

Allowable limit

the

allowable limit, replace

spec.

0.04

to

0.0016

0.3

mm

0.0118

...v:

and

the

oil

0.16 mm

to

0.0063

in.

in

.

WESTERBEKE

Engines & Generators

53

FEELER

GAUGE

SERVICING

Clearance between Outer Rotor and

1.

Measure the clearance between

Pump

Body

the

outer rotor and the pump

body with a feeler gauge.

2.

If

the clearance exceeds the allowable limit, replace the oil

pump rotor assembly.

0.100

to

0.184

Clearance

outer

rotor

body

between

and

pump

Factory

spec.

Allowable

limit

0.0039

0.3

mm

0.0118

to

0.0072

in.

mm

in.

Clearance between Rotor and Cover

1.

Put a strip

of

plastigage onto the

rotor face with grease.

2.

Install the cover and tighten the screws with the specified

torque.

3.

Remove the cover carefully,

and

measure the amount of the

flattening with the scale and get the clearance.

4.

If the clearance exceeds the allowable limit, replace oil pump

rotor assembly and the cover.

Clearance

rotor

and

between

cover

Factory

spec.

Allowable

limit

0.02510 0.075

0.0010

0.225 mm

0.0089 in.

to

0.0030

mm

in.

FEELER

GAUGE

Tightening

torque

Oil

pump

cover

screw

7.9

0.80

5.8

to

9.3

N·m

to

0.95

to

6.9 tt-Ibs .

PLASTIGAGE

kgf·m

..,y"

WESTERBEKE

Engines & Generators

54

ENGINE

BODY

SERVICING

SPECIFICATIONS

Item

Cylinder Head Surface Flatness 0.05 mm

Top Clearance

Compression Pressure

Variance Among Cylinders Valve

Seat

Width IN. 2.12 mm

V3300-E2B

V3300-T -E2B 0.92101.10 mm

V3300-E2B 4.32 MPa I 3.26

V3300-T-E2B 3.92

Factory

0.0283

0.0362

Specification

-

0.72

to

0.90 mm

to

0.0354 in.

to

0.0433

250 min" 1 (rpm)

44 kgf/cm2 I 33.2 kgf/cm

250 min·' (rpm)

626 psi

250 min·' (rpm) 250 min·' (rpm)

MPal

250 min·' (rpm)

40 kgf/cm21 30.5 kgf/cm2 I

250 min·' (rpm)

569 psi

250 min·' (rpm)

in.

I

-

0.0835

in.

Allowable

0.0020 in.

-

250 min·' (rpm)

472 psi I

2.99

250 min·' (rpm)

250 min-1 (rpm)

434 psi I

250 min-1 (rpm)

10 % or

-

MPal

less

Limit

2

I

Valve Seat Angle

Valve Face Angle

Valve Recessing

Valve

Clearance (Cold) 0.23 to 0.27 mm

Intake Valve Timing

Exhaust Valve Timing

EX. 2.12 mm

0.0835

IN.

EX. 0.785 rad

IN.

EX.

IN.

EX. -0.05 to 0.15 mm

Open 0.24

Close

Open

1.047 rad

0.785 rad

-0.2

-0.079 to 0

-0.0019 to 0.0059 in.

0.0091

before T.D.C.

0.61 after B.D.C.

0.79 before B.D.C.

in.

0

60

0

45

0

60

0 -

45 to 0 mm

in.

to

0.0106

rad

(14

0)

(45

0

)

0

)

rad (36

rad

in.

-

-0.4 mm

-0.0157 in.

-0.4 mm

-0.0157 in.

-

"~-.

Close

,."WESTERBEKE

, Engines & Generators

55

0.29

altel"

rad

(17

LQ,C_.

0)

__

.

-

--

SERVICING

SPECIFICATIONS

Valve Stem

Valve Spring

Setting Load

to

Valve Guide

I Setting Length

Item

Factory Specification

Clearance (IN.) 0.055 to 0.085 mm

0.0022 to 0.0033

Valve Stem (IN.) 0.2740 to 0.2764 in.

Valve Guide (IN.) 0.2768 to 0.2774 in.

Clearance (EX.) 0.040 to 0.070 mm

Valve Stem (EX.) 0.3134 to 0.3140 in.

Valve Guide (EX.) 0.3155

Intake

Exhaust

Intake

0.0.

1.0.

0.0.

1.0.

6.960 to 6.975 mm

7.030 to 7.045 mm

0.0016 to 0.0028 in. 0.0039 in.

7.960 to 7.975 mm

8.015 to 8.030 mm to

0.3161 in.

35.1

to 35.6 mm 34.6 mm

to

1.3819

41.7 to 42.2 mm 41.2 mm

1.6417to 1.6614in.

63.547 N I 31.5 mm

6.48 kgf

14.256

1.4016 in. 1.3622 in.

131.5 mm

Ibs

11.2401

in.

Allowable Limit

0.1

mm

0.0039

in.

-

0.1

mm

-

1.6220 in.

45.864 N

4.68 kgf

10.296 Ibs

131.5 mm

I 31.5 mm

11

in.

.2401

Tilt (Valve Spring)

to

Rocker Arm Shaft

Valve Arm Bridge and Valve Arm Bridge

Shaft

Push

Hod

Rocker

Arm

Exhaust 117.6 N

12

26.4

I 35 mm 100 N

kgf 135 mm

Ibs

11.3780

in.

-

Oil Clearance

Rocker Arm Shaft 15.973 to 15.984 mm

0.0.

1.0.

Rocker Arm

Shaft

Clearance

Valve Arm Bridge

(1.0.)

Valve Arm Bridge

Shaft

(0.0.)

Alignment

for

0.016

to 0.045 mm

0.00063

0.6289 to 0.6293 in.

16.000 to 16.018 mm

0.6299

0.018

0.0007 to 0.0017

9.050 to 9.065

0.3563 to 0.3569

9.023 to 9.032

0.3552

to

0.00177

to

0.6306 in.

to

0.042 mm 0.15 mm in.

mm

in.

mm

to

0.3556 in.

-

10.2 kgf

22.51bs 11.3780 in.

1.0mm

0.039 in.

0.15 mm

in.

0.0059

0.0059 in.

0.25

0.0098 in.

135

-

135

mm

in.

~

WESTERBEKE

Engines & Generators

56

SERVICING

SPECIFICATIONS

Item Factory Specification

Piston Ring Gap

Connecting Rod

Piston Pin to Small End Bushing

Crankshaft

Allowable Limit

Compression Ring

1

Compression Ring 0.30 to 0.45 mm 1.25

2 0.0118

Oil Ring

Alignment

Clearance 0.020 to 0.040 mm 0.15

Piston Pin 30.006 to 30.011 mm

(0.0.)

Small End Bushing

(1.0.)

Side Ciearance

Alignment 0.02

0.30 to 0.45 mm 1.25

0.0118

0.0098

0.0008

1.1813t01.1815in.

30.031 to 30.046 mm

1.1823 to 1.1829 in.

0.0059 to 0.0122 in. 0.0197

to

0.0177 in. 0.0492

to

0.0177 in.

0.25 to 0.45 mm 1.25 to

0.0177 in. 0.0492

-

to

0.0016 in. 0.0059 in.

0.15toO.31 mm 0.50 mm

-

0.0492

0.05

0.0020

0.00079 in.

mm

in.

mm

in.

mm

in.

mm

in.

mm

-

in.

mm

Crankshaft

Crankshaft Journal to Crankshaft Bearing

Crank Pin

Crank Pin to Pin Bearing

Cylinder Bore

Cylinder Bore (Oversize)

Journal

0.0

Oil Clearance

0.0.

Oil Clearance

1.0.

74.977 to 74.990 mm

2.9518

0.018

0.0007 to 0.0024 in.

52.977 to 52.990

2.0857 to 2.0862 in.

0.018

0.0007 to 0.0020 in.

98.000 to 98.022 mm

3.8582

98.500 to 98.522 mm 98.65

3.8780 to 3.8788 in.

to

2.9524 in.

to 0.062 mm

mm

to 0.051 mm

to

3.8591 in. 3.8642

-

0.20

0.0079

-

0.20

0.0079

98.15

3.8839

mm

in.

mm

in.

mm

in.

mm

in.

~

WESTERBEKE

Engines & Generators

57

SERVICING

SPECIFICATIONS

Item

Factory Specification

Allowable Limit

Timing

Gear

Idle

Gear 1

to

Crank

0.049

to

0.193 mm 0.22 mm

Gear

0.0019

to

0.0076 in.

0.0087

in.

(Backlash) Idle

Gear 1

to

Cam

0.049

to

0.189 mm

0.22 mm

Gear (Backlash)

0.0019

to

0.0074 in.

0.0087

in.

Idle Gear 1

to

Idle

0.044

to

0.185 mm

0.22 mm

Gear 2 (Backlash)

0.0017

to

0.0073 in.

0.0087

in.

Idle Gear 2

to

Injection Pump 0.044

to

0.177 mm

0.22 mm

Gear

0.0017 to 0.0070 in.

0.0087 in.

(Backlash) Cam

Gear to

0.047

to

0.182 mm 0.22 mm

Balancer Gear 1 (Backlash)

0.0018

to

0.0072 in. 0.0087 in.

Idle Gear 1

to

0.044

to

0.183 mm 0.22 mm

Balancer Gear 2 (Backlash)

0.0017

to

0.0072 in. 0.0087

in.

Idle

Gear

Shaft 1, 2

to

Idle Gear

1,

2

Oil Clearance 0.050

to

0.091

mm

0.10mm

Bushing

0.0020

to

0.0036 in. 0.0039 in.

Idle Gear

1,

2

45.025 to

45.050 mm

Bushing

1.7726

to

1.7736 in.

-

(1.0.) Idle Gear

1,

2 Shaft 44.959

to

44.975 mm

-

(0.0.)

1.7700 to 1.7707 in.

Idle Gear

Side Clearance

0.15to

0.30 mm 0.9 mm

0.0059 to 0.0118 in. 0.0354 in.

Balancer Shaft (Balancer Model Only)

Side Clearance 0.07

to 0.22 mm

0.3mm

0.0028 to 0.0087 in.

0.0118 in.

Balancer Shaft (Balancer Model Only)

Alignment 0.02

mm

-

0.0008 in.

Balancer Shaft (Balancer Model Only)

Oil Clearance 0.070

to 0.159 mm

0.2mm

0.0028

to

0.0063 in.

0.0079 in.

Balancer Shaft

50.92

to

50.94 mm

Journal

2.0047

to

2.0055 in.

-

(0.0.) Balancer Bearing 51.01

to

51.08 mm

-

(1.0.)

2.0083

to

2.0110 in.

Piston Pin Bore

1.0.

30.000 to 30.013 mm

30.05 mm

1.1811

to

1.1816 in.

1.1831 in.

Compression Ring 2

to

Ring Groove

Clearance

0.093

to 0.120 mm

0.20 mm

0.0037

to

0.0047 in. 0.0079 in.

Oil Ring to Ring Groove

Clearance

0.02

to

0.06 mm

0.15 mm

0.0008

to

0.0023 in.

0.0059 in.

~

WESTERBEKE

Engines &

Generators

58

SERVICING

SPECIFICATIONS

Item

Factory Specification Allowable Limit

Tappet to Tappet Guide

Clearance

0.020

to 0.062

mm

0.07 mm

0.0008 to 0.0024 in. 0.0028 in.

Tappet Guide Bore

24.000 to 24.021 mm

(1.0.)

0.9449 to 0.9457 in.

-

Tappet

23.959 to 23.980

mm

(0.0.)

0.9433 to 0.9441 in.

-

Camshaft

Side Clearance

0.07

to 0.22

mm

0.3mm

0.0028 to 0.0087 in. 0.0118 in.

Alignment

0.01

mm

-

0.00039 in.

Cam

Height

IN.

37.63 mm

37.13 mm

1.4815 in.

1.4618 in.

EX.

38.96 mm 38.46 mm

1.5338 in. 1.5141 in.

Camshaft

Oil Clearance

0.050

to 0.091

mm

0.15 mm

0.00197 to 0.00358 in. 0.0059 in.

Camshaft

Journal

45.934 to 45.950

mm

(0.0.)

1.8084 to 1.8091 in.

-

Camshaft Bearing

46.000

to 46.025

mm

(!.D.)

1.8110to

1.8120 in.

-

FUEL SYSTEM

Item

Factory Specification Allowable Limit

Injection Timing V3300-E2B 0.20 to 0.22 rad

(11.5 to

12.5°)

-

before T.D.C.

V3300-T-E2B 0.11 toO.13 rad

(6.5 to 7.5

0)

-

before T.D.C.

Fuel

Injection

Nozzle

Injection

Pressure 13.73 to 14.71 MPa

140 to 150 kgf/cm

2

-

1991 to 2134 psi

Valve Seat When the pressure

is

Tightness 12.75

MPa

(130 kgf/cm2.

-

1849 psi). the valve seat

must be

fuel tightness

COOLING

SYSTEM

Item

Factory Specification

Allowable Limit

Thermostat

Valve Opening

74.5 to 78.5

°c

-

Temperature 166.1 to 173.3

OF

Valve Opening Temperature

90°C

-

(Opened

194

OF

Completely)

I~IWESTERBEKE

I Engines & Generators

59

SERVICING

SPECIFICATIONS

LUBRICATING SYSTEM

Item

Factory Specification Allowable Limit

Engine Oil Pressure

At

Idle Speed

49 kPa

-

0.5

kgf/cm2

7 psi

At Rated

Speed

196

to

392 kPa

147.1 kPa

2.0 to 4.0 kgf/cm2 1.5 kgf/cm2

28

to

57 psi

21.3 psi

Engine

Oil Pressure Switch Working Pressure

39.2

to

58.8 kPa

0.4 to 0.6 kgf/cm2

-

5.6

to

8.4 psi

Inner Rotor

to

Outer Rotor

Clearance

0.04

to

0.16 mm

0.3mm

0.0016

to

0.0063

in.

0.0118 in.

Outer Rotor

to

Pump Body

Clearance

0.100

to

0.184

mm

0.3mm

0.0039

to

0.0072

in.

0.0118 in.

Rotor to Cover

Clearance

0.025 to 0.075 mm 0.225 mm

0.0010

to

0.0030

in.

0.0089 in.

Relief Valve

Working Pressure

885 kPa

9.04 kgf/cm2

-

129 psi

ELECTRICAL SYSTEM

Item

Factory Specificatioil

Allowable Limit

Commutator

0.0.

32

mm

31.4 mm

1.2598 in.

1.2362 in.

Mica

Undercut

0.5mm

0.2mm

0.0197

in.

0.0079

in.

Brush (Starter)

Length 18 mm

11

mm

0.7086 in.

0.4331 in.

Alternator

No-load Voltage

14

Vat

4000 min-I (rpm) -

Rotor Coil

Resistance 2.8 to 3.3 Q

-

Slip Ring

0.0.

22.7 mm

22.1

mm

0.894 in.

0.870 in.

Brush (Alternator)

Length 18.5 mm

5.0mm

0.728 in.

0.197

in.

Glow Plug

Resistance Approx.

1.0 Q

-

..-v-

WESTERBEKE

Engines & Generators

60

ENGINE

ADJUSTMENTS

Injection Timing

1.

Make sure of matching the injection timing align

mark

(1)

of the

injection pump unit

and

the plate (gearcase),

as

shown

in

the

illustration.

2. Remove the injection pipes.

3.

Remove the stop solenoid.

4. Turn the

flywheel counterclockwise (viewed from flywheel

side)

until the fuel fills up to the hole of the delivery valve

holder

(2)

for

No.1

cylinder.

5.

After the fuel fills

up

to the hole of

the

delivery valve holder for

No.1

cylinder, turn back (clockwise) the flywheel around 1.57

rad

(90

0).

6.

Turn the flywheel counterclockwise to set at around 0.35

rad

(20

~)

before T.D.C.

7.

Slowly turn the flywheel counterclockwise

and

stop turning

when the

fuel begins to come

up,

to get the present injection

timing.

8. Check to see the degree

on

flywheel.

The flywheel has mark

"1

TC", "10" and "20" for the crank angle

before the top dead center of

No.1

piston.

9.

If the injection timing

is

not within the specification, rotate the

injection pump unit

to

adjust the injection timing .

•

IMPORTANT

•

When

installing

the

injection

pump

unit

to

the engine

body,

follow

the

correct

procedure.

0.20 to 0.22

rad

(t t

.5

" to

Factory

12.5")

before T.D.C.

Injection

timing

spec.

Injection pipe retaining

22.6 to 36.3

N·m

2.3 to 3.7 kgf·m

nut

16.6 to 26.8

ft-Ibs

Tightening torque

Injection

pump

unit

17.7 to 20.6

N·m

1.8 to

2.1

kgf·m

mounting

nut

13.0 to t 5.2 ft-Ibs

See

the

"Injection

Pump

Unit"

Disassembly

and

Assemble

section.

~

WESTERBEKE

Engines & Generators

61

(a)

Injection

Timing

Advanced

(b)

Injection

Timing

Delayed

VIEWING

THE

DELIVERY

VALVE

HOLDER

DELIVERY

VALVE

FLYWHEEL

VIEWING

THE

FLYWHEEL

ENGINE

ADJUSTMENTS

Checking Valve Clearance

•

IMPORTANT

• Valve clearance engine

1.

Remove the head cover. Align the

2.

is cold.

HC

housing timing windows

must

be checked and adjusted when

mark of flywheel and the convex

so

that

the

first piston (gear case side)

of

flywheel

comes to the compression top dead center.

3.

Before adjusting the valve clearance of intake valve, adjust the

bridge to set the height of intake valve.

and

4. Loosen the lock nut

5.

Slightly push the rocker arm (intake side) screw

touch the top

in

the adjusting screw slowly until

of

valve stem, then tighten the lock nut.

6. Loosen the lock nut of adjusting screw (push and insert the thickness gauge between the rocker the bridge head. Set

value, then tighten

the

return the adjusting screw

the

adjusting screw to

lock nut.

by

your fingers

you

feel the screw

the

and

rod

side)

arm

and

specified

7. Adjust the clearance between the rocker arm (exhaust side)

and the exhaust valve to the specified value.

0.23

to

0.27

Valve

clearance

Factory

spec.

0.009t

to

O.OtOS

mm

in.

TIMING

WINDOW

ADJUSTING SCREWS

Tightening

When

No.1

piston

Is

cDmpressed

Top

Dead

Cenler

When

No.1

piston

is

overlap posilion

in

torque

1s1 2nd

3rd

41h 1st

2nd 3rd 41h

Cylinder

screw

IN

0 0

0

head

cover

EX

0

IN

0

S.9

0.7

5.1

EX

0 0

0

.

to to to

IN

0 0

0 0 0

11.3

1.15

8.32

N'm kgl·m ft-Ibs

EX

0

ADJUSTING

SCREWS

LOCK

NUT

(ENGINE

COLD)

0.23 -0.27mm (0.0091 . 0.0106

in)

62

ENGINE

ADJUSTMENTS

OIL

PRESSURE

TESTING

GAUGE

OIL

PRESSURE

To test the oil pressure, remove install a wanning

m,echanical

up

the engine, set the engine speed at idle and

oil pressure gauge

the oil pressure gauge.

OIL

PRESSURE

LOW

The specific safe minimum ualloss

ENGINE

1.

Draining the Oil Sump. Discharge

WILL

RANGE

BETWEEN

OIL

PRESSURE

oil

of

oil pressure usually indicates

OIL

CHANGE

the sump drain hose (attached while the engine

replace the hose

is

wann. Drain

in

its bracket, and replace the

securely.

NOTE:

is

114

Thread size

NPT.

for

the lube oil drain hose capped end

'lIHl'l'.:;;"" . , " .

the

oil

pressure sender,

in

it's place. After

50

AND

55PSI

AT

1800

pressure

is

5 -

10

worn

bearings.

the

used

to

the front of the engine)

the

used

oil

completely,

~':I~-8mlm

. apply a

"~

'"

" . "

then

read

RPM

psi. A grad-

oil

through

end

cap

[11/161

SOCKET

When installing the gasket's sealing surface

thin

coat

on

the

new

oil

filter nipple,

WIPE

SURFACE

BEFORE

INSTALLING.

3.

Filling the Oil Sump. Add new oil through

cap

on

the

top

After refilling, checking the around the

new

oil filter element, wipe

on

the engine block

of

clean engine oil to

filter.

Screw

the

filter onto the threaded

and

then tighten

,':':

.::.

CLEAN

of

the engine or through the

run

the generator for a

oil

pressure. Make sure there

the

filter

APPLY

ENGINE

oil filter or from the

oil stop the engine. Then check the quantity lube oil dipstick. Fill dipstick, should

Use

a heavy CG-4, hours

duty

CH-4 or

of

CI-4.

break-in operation, and every 100 hours

to,

but not over the high mark

the

engine require additional

engine oil with

an

API classification of

Change the engine oil after

thereafter. For recommended oil use SAE (oil

viscosity). WESTERBEKE recommends the

synthetic oil.

free

the

rubber gasket

firmly

by

CLEAN

o/L

INSTALLING

the

side

few

moments while

is

no

drain system,

of

oil

with

oil.

an

of

15W-40

use

the

filter

of

oil

hand.

oil

filler

oil

filL

leakage

and

the

on

initial 50

operation

of

and

oil

the

CF,

2.

Replocing the Oil

filter,

you may

in

the upper and lower portion

Filter.

When

find

it helpful and cleaner

oil from it into a container before removing

to lessen spillage. A small style automotive filter wrench

should be helpful

NOTE:

Do

not

filter to

make

in

removing

punch this hole without first loosening the

certain il can

be

removing

of

the

old filter

the

old

oil

removed!

W",IWUIVt

UP

the

used

to

punch a hole it

filter.

"Mr

USING

AN

8MM

OR

PUMP

HOSE

{lJ/76',

THE

THRU

OIL

THE

oil

to

drain

the

This helps

WESTERBEKE

Engines & Generators

63

SOCKET

THE

WARMED

OIL

GALLERY

FUEL

SYSTEM

Fuel Injection Pressure

1.

Set the injection nozzle to a nozzle tester.

2.

Slowly move the tester handle to measure the pressure at

which

fuel begins jetting out from the nozzle.

3.

If

the measurement

replace the adjusting washer

is

not within the factory specifications,

(1)

in

the nozzle holder

it.

See the "Disassembling and Assembling" for nozzle holder.

13.73

to

14.71

MP.

Fuel

injection pressure Factory

spec.

140

to

150 kgffem'

1991102134 psi

(Reference)

• Pressure variation with

0.01

mm

(0.0004 in.) difference of adjusting washer thickness. Approx. 235

kPa (2.4 kgf/cm', 34 psi)

Nozzle Spraying Condition

1.

Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2.

If

the spraying condition is defective, replace the nozzle piece.

to

adjust

PRESSURE

TEST

Valve Seat Tightness

1.

Set the injection nozzle to a nozzle tester.

2.

Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm', 1849 psi) for

3.

If any fuel leak

Valve

seat tightness Factory

10 seconds.

is

found, replace the nozzle piece.

No fuel leak

spec.

12.75 130 kgffem'

iB4~

at

MP.

psi

DISASSEMBLY

Nozzle Holder

1.

Sec.ure the nozzle retaining nut

2.

Remove the nozzle holder (1), and take out parts inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install

the push

rod

(4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel injection pressure.

Nozzle holder 3.5

Tightening torque Overflow pipe nut

Nozzle holder assembly

(7)

with a vise.

34.3

25.3

19.6

2.0

14.5

49.01068.6

5.0

36.2

to

39.2

to

4.0 kgf·m

to

28.9 ft·lbs

to

24.5

to

2.5 kgf·m

to

18. I ft-Ibs

to

7.0 kgf·m

to

50.6 ft-Ibs

Nm

N·m

NOZZLE HOLDER

(1)

GOOD

DEFECTIVE

J....._-WASHER

RETAINING

ADJUSTING

(1)

NUT

(7)

...,yo

WESTERBEKE

Engines & Generators

64

GLOW

To then clean solution examine replace

Touch

other plug be an

Re-install plugs seconds_ circuit. compound

FUEL

The

the

in bench-tested

Speed servicing

ENGINE

of

FLUGS

inspect

will used ammeter

the plug, remove the electrical terminal connections,

unscrew

each

plug's tip and threads with a soft brush and cleaning

to

remove any carbon and oil deposits. Visually

the plug tip for electrical erosion if this is evident,

the

glow plug.

one

prod

to

the

body

have a 1.0 -

with

the plugs

should

If

the plugs don't heat up quickly, check for a short

When

on

INJECTION

fuel

injection pump is the most important component

diesel

handli

adjustments

engine

ng.

(hertz)

dealer can perform on the injection pump. See the

ADJUSTMENT section in this manual. Other types

each plug from the cylinder head. Thoroughly

to

the glow plug's wire connection, and the

of

the plug in or out

to test the power drain

in

get very hot (at the terminal end) within 7 to

reinstalling the glow phigs, use anti-seize

the threads. (sparingly).

PUMP

and,

The fuel injection pump has been thoroughly

and should not be tampered with.

and timing are the only adjustments the

or repairs must be performed by a qualified

injection service shop.

NOn:

must

When

be

servicing

advised

that the pump

application.

FUEL

the glow plug, as shown. A good glow

1.5

ohm resistance. This method 'can

of

the engine.

(8

- 9 amps per plug)

the engine and test them again. The

therefore,

the

calls

for

jnjection pump, the service shop

is

being used

the

You

utmost

in

can also use

caution

a generator

SYSTEM

TIP'

TIGHTENING

1.0

-

15

FUEL

RETURN

of

1.5

TORQUE

M-KG

(7

-11

GLOW

+

Fr-LB)

PLUGS

----

FUEL

FROM

RETURN

FILTER

INJECTORS

ACTUATOR

.

<>

,-

FUEL

LI

Periodically pump

and

fittings one secured

When will flow

are

of

the

energized

purge

of

fuel

,

FUEL

INJECTION

PUMP

FT

PUMP

check the fuel connections to and out

make

sure that no leakage is present and that the

tight and secure. The

pumps mounting bolts should be clean and well

by

the mounting bolt to ensure proper pump

thru the preheat circuit, the fuel lift pump

air

from the fuel system and provide a continuous

as the engine is running.

DC

ground connecl1on at

BLEED

SCREW

-

BLEEO

SCREW

OPEN

POSITION.

AIR

IN

THE DELIVERED RETURN

OPERATION

of

the

...v-

THE

SHOULD

mls

FUEL

SYSTEM

BACK

SYSTEM

DURING

.

WESTERBEKE

Engines & Generators

INJECTION

BE

WILL

TO

THRU

THE

ENGINE

PUMP

LEFr

IN

THE

ALLOW

FOR

BE

FUEL

FUELIN~

INLET

FUEL

FILTER

1_

Shut off the fuel supply fuel supply line to the inlet filter and unscrew the filter from the pump inlet. Take care to catch any fuel that may be present.

2. Thread on the replacement inlet filter and connect the fuel supply line. fuel supply line so as not to distort the inlet filter.

Use care when connecting and tightening the

to

the generator. Disconnect the

65

RAW

WATER

PUMP

#052650

PARTS

LIST

GASKET

END M4x

034463

IMPELLER

COVER

SCREWS

1.0x8MM

PROPULSION

33KW HOSE

WEAR

PLATE

302574

KIT

~_~

(6)

SCREW

017012

ENGINES

EOE

CONNECTIONS

END

COVER

049170

(4)

M6 X 1.25 X 16MM

WASHER

AND

GENERATOR

FRONT

(4)

ASSEMBLY

031783

MARINE

GENERATORS

017012

CAM

RETAINING

SEE

REAR

ASSEMBLY

SCREW

(4)

MG x 1.25 x 16MM

FLAT

WASHER

NOTE:

The parts slwwn along with a glycerine pack are included in WESTERBEKE'S

with the exception

and

the adapter flange.

SCREW

(4)

M6

PUMP

of

the pump body

BELOW

031783

KiT#052650

SPACER THE PINS

PRESSES

O-RING.

FIT

AGAINST

SPACER

REAR

ASSEMBLY

AGAIN:;7 THE

LlPSEAL

O-RING

CIRCLIP

~

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GRO,OVE'

THE

BEARINGS

AGAINST

THE

CIRCLIP

WESTERBEKE

Engines & Generators

66

CIRCLIP

053366

I"'V",LLI

CIRCLIP GROOVE

SHAFT

BALL

FITS

IN

BEARING

INTO

PUMP

(2)

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MARINE

GENERATORS

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L~~~~~~~~~~·~~".~"~L8~l~l[.~

_

i' Engines & Generators

'~'WEsn:RBE«E

---

__

J

67c

65-A

-FOUR

SPECIFICATIONS

Engine

Type

Aspiration Compression Governor

Combustion

Bore & Stroke

Piston

Hp@2800rpm firing

Inclination

Weight

Compression

(allowable

Variation

cylinders

Injection

Engine

Valve

(engine

Injector

Valve

Starting Battery DC

Charging Starter Starting

DC

Cranking

Chamber

Displacement

Order

(dry)

Pressure

limit)

between

Timing

Speed

Clearance

cold)

Pressure

TIming

Battery

Capac',ty

Allernator

Aid

Current

ENGINE

Diesel,

water-cooled,

mechanism

Naturally

Ratio

22.6:

Electronic

Swirl 98 x 110

3.31 65

1 - 3

Continuous

Temporary 7321bs

TUNE-UP

626

(472

10%

13°

(rpm)

Idle -750 -1000 Cruise -2000 -2400 Max. -2750 -2800

0.23 -0.27 (0.00091

1991 -2134 Intake

Intake Exhaust

Exhaust

ELECTRICAL

12-Volt 800 60

2.5Kw, Glow 400 -600

SPECIFICATIONS

four-cycle,

1

type

lilers

-4

(352

vertical

aspirated

mm

(3.86 x 4.93

(202.53

-2

0

14

25°

(not

kgs)

four-cylinder,

in-line

cubic

to

overhead

inches)

exceed

fresh

10

min.)

SPECIFICATIONS

psi

(44

kgflcm')

at

250

rpm

psi

(30.5

kgl/cm'})

or

less

8TaC

mm

·0.0106) psi

(140

Opens W BTaC

Closes

36°

Opens

45°

Closes 1 yo

-105

ABDC

BBDC ATaC

limit

kgflcm')

SYSTEM

DC

(-)

negative

ground

-1000

CCA

Amp

rated,

belt

driven

12

VDC

direct

drive

plugs,

sheathed

type

(includes

glow

plugs)

valve

General

Operating Fresh Raw

Raw

at System

(fresh

Air

NOTE:-

compartment 2

General

fuel

Fuellnjeclion

Fuel

Injector

fuel

Air Air

General

Oil

Sump

(includes

Operating

(engine Oil

Exhaust

Water

2800

rpm

Capacity

water)

Flow

Engine

The

inches

Injection

Nozzle

filter

Intake Flow

Combustion

filter

Capacity

hot)

Grade

Elbow

Hose

Temperature

Pump

Flow,

pressure

of

water

oil

lilter)

Oil

Pressure

COOLING

Fresh

thermostatically-controlled

160-1800f(71-82°C}

Centrifugal Positive

gear-driven.

17.0

16.0

Cooling

versus

(51

150

differential the

mm)

inside

at

full

between

of

FUEL

Open (electromagnetic

No.2 Pump Timing

Bosch

yo

BlDC

Bosch

Spin-on

Metal

165

clm

LUBRICATION

Pressure Full

flow,

14.0

28 -57

API

Specification

SAE

EXHAUST

45°

Size

3"

1.0.

SYSTEM

water-cooled

type,

metal

displacement,

US

gpm

(41.6Ipm)

gpm

(151Ipm)

clm

(4.2

cmm)

the

open

outside

engine

compartment

throttle

SYSTEM

flow,

self

bleeding -self

fuel

diesel

oil

(cetane

type

mini

pump

(spill)

throttle

type

screenlintake

(4.7

cmm)

SYSTEM

fed

system

paper

element,

U.S.

qts

(13.2

psi

(2.0 -4.0

30,

(76.2

CF

10W-30,

mm)

engine

impeller, rubber

of

(measure

pump)

rating

silencer

wi~h

external

spin-on

liters)

kg/cm')

or

CG-4,

15W-40

block,

with

heat

exchanger.

belt-driven

impeller,

the

engine

should

not

45

relief

type

or

higher)

valve

CH-4

exceed

with a manometer)

priming

of

box

Cf-4

NOTE:

Engine Idle Speed must be adjusted with the engille at

nonnal operating temperature. Idle in

the range specified where it operates the smoothest.

speed

Different model transmissions will affect engine idle speeds.

should be adjusted

~

WESTERBEKE

Engines & Generators

68

SPECIFICATIONS

33KW

EDE

Engine

Type

Aspiration

Compression

Governor

Combustion

Bore & Stroke Piston Firing

Inclination

Weight

Chamber

Displacement

Order

(dry)

Compression

(allowable Variation

cylinders Injection Engine

Valve

(engine

.

Injector Valve

Starting Battery DC Starter Starting DC

General Oil Sump

(includes

Operating (engine

Oil

between

Timing

Speed

Clearance

cold)

Pressure

Timing

Battery

Capacity

Charging

Aid

Cranking

Alter

Capacity

oil

Oil

hot)

Grade

limit)

filter)

ENGINE

Diesel,

water-cooled,

mechanism Naturally

Ratio

21.6:1

Electronic

Swi~

96 x 110

3.31 1-3-4-2

Continuous Temporary

11351bs

TUNE-UP

Pressure

626 472

10%

7" 1600

lS00

0.23 (0.00091

1991 Intake

Intake Exhaust

Exhaust

ELECTRICAL

12-Volt 600-1000

A1temator

Current

60

2.SKw, Glow 260 -320

LUBRICATION

Pressure

Full 14

Pressure

26 -S7

API

SAE

SPECIFICATIONS

four-cycle,

type

liters

vertical

(46

hp

aspirated

mms

(3.66 x 4.33

(202.53

0

20

300 (not

(514.6

kgs)

four-cylinder,

in-line

overhead

at

1600

rpm

inches)

cubic

inches)

to

exceed

10

fresh

maximum)

min.)

SPECIFICATIONS

psi

(44

kgf/cm')

at

2S0

psi

or

BlDC

rpm

to

Opens Closes

(30.5

less

60

SO

0.27

mm

to

0.0106

2134

Opens Closes

kgf/cm')

Hertz Hertz

psi

(140to

14"

BlDC

36"

ABOC

4S" 17"

at

2S0

inches)

lS0

BBDC AlDC

rpm

kgf/cm')

SYSTEM

DC

(-)

negative

ground

CCA

Amp

rated,

belt-driven

12VDC

direct

drive

plugs,

sheathed

type

Amps

SYSTEM

fed

system

with

external

relief

flow,

paper

element,

spin-on

type

U.S.

qts

(13.2

liters)

psi

(2.0 -4.0

Specification

10W-30,

CF,

CG-4

lSW-40

kIJ/cm')

or

CF-4

valve

General

Operating

Fresh

Raw

System (fresh

Raw

(at

General

Fuel

Fuellnjeclion

Fuel

Injector

Fuel Air

Air

(generator

NOTE: Generator

Ambient

General

Single Voltage

Voltage -Single

Voltage

Frequency

Temperature

Water

Pump

Water

Pump

Capacity

water)

Water

Flow

1600

rpm)

Pump

Injection

TIming

Nozzle

Filter Intake Flow

Combustion

Requirements

cooling)

Increase

Compartment

Temperature

-3

Phase

-3

Phase

Regulation

COOLING

Fresh

thermostatically-controlled

160

-160" F

Centrifugal Positive

gear,driven.

16

qts

Rate

11.0

gpm

FUEL

Open

flow,

(electromagnetic No.2 Bosch

7"

BlDC Bosch Spin-on

Metal

lOS

cfm

GENERATOR

0.6

Power

cooling

air

flow

15%

1220 F

AC

GENERATOR

Brushless,

lubricated

reconnectable Reconnectable Reference

(multiple)

Phase

120

or

115/230

+

or -2%

+

or -.3

outlet

SYSTEM

water-cooled

displacement,

(15.1

(71 -62"

type,

metal

liters)

(41.6Ipm)

engine

SYSTEM

self

bleeding,

fUel

diesel

(cetane

rating

type

mini-pump

(spill)

throtlle

type

screenJintake

(3.0

silencer

cmm)

COOLING

factor

unit.

for

slower

turning

(500 C)

maximum

four

pole

with

to

SO

load

(.5%)

revolving

bearing

solid

Double

volts

Hz

to

full

no

load

single

connection

1201240

volts

no

hz

block,

with

C)

impeller, rubber

self

pump)

of

box

SOD

CFM

50hz

design.

state

Della

chart

and

60

Hz

rated

to

full

heat

exchanger.

belt-driven

impeller,

priming

4S

or

higher)

(lS.0

CMM)

units.

field,

sealed

12

wire

voltage

regulator.

AC

voltages

amperage

rated

amperage

outlet

Engines & Generators

69

AC

GENERATOR

Single

Phase

Vottage

Voltage

Regulalion Frequency Rating

60

50

Generator

Air

(Single

Generator Ambient

Recommendations

Regulation

(Vans

Hz

requirements

AC)

(1800

rpm)

(1500

rpm)

COOling

& 3

phase)

Compartment

Temperature

SPECIFICATIONS

(Single

Brushless, Sealed Lead volts, With

120

230

'±2%

.3

120

1201240

230

500

NOlE:

aperaUan

122'F

NOlE:

to

temperatures

six·

lubncated,

reconnectable

60hz.)

(Senes

solid

state

or

1201240

Volts·

50

no

load

Hertz

(5%)

volts

cfm

(14.1

Increase

(1500

(50'C)

Forr:ed

maintain

generator

Phase

pole,

revoMng

slngle-beanng

(Double

Star

voltage

regulator.

vans·

60

Hertz to

full

load.

no

load

to

275

amps

2751137.5 113

amps

cmm)

air

supply

rpm)

maximum

ventilation

below

should

comparlment

104'F

Delta

for

230

hertz

full

amps

15%

(40'C).

I

field.

design.

volts,

load.

for

be

12

for

1201240

50hz)

50

Hertz

provided

33.0/26.0KW

Three

Phase

Vonage

• 3

(60

Voltage· 3 Phase (50

Amperage· 3 phase (60

Amperage· 3 phase (50

Generator

Air

(60

Generator

Ambient

Recommendations

phase

Hertz)

Cooling

requirements

Hz)

at

1800

Compartment

Temperature

EDE

AG

GENERATOR

rpm

(3

Brushless,

lubncated,

reconnectable. Low

High DELTA

Low High DELTA

High DELTA

225 • 250

NOlE:

aperaffan

122'F

NOlE:

to

temperatures

s~·pole,

single-beanng

Voltage

cfm

Increase

(1500

(50'C)

Forr;ed

maintain

Solid

WYE

(5.66 • 6.37

maximum

venUlaUan

generator

belaw

Phase)

revolving

state

airsupply

rpm)

compartment

104'F

field.

design.

voltage

240 480 277

400 230

99.3

49.6

86.0

46.9

81.6

cmm)

15%

should

(40'C).

Sealed

12

Lead

regulator.

Volts Volts Valls

Volts Volts

Amps Amps Amps

Amps Amps

far

50

Hertz

be

provided

~

WESTERBEKE

Engines & Generators

69A

AC

GENERATOR

Single

Phase

Voltage

vonage

Regulalion Frequency Rating

&0

1UIIW

50

UIIW

Generator rur (Single

Generator Ambient Recommendations

Regulation

(Volts

Hz

AC)

(1800

rpm)

(1500

IJIIIO

Cooling

requlremenls

& 3

phase)

Compartment

Temperature

(Single

Brushless, Sealed Lead valls, With

120 230

. ±2%

.3

120 1201240

230

400 NOTE:

opemNon

122'F

NOTE:

to

lempemtures

six-

lubricaled,

reconnectable

60hz.)

solid

slate

or

1201240

Valls -50

no

load

Hertz

(5%)

volts

valls

elm

(11.3

Increase

(1500

(50'C)

Fo«:ed

maintain

SPECIFICATIONS

25.5/21.DKW

Phase)

pole,

revoMng

single-bearing

(Double

(Series

Slar

vollage

volts -60

Hertz to

full

no

load

212.5

212.5/106.3

91.3

emm)

air

supply

rpm)

maximum

venOlaOon

genemtor

below

104'F

field.

design.

Della

for

230

volts,

regulator.

hertz

load.

to

full

load.

amps

15%

tor50

should

compartment

be

(40·C).

for

1201240

50hz)

Hetlz

provided

12

Three

Vollage (60

Voltage (50

Amperage (60

Amperage (50

Generator

Air

(60

Generator

Ambient

Recommendations

Phase

-3

phase

Hertz)

-3

Phase

Hertz)

- 3

Hertz)

requirements

Hz)

phase

- 3

phase

Cooling

at 1 BOO

rpm

Compartment

Temperalure

EDE

AC

GENERATOR

Brushless, lubricated, reeonneelable.

Low

Voltage

High

Voliage

DELTA High

Vollage

DELTA Low

Vollage

High

Vollage

DELTA High

Vollage

DELTA 225 -250

NOTE:

opemOon

122'F

(50'C)

NOTE:

to

maintain

tempellltures

(3

six-pole,

single-bearing

Solid

WYE

elm

(5.66 -6.37

Increase

air

(1500

rpm)

maximum

Forced

venOlation

generator

below

Phase)

revolving

design.

state

vollage

240

4BO

277 400

230 76

3B

66.5

37.9

65.9

emm)

supply

15%

should

compartment

104°F

(40·C).

field.

12

regulalor.

Valls

Valls Volts

Volts

Amps Amps

Amps

tor

be

Sealed

Lead

50

Hetlz

provided

AC

GENERATOR

Single

Phase

Voltage

Regulation Frequency RatIng

&0

50

Generator Air (Single

Generator Ambient

Regulation

(Volts

Hz

AC)

(1800

rpm)

(1500

rpm)

Cooling

requirements

& 3

phase)

Compartment

Temperature

Recommendations

SPECIFICATIONS

(Single

Brushless, Sealed Lead volts, With

120 230

±2%

.3

120volls 1201240

230

400 NOTE:

opellltion

122'F

NOTE:

to

tempellltures

six-

lubncated,

reconnectable

60hz.)

solid

state

or

1201240

Valls -50

no

load

Hertz

(.5%)

valls

volts

elm

(11.3

Increase

(1500

(50'C)

Forced

maintain

generator

pole,

revolving

single-bearing

(Double

(Series

Star

vonage volts

-

Hertz to

tuilioad.

no

load

237.5

237.5/11

102.2

emm)

air

supply

rpm)

maximum

ventilation

below

104'F

Phase)

field.

design.

Delta

for

230

valls,

regulator.

60

hertz

to

fuilioad.

amps

B.B

amps

15%

for

50

shoufd

be

compartment

provided

(40"C).

12

1201240

50hz)

Hetlz

28.5/23.5KW

Three

Phase

Voltage

- 3

(60

Vollage (50

Amperage (60

Amperage (50

Generator Air

(60

Generalor

Ambient

Recommendations

phase.

Hertz)

-3

Phase

Hertz)

-3

Hertz)

requirements

Hz)

phase

-3

phase

COOling

at 1 BOO

Compartment

Temperature

EDE

AC

GENERATOR

rpm

(3

Brushless, lubricated, reconnectable.

Low High DELTA

High DELTA

Low High DELTA

High DELTA

225 -250 NOTE:

opellltion

122'F NOTE:

to tempellltures

Voltage

Vollage

Vonage

Voltage

elm

Increase

(1500

(50'C)

Forced

maintain

Six-pole, single-bearing

Solid

WYE

,WYE

(5.66 -6.37

maximum

venNfaNon

generator

below

Phase)

revolving

state

air

supply

rpm)

compartment

104'F

field.

design.

vollage

240 4BO 277

400 230

B5.8

42.9

74.3

42.4

73.B

emm)

15%

should

(40·C).

Sealed

12

Lead

regulator.

Valls Valls Valls

VoIIs Volts

Amps Amps Amps

Amps Amps

for

50

Hetlz

be

provided

"toY

WESTERBEKE

Engines & Generators

69B

AC

GENERATOR

Single

Phase

Vollage

Regulation Frequency Rating

60

2O.0KW

50

16.0KW

Generator Air

(Single

Generator Ambient Recommendations

Regulation

(Volts

Hz

AC)

(18011

rpm)

(1500

rpm)

Cooling

requirements

& 3

phase)

Compartment

Temperature

(Single

Brushless. Seal

12

1201240

volts, 120

230

±

.3

120

1201240

230

400

NOTE:

operation

122°F

NOTE:

to

temperatures

six·pole.

lubricated.

lead

reconneclable.

volts.

50hz)

with

or

1201240

Volts -50

2%

no

load

Henz

(.5%)

volts

cfm

(11.3

Increase

(1500

(50°C)

Forced

maintain

generator

SPECIFICATIONS

20.0KW

Phase)

revolving

single

bearing

(Double

60hz.)

(Series

solid

slate

volts -60

Hertz to

full

load.

no

load

to

166.6

amps

166.6/83.3

69.5

amps

cmm)

air

supply

rpm)

maximum

ventilation

compattment

below

104°F

field.

design.

Slar

regulator.

hertz

full

load.

amps

15%

should

(40°C).

Della

for

50

be

provided

for

230

Hertz

Three

20.0

16.0

Vollage (60

Vollage (50

Amperage (60

Amperage (50

Generator Ambient Recommendations

Phase

Kw -60 Kw -50

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Compartment

Temperature

EDER

AC

GENERATOR

Hertz Hertz

phase

Brushless, lubricated,

reconnectable.

Low High DELTA

High DELTA

Low High DELTA

High DELTA

122°F

NOTE:

fa

temperatures

six-pole,

single-bearing

Vollage

Voltage

Vollage

(50°C)

Forced

maintain

(3

Phase)

revolving

Solid

state

WYE

maximum

ventilation

generator

below

compartment

104°F

field.

design.

voltage

240 480 277

400

230

60 30 59

28.9

50.2

should

(40°C)

Sealed

12

Lead

regulator.

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps Amps

be

provided

AC

GENERATOR

Single

Phase

Voltage

Vollage

Regulation

Frequency

Rating

60

26_0

50

2O.8KW

Generator Air

(Single

Generator

Ambient Recommendations

Regulation

(Volts

Hz

requirements

AC)

(18011

rpm)

KW

(1500

rpm)

Cooling

& 3

phase)

Compartment

Temperature

(Single

Brushless, Seal 12 1201240 volts,

120 230

±

.3

120

1201240

230

400cfm

NOTE:

operation

12n

NOTE:

to

temperatures

six-pole,

lubricated,

lead

reconneclable,

volts,

50hz)

with

or

1201240

Volts -50

2%

no

load

Hertz

(.5%)

volts

(11.3

Increase

(1500

(50°C)

Forced

maintain

generator

SPECIFICATIONS

26.0KW

Phase)

revolving

single

bearing

(Double

60hz.)

(Series

solid

slate

volts -60

Hertz

to

tuilioad.

no

load

to

2t6.6

216.6/108.3

90.4

amps

cmm)

air

supply

rpm)

maximum

ventilation

compartment

below

104°F

regulator.

hertz

full

amps

15%

should

(40°C).

field.

design.

Della

Slar

for

load.

amps

for

50

be

for

230

Hertz

provided

Three

26.0

20.8

Vollage

(60

Vollage (50

Amperage

(60

Amperage

(50

Generator Ambient

Recommendations

Phase

Kw -60 Kw -50

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Compartment

Temperature

EDER

AC

GENERATOR

Brushless,

Hertz Hertz

phase

lubricated, reconnectable.

Low High DELTA

High DELTA

Low High DELTA

High DELTA

122'F

NOTE:

temperatures

Vollage

Voltage

Vollage

Voltage

(50°C)

to

maintain

(3

six-pole, single-bearing

Solid

WYE

.

maximum

Forced

ventilation

generator

below

Phase)

revolving

field.

design.

slate

vollage

240 480 277

400 230

78.2

39.1

67.8

37.5

65.3

should

compartment

104°F

(40°C)

Sealed

12

Lead

regulator.

Volts Volts

Vans

Amps Amps Amps

Amps Amps

be

provided

REVISED AUGUST 2(09

Engines & Generators

69C

NOTE

·For "*" marked screws,

tightening. The letter the two

"M"

nominal

threads.

in

Size x Pitch means that

outside

diameter

bolts

TORQUE

and

nuts

on the table,

the

in mm

of

the threads. The

SPECIFICATIONS

screw,

apply

bolt

or

pitch

nut

engine

dimension

is

oil

the

to

their

stands

nominal

threads and seats

for

metric.

distance

in

The

mm

between

before

size

is

Item Size x Cylinder head cover screw 'Cylinder head screw 'Connecting rod screw

'Flywheel screw 'Crankshaft screw

bearing case screw

'Main Rocker arm Nozzle holdor assembly Nozzle holder

Injection pipe retaining nut Overflow pipe assembly retaining nut Oil switch taper screw Oil cooler joint screw - 39.2 Oil pump cover screw - 7.9 to 9.3 0.80 Glow plugs

br

dcket screw

Pitch

-

M12x M10 x 1.25 M12 x 1.25

M10x1.25

1.25

M16x1.5 M14x1.5

M20 x 1.5

-

M12 x 1.5 M12x1.5

1/8

R

M10

x 1.25

N·m

6.9 to 11.3 0.7

98.1

to 107.9 10.0

78.5 to 83.4

98.1

to 107.8 10.0

255.0 to 274.6

137.3to

49.0 to 55.9 5.0

49.0 to 68.6

34.3 to 39.2 3.5 to 4.0

22.6 to 36.3

19.6 to 24.5 2.0

14.7 to 19.6 1.5 to 2.0 10.8

19.6 to 24.5

147:1 14.0 to 15.0

..

to

44.1 4.0 to 4.5 28.9 to 32.5

8.0

26.0

5.0 to

2.3

2.0

kgf·m

to

1.15

to

11.0 to 8.5 to

11.0 to

28.0

to

5.7

7.0

to

3.7 to

2.5 14.5

to

0.95 5.8 to 6.9

to

2.5 14.5

72.3 to 79.6

57.9

72.3 to 79.6

188.1

101.3 to 108.5

36.2

25.3

16.6 to 26.8

5.1

ft-Ibs

to

8.32

to

61.5

to

202.5

to

41.2

to

50.6

to

28.9

to

18.1

to

14.5

to

18.1 Starter's terminal B mounting nut Injection pump gear mounting nut Injection pump unit mounting nut

Gear case cover Relief valve Idle gear mounting screw Plate

mounting screw Camshaft set screw Flywheel Crankcase 2 mounting screw Injection pump mounting screw Injection pump mounting nut

Boost Actuator Governor weight mounting nut Fuel camshaft stopper mounting screw

retaining screw

housing mounting screw

M8 x 1.25 M14x1.5 M8

M8 x 1.25

M8 M8 x 1.25

M8 M12 x 1.25 M10 x 1.25

M8

M12 x 1.25

x 1.25

-

x 1.25

x 1.25 x 1.25

-

9.8

to

11.8 1.0 to 1.2 7.2

73.6 to 83.4 to

17.7

23.5 to 27.5 2.4 to 2.8 17.4

68.6 to 78.4 7.0 to 8.0 50.6

23.5

77.5

49.0

23.5 to 27.5 2.4 to 2.8 17.4

17.7 to 20.6

39.2

62.8

20.6 1.8 to

to

27.5 2.4 to 2.8 17.4 to 20.3

to

27.5 2.4

to

27.5

to

90.2 7.9

to

55.9 5.0 to 5.7

to

45.1

to

72.6

7.9

to

9.3 0.80

7.5 to 8.5 54.2

2.1

to

2.8 17.4

2.4 to 2.8 17.4 to

9.2

1.8t02.1

4.0

to

4.6

6.4 to 7.4 46.3

to

0.95 5.8

13.0t015.2

57.1

36.2

13.0

28.9

to to

to

to to to to to to to to

to

8.7

61.5

20.3

57.9

20.3

66.5

41.2

20.3

15.2

33.3

53.5

6.9

"""

WESTERBEKE

Engines & Generators

70

TORQUE

SPECIFICATIONS

x Pitch

Item

Size

Governor housing mounting screw M6 x 1.0

Anti-rotation nut Balancer shaft set screw Bearing case cover mounting screw

M5 x 0.8

M8 x 1.25

Alternator pulley nut -

When the tightening torques

!~e

Nominal

Diameter

M6

M8

M10

M12

Unit

are

N·m

7.9

to

9.3 0.80

t7.7

to

20.6

39.2 to

45.1

62.8 to 72.6

not specified, tighten the screws, bolts and nuts according to the table below.

Standard Screw

and

Bolt

@

kgf·m

to

0.95 5.8

t.8

to

2.t

4.0

to

4.6 28.9

to

7.4 46.3 to 53.5

6.4

It·lbs

13.0 to

Screw and bolt material grades are shown by numbers punched

be sure

to

check out the numbers as shown below.

Punched

None

number

or

4

7

Screw

Standard

Sp.;cial screw and bolt S43C, S48C (Refined)

and

screw

bolt

and

material

bolt

8841 , S20C

grade

N·m

9.8 to 11.3

2.8 to 4.0

23.5 to 27.5

23.5

to

58.3 to 78.9

to

6.9

to

15.2 23.5

33.3

on

the screw and bolt heads. Prior

kgf·m

1.0t01.15

0.29 to to

2.4

27.5

2.4 to 2.8

5.95 to 8.05 43.0

Special Screw and Bolt

N·m kgf·m

9.8

to

t t.3

to

27.5

48.11055.9 4.9

77.5

to

90.2 7.9

t.OO

2.4

0.41

2.8

(j)

to

1.15 7,23

to

2.8 17.4

to

5.7 35.4

to

9.2

ft-lbs

7.23 to 8.32

2.1

to

3.0

17.4

to

20.3

17.4 to 20.3 to

58.2

It·lbs

to

8.32

to

20.3

to

41.2

57.1

to

66.5

to

tightening,

Engines

71

& Generators

(1)

,

~

I?,§

((==-:J)

A=

SPECIAL

Diesel Engine Compression Tester

Code

TOOLS

No

~~('~

(3)

(4) (5) (6) (7) (8)

(9)

t~t~t\@'

_ .

=tJ

~(2)

"

Ii

~

:;

(4)

~ ~

® <!)

(5)

(6)

Application: Use to measure diesel engine compression and

(1

)

Gauge

(2) L

Joint

Adaptor A (9)

(3) (4)

Adaptor B

(5)

Adaptor C

(6) Adaptor E

Oil Pressure Tester

Code No : Application:

(1) Gauge

(2) Cable

(3) Threaded Joint (4) Adaptor 1

: 07909-30208 (Assembly)

07909-30934 07909-31211 07909-31231

diagnostics of need for major

07916-32032

Use to measure lubricating oil pressure.

(A

to

F)

(E

and

(H)

(7) Adaptor F (8) Adaptor G

(10) Adaptor t (11

)

(5) Adaptor 2

(6) (7) (8)

07909-31251 (G) 07909-31271

F)

07909-31281 (J)

overhaul.

Adaptor H

Adaptor J

Adaptor 3 Adaptor 4 Adaptor 5

(I)

~j~~

(1) (2) (3) (7) (8)

Plastigaae

Code No : 07909-30241

Application: Use to check the oil clearance between

..

rod

alignment.

1.0.

11.81

in.)

on

cylinder head, cylinder

Measl.ring :

range

Connecting Rod

Code

No: Application: Applicable: range 30 to

Red Check

Code No : Application:

crankshaft and bearing, etc

Green ..... 0.025 to 0.076 mm (0.001

Red .........

Blue ......... 0.102 to 0.229 mm (0.004

Alignment Tool

07909-31661

Use to check the connecting

Connecting rod big end

Connecting rod 65

07909-31371

Use to check cracks block,

0.051 to 0.152 mm (0.002

75

mm (1.18 to 2.95 in.) dia.

length

to

300 mm (2.56

etc

..

to

0.003 in.)

to

0.006 in.)

to

0.009 in.)

...v:

WESTERBEKE

Engines & Generators

72

c

I--'

E

The

G

f-'!..

A

SPECIAL

TOOLS

following special tools are not provided, so make them referring to the figure.

Engine

Stand

D

F

~.

~

If

:/

1B

J

.---III:IP

K

Application

A

B

C

0

E

F

G

H

I

J

K

L

,

M

N

0 6

p

C10

:Use

to

support engine.

480

mm

(18.90 in.)

50 rnm (1.97 in.)

10B.S

mm

(4.272 in.)

263 mm (10.35 in.)

12.5

mm

(0.492 in.)

237.5

mm

(9.350 in.)

142.5

mm

(5.610 in.)

95 rnm (3.74 in.)

4.14

mm

dia. (o.S5 in. dia.)

40 rnm (1.57 in.)

210

mm

(8.27

in.)

190

mm

(7.48 in.)

100

mm

(3.94 in.)

6

mm

(0.24 in.)

mm

(0.24 In.)

25

mm

dia. (0.98 in. dia.)

Chamfer 10 mm (0.394 in.)

B

E

F

I

'¥

r

H I

Flywheel Stopper (for

Application:

A 140

A

C

o I

{l1-

{

J

B

C

0 49.3

E

F 23.8

G

H

I

J 8 mm (0.31 in.)

Tool

for

Application:

A

B C

0

E

F

G

H

I

J

K

mm

aOmm(3.15in.)

49.3

mm mm

23.8

mm mm

11

mm

56.5

mm

56.5

mm

Aligning

Use

115

mm

56 mm (2.2047 in.) 17 mm (0.6693 in.) 20 mm (0.7874 in.) 14 mm dia. (0.5512 in. dla.) 11

mm

14

mm

17.5

mm

17.5

mm

35 mm (1.3780 in.)

19 mm (0.7480 in.)

SAE

Use

to

loosen

(5.5 in.)

(1.94 in.)

(0.94 in.)

dia. (0.43 in. dia.)

(2.22 in.) (2.22 in.)

the

Crankcase 1

Flywheel

and

tighten the flywheel screw.

and

2

for aligning the crankcase 1

(4.5276 In.)

dia. (0.4331

dia. (0.5512 in. dia.)

(0.6890 in.) (0.6890 in.)

In.

dia.)

Housing)

and

2

~

WESTERBEKE

Engines & Generators

73

A

B

f,..

~

E

f---

L

-

(

IF

G

H

I J K

'-

h,

-

L

M

N

A

~

C

0

FI

c

1

7:1

C1

C 2

a b

SPECIAL

TOOLS

Gear Case Oil Seal Replacing Tool

Application: Use to press fit the oil seal.

A 148.8

mm

(5.8582

in.)

B

50

mm

(1.9685 in.)

C

18.8

mm

(0.7401 in.)

D

13.7 to 13.9

mm

(0.5394 to 0.5472 in.)

E

11

mm

(O.433 in.)

F

18

mm

dia. (0.7087 in. dia.)

G 38

rnm

dia. (1.4961 in. dia.)

H

45

rnm

dia. (1.7716

in.

dia.)

I 57.9

to

58.1

mm

dis. (2.2795 to 2.2874 in. dia.)

J

79.5

mm

dia. (3.1299 in. dia.)

K

87

mm

dia. (3.452 in. dia.)

L

12

mm

(0.4724 In.)

M

40

mm

(1.5748 In.)

N 120

mm

(4.7244

in.)

Small End Bushing Replacing Tool

Application:

Use to press out and to press fit the small end bushing.

[Press oul)

A

157mm(6.1811

in.)

B

14.5

mm

(0.571

in.)

C

120

mm

(4.7244 in.)

D

30.0

mm

dis. (1.1811 in. dia.)

E

32.95

mm dia. (1.2972 in. dia.)

F

20

mm

dla. (0.7874 in. dia.)

a

6.3

Jim

(250 #In.)

b

6.3

tim

(250 pin.)

C1

Chamfer 1.0

mm

(0.039 in.)

C2

Chamfer

2.0

mm

(0.079 in.)

[Press

Iii)

A

157mm(6.1811

in.)

B

14.5

mm

(0.571 in.)

C

120 mm (4.7244 in.)

D

30.0

mm

dia. (1.1811 in. dia.)

E

42.000 mm dla. (1.6535 in. dia.)

F

20 mm dia. (0.7874 in. dia.)

a

6.3

pm

(250

pin.)

b

6.3

pm

(250 /lin.)

C1

Chamfer 1.0

mm

(0.039 in.)

C2

Chamfer

2.0

mm

(0.079 in.)

Engines & Generators

74

.

e

".~]:

MIgl

~5

-L.

·0

~

C

1

ci

a b

R

~W

~

U

A

C

FI

Cl

C 2

SPECIAL

TOOLS

Injection Pumo Gear Puller

Application

:Use for remove the injection pump gear from

governor shaft.

A

10

rnm

dia. (0.39 in. dia.)

B

M16

x Pitch 1.5

C 19

mm

(0.75 in.)

0

0.5

mm

radius (0.02 in. radius)

E 0.89 rad (50 ")

F

10

mm

(O.39 in.)

G 20

mm

(0.79 in.)

H 5

mm

(0.20 In.)

I 95

mm

(3.74 in.)

J 125 rnm (4.93 in.)

K

5

mm

(0.20 in.)

L

M16

x Pitch 1.5

M 30

mm

(1.18in.)

N

9.5

mm

(0.3740 in.)

0

11

mm

(0.4331 in.)

p

9.5

mm

(0.3740 in.)

Q

15.5

mm

(0.6102 in.)

R

4.5

mm

radius

(0.1

B in. radius)

S 20

mm

(0.79

in.)

T

20

mm

(0.79

in.)

U

80

mm

(3.1496 In.)

W 12

rnm

(0.47

in.)

C2

Chamfer

2.0

mm

(0.079 in.)

Idle Gear Bushing Replacing Tool

Application:

Use to press out and to press fit the bushing.

1.

For idle gear bushing

A

196

mm

(7.7165 in.)

B

37.Smm

(1.476 In.)

C

150

mm

(5.9055 in.)

0 44.95

mm

dia.{1.7697 in. dia.)

E 48.100

to

48.075

mm

dia. (1.8937 to 1.8927

in.

dia.)

F

20

mm

dia. (0.7874

in.

dia.)

a

6.3

lim

(250 liin.)

b

6.3

Jim (250 Jiin.)

Cl

Chamfer

1.0

mm

(0.039 in.)

C2

Chamfer

2.0

mm

(0.079 in.)

Engines & Generators

75

o

E

F

""

f2

Cl

C~

C

A

B

C

1

SPECIAL

TOOLS

Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

[Intake valve guide]

A 20

mm

dia. (0.79 in. dia.)

B 11.7 to 11.9

mm

dia. (0.460 to 0.468 in.dia.)

C 6.5 to 6.6

mm

dia. (0.256

to

0.259 in.dia.)

0 225

mm

(8.86 in.)

E

70 mm (2.76 in.)

F

45

mm (1.77 in.)

G

25

mm

(O.9B

in.)

H

5mm(O.197in.)

I

6.7

to

7.0

mm

dia. (0.263 to 0.275 in.dia.)

J

20

mm

dia. (0.787 in.dia.)

K 12.5

to

12.8

mm

dia. (0.492 to 0.504 in.dia.)

L

B.9

to

9.1

mm (0.350 to 0.358 in.)

Cl

Chamfer 1 .0

mm

(0.039 in.)

C2

Chamfer

2.0

mm

(O.079 in.)

CO.3

Chamfer 0.3

mm

(0.012 in.)

[Exhaust valve guide]

A 20

mm

dla. (0.79

in.

dia.)

B

12.96 to 12.98

mm

dia. (0.510 to 0.511 in.dia.)

C

7.50

to

7.70

mm

dia. (0.295 to 0.303 in.dia.)

0 225

mm

(8.66 in.)

E

80

mm (3.15 in.)

F 40

mm

(1.57 in.)

G

14.5 to 15.5

mm

(0.57 to 0.61 in.)

H 5

mm

(0.197 in.)

I 8.0 to

8.1

mm

dia. (0.31 to 0.32 in.dia.)

J

17.5 to 18.5

mm

dia. (0.689

to

0.728 in.dla.)

K

13.1 to

13.2

mm

dia. (0.516 to

0.520

in.dia.)

L 9.9 to 10.1

mm

(0.390 to 0.398 in.)

Cl

Chamfer

1.0

mm

(0.039 in.)

C2 Chamfer

2.0

mm

(0.079 in.)

CO.3

Chamfer 0.3

mm

(0.012 in.)

Balancer Bushing Replacing Tool 1 Assembly

Application: Use to press fit the bushing.

No.

name

of ParI Q'ly

(1)

Shaft

1

(2) Piece 1

1

(3).

Piece 2

1

Remarks

(4)

Boll

2

M6 x Pl.0

~

WESTERBEKE

EngInes & Generators

76

SPECIAL

TOOLS

(1)

Malenai: 845C-D

(2) Permanent Magnet: ¢ a

rnm

(0.3150 in. dia.)

Thickness: 3 mm (0.1181 in.)

A

CO.2

C3

.p---'-'-----"'r-(,

BCD

A

co_~

FO:;

H

I J

Cl

E L

G

.~

~

----

L M

5

r-

r~

N

9

Jig for Governor Connecting Rod

Application :Use for connecting the governor connecting rod to

the rack pin of the fuel injection

pump

assembly.

A

A1

mm

(O.0394

in. radius) V

3

rnm

(0.1181 In.)

B

Chamfer 0.2

mm

(0.0079 in.) W

10

mm

(0.3937

in.)

C

Chamfer 2

mm

(O.OlB?

in.) X

a mm (0.3150 in.)

D

35

rnm

dia.{1.3780

in.

dia:)

E Chamfer 1

mm

(0.0394 in.)

F Chamfer

0.1

rom

(0.0039 in.)

G

R1

mm

(0.0394

in.

radius)

H Chamfer 0.2

rom

(0.0079 in.)

i

RS

mm

(0.3150

In.

radius)

J

Rl

mm

(0.0394 in. radius)

K

Rl

rom

(0.0394

in.

radius)

L Chamfer 0.2

rom

(0.0079 in.)

M Chamfer 0.2 mm (0.0079 in.) N

29

mm(1.1417in.)

0

6 mm

{O.2362

in.j

p

10.7 mm

(O.4213

in.)

a

35

mm

(1.3780 in.)

---

R 99.3 mm (3.90'35 in.)

8

45.65

to

45.75 mm (1.7972

to

1.8012 in.)

T

145

mm

(5.7087 in.)

u 16.15

to

16.35

mm

dia. (0.6359 to 0.6439 in. dia.)

..

Auxlhary Socket for Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve.

A

Rmax",

t2.5

S

B

94.5 to 95.0 mm (3.7205

to

3.7402 in.)

C

40 mm (1.5748 in.)

D

30mm

(1.1811 in.)

E 12 mm (0.4724 in.)

F

7.9 to

8.1

mm (O.3110

to

0.3189 in.)

G

20 mm (O.078? in.)

H

130mm(5.1181

in.)

i 99.410 99.6 mm (3.913410 3.9213 in.)

J 95.05 to 95.20 mm (3.7421

10

3.7480 in.)

K 3 mm dia. (0.1181 in.dla.) L 15 mm (0.5905 in.)

M

10 mm (0.3937 in.)

N

90 mm (3.5433 in.)

0 115 mm (4.5275 in.)

p

16.910

17.1

mm (0.665410 0.6732 in.)

Cl

Chamfer 1.0 mm (0.039 in.)

C3

Chamfer 3.0 mm (0.1181 in.)

C5 Chamfer 5.0 mm (0.1969 in.)

CO.2

Chamfer 0.2 mm (0.0079 in.)

1--60.3

Chamfer 0.3 mm (0.0118 in.)

Engines & Generators

77

la)

[b)

(3)

(2)

(1)

Ie)

(3)

~

..

_-

(1)

F

(3)

(2)

(1)

G

c

(4)

A-A

)@K(7)

(8)

(6)

(9)

(4)

(11)

(4)

A

B

A

o E

A

(5)

SPECIAL

TOOLS

Balancer Bushing Replacing Tools

3.

4.

5

Application:

Use to press fit the bushing.

No.

Name

of

Part

(1

)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

[a] Tool 3 [b]

Tool4

Bracket

Flange

Nul

Washer

Shaft

Piece

1

Crevis Washer

Cotter Pin Joint

1

Piece 2 Joint

2

Piece

3

[e]

Tool5

A:

Section

Balancer Bushing Replacing Tool Components parts

1) Bracket

A

12 mm (0.47 in.)

8

50

mm

(1.97

in.)

C

Chamfer 1 mm

(0.04 in.)

0

60

mm

(3.15 in.)

E

104

mm

(4.09

in.)

F

22

mm

(0.87

in.)

G

13

mm

dia. (0.51 in. dia.)

2) Shaft

A

44

mm

dia.

(1.73

in. dia.)

B

12

mm

(0.47 in.)

C

Chamfer 1

mm

(0.04 In.)

0

3 mm (0.12 in.)

E

3 rnm (0.12 in.)

F

30

mm

(1.18in.)

G

38 mm (1.38 in.)

H

35

rnm (1.36 in.)

I

M12

x P1.25

J

53

mm

(2.09

in.l

K 4 mm (0.16 in.)

L 75

mm

(2.95 in.)

M

57

mm (2.24 in.)

~-

70 mm (2.76 in.)

0

19.5 rnm (O.77 in.)

p

12 mm (0.47 in.)

0

0.8

mm

(O.03

in.)

A

6 mm (0.24 in.)

~

WESTERBEKE

Engines & Generators

78

O"y

1 1 1

1 1 1 1

1 1 1 1 1

SPECIAL

TOOLS

3)

Piece 1

A

26 mm (1.02 in.)

B

18 mm (0.71 in.)

C

16.5 to 17.0

mm

(0.6496 to 0.6693 in.)

0 1.5

mm

(0.06 in.)

E

54.0 to 54.2

mm

dia. (2.1260

to

2.1339

in.

dia.)

F

50.55 to 50.75

mm

dia. (1.9902 to 1.9980

in.

dia.)

G 16 mm (0.63 in.)

H

Chamfer 1

mm

(0.04 in.)

I

8.5 mm dia. (0.33 in. dia.)

J 0.4

mm

(D.OIS? in.)

K

3 mm (0.12 in.)

L

19

mm

(0.75 in.)

M

Chamfer

0.5

mm

(0.02 in.)

N 36

mm

(1.42 in.)

0

45

mm

dia. (1.77 in. dia.)

p

0.78 rad (45

')

Q

11.5

mm

(0.45 in.)

4)

Joint

1

E B A

B

-,

-\

~

;'

:fD~

-I-.

. -

-

1'-.

.-

.

!~

..A/

r,

G

I

c

B

A

M12 x Pl.2S

J 85

mm

(3.35 in.)

B Chamfer 1

mm

(0.04 In.) K 70 mm (2.76 in.)

C

30

mm

dia. (1.18 in. dla.)

L

178

mm

(7.01 in.)

0

13

mm

dia. (0.51 in. dia.)

E

Chamfer 3

mm

(0.12 in.)

H K

F

3mm(O.12in.)

J

G

45 mm (1.77 in.)

L

H 75

mm

(2.95

in.)

I 57

mm

(2.24 in.)

5)

Piece2

A

+

~J

~

-

Q

A 26

mm

(1.02 in.)

B

18

mm (0.'l1 in.)

C

16.5 to

17.0 mm (0.6496 to 0.6693 in.)

E

~l~

L

r'-J

F n.l

--

~

-1-

/M

Q-

0 1.5

mm

(0.06 in.)

E 53.5 to 53.7

mm

diet.

(2.1063 to

2.1142

in. dla.)

F

50.05 to 50.25 mm dia. (1.9705 to

1.9783

in. dia.)

G

16

mm (0.63 in.)

-1.

p

H Chamfer 1 mm (0.04 in.)

I 8.5

mm

dia. (0.33 in. dia.)

J 0.4

mm

(0.0157 in.)

K

3mm(0.12in.)

L 19 mm (0.75 in.) 0 45 mm dia. (1.77 in. dia.)

M Chamfer

0.5 mm (0.02 in.) P 0.78 rad

(45°)

N 36 mm (1.42 in.)

Q

11.5 mm (0.45 in.)

-..v:

WESTERBEKE

Engines & Generators

79

SPECIAL

TOOLS

6)

Joint

2

EB

A

B

-,

\

I.

A

M12 x P1.25

8

Chamfer

1 mm (0.04 in.)

:tDI

+

.,.

~I-'Y

B

G

,

c

C

30

mm

dia. (1.18 in. dia.)

D

13

mm

dia. (0.51 in. dia.)

E

Chamfer 3 mm

(0.12 in.)

H

K

F

3

mm

(0.12 in.)

J

L

G 45

mm

(1.77 in.)

H 75

mm

(2.95 in.)

I 57

mm

(2.24 in.)

J 85

mm

(3.35 in.)

K 70

mm

(2.76 in.)

L 394

mm

(15.51 in.)

7) Piece 3

A 26

mm

(1.02 in.)

Q

8 18

mm

(O.7t in.)

C

16.5

to

17.0

mm

(0.649610 0.6693 in.)

D

1.5

mm

(0.06 in.)

--

N

Q_

E

53.0

to

53.2

mm

dia. (2.0866 to 2.0945 in. dia.)

F

49.55 to

49.75

mm dia. (1.9508

to

1.9587 in. dia.)

G 16

mm

(0.63 in.)

H

Chamfer 1 mm

(0.04 in.)

I 8.5

mm

dia. (0.33

in.

dia.)

J

0.4

mm

(0.0157 in.)

K

3

mm

(0.12

in.)

L

19

mm

(0.75 in.)

M

Chamfer

0.5

mm

(0.02 in.)

N

36

mm

(1.42

in.)

0

45

mm

dia. (1.77 in. dia.)

p

0.78

,ad

(45

')

Q

11.5

mm

(0.45 in.)

Engines & Genera/ors

80

A

E

B F

J

C

D F

F~

Fl,u

/-

·G -tt-

K·

Lr?/P

Q~

(

17

M

'N

.t

R

N

V

W

x

y

A

B

D E

C

F

G

L

C

J

H

SPECIAL

TOOLS

V-s

I'.

Balancer Bushing Replacing Tool 1 Componenls Parts

1)

Shaft

A

498

mm

(19.61 in.)

B

318.810319.2

mm

(12.5726 to 12.5669 in.)

C 102.810103.2

mm

(4.047210 4.0630 in.)

0 60 mm (2.36 in.)

E 8

mm

(0.31

in.)

F

5

mm

(0.20 in.)

G

30

mm

dla.

(t.tS

in.

dia.)

H

65

mm

dia. (2.56 in. dia.)

I 6

mm

(0.24 in.)

J Chamfer 1

mm

(0.04 in.)

K

53

mm

dia. (2.09 in. dia.)

L 54.7 to 54.9 mm dia. (2.1535

1021614

in.

dia.)

M

0.26

rad.

(15

')

N

Chamfer

0.5

mm

(0.02

in.)

0

41

mm

dla. (1.61 in. die.)

p

32

mm

dla. (1.26 In. dia.)

Q

33.961 to 34.0

mm

die. (1.33/0 to 1.3386

in.

dia.)

A

18

mm

dia. (0.71 in. dla.)

S

19.96710

20.0

mm

dla. (0.7861 to 0.7874 In. die.)

U

3

mm

(0.12 in.)

V 149.1 to 149.4

mm

(5.8701 to 5.8819 in.)

W 365.1 to 365.4

mm

(14.3740 to 14.3858 in.)

X 123

mm

(4.84 In.)

y

375

mm

(14.76 in.)

Z

M6 x Pl.0

depth 7 mm

(0.28 in.)

a

Chamfer 2 mm

(0.08 in.)

2) Piece 1

A

Chamfer

0.1

mm

(0.004 in.)

B 1

mm

(0.04 in.)

C

Chamfer 1 mm

(0.04 in.)

0

53.81053.9

mm

dia. (2.118110 2.1220 in. dia.)

E

20.021020.041

mm

dia. (0.788210

0.7890

in. dia.)

F

48

mm

dia. (1.89 in. dia.)

G 49.934 to 49.94

mm

dia.

(1.9659101.9661

in. dia.)

H 8

mm

(0.31 in.)

I 2

mm

(0.08 in.)

J

35

mm

(1.38 in.)

K 5

mm

(0.20 in.)

L

0.26

rad (15

')

Engines & Generators

81

,

o

E

/'

B

C,.

F

.-.-

'-

r!

~J

H

L

M

A

---AL

-K

J

}

A

G

E F G H

P

o

SPECIAL

3)

TOOLS

Piece 2

A

Chamfer

8 1 mm (0.04 in.)

C Chamfer 1

D

54.31054.4

E 34.025

F 48.5

50.421 to 50.44

G H 8

I 2 mm

35

J

5 mm

K

0.26 rad (15

L

mm

0.1

to

34.05

mm

dia.

(0.31 in.)

(O.OB

(1.38 in.)

(O.20

mm

in.)

0)

rnm

(O.004

(0.04 in.)

dia. (2.137810 2.1417

mm

dia. (1.3396 to 1.3406 in. dia.)

(1.9094

in.

mm

dia. (1.9851 to 1.9858 in. dia.)

Balancer Bushing Replacing Tool 2

Application: Use to press fit the bushing.

35

A

8

C Chamfer 0.5

D

E Chamfer 1

F 40 mm dia. (1.57 in. dia.)

G

H

I

J

K 6 L

M

N

0

p

mm (1.38 in.)

33

mm (1.30 In.)

mm

1 mm

(O.04

in.)

mm

50.921

to 50.94

54.8 to 54.9 30

mm

49

mm

125

160 mm (6.30 in.) 3 mm (0.12 in.) 5 mm (0.20 in.)

0.26 rad (15°)

mm

dia. (1.18 in. dia.)

dia. (1.93

(0.24 in.)

mm

(4.92 in.)

(0.02 in.)

(0.04

In.)

mm

dia. (2.0048 to

dia. (2.1575 to 2.1614 in. dia.)

In.

dia.)

in.)

dia.)

in.

2.0055

dia.)

in. dia.)

Engines & Generators

82

GENERATOR

USE

OF

ELECTRIC

The power required

more than is required to keep it running after it is started.

Some

motors

require

others. Split-phase (AC) motors require more current to start,

under

similar

monly used on easy-starting loads, such as washing

machines, or where loads are applied after the motor is

started, such as small power tools. Because they require 5 to

7 times as much current to start

avoided, whenever possible,

ven

by a small

motors

to

run. The current required to start any motor varies with the

load

connected

compressor, for example, will require more current than a motor to which no load is connected.

In

general, the cunent required

to medium starting loads will be approximately as follows:

MOTOR

"NOTE:

more

for

Ihis

made

jn

Because the heavy surge

motors

be damaged

seconds. off all other electrical loads and, on the electric motor.

Required

Run the genera)or first with no load applied, then at half the generator's capacity, and finally loaded indicted on the generator's data plate. The output voltage should be checked periodically to ensure proper operation the generating plant and the appliances it supplies. voltmeter or ampmeter is not installed to monitor voltage and

load, check it with a portable meter and amp probe.

circumstances,

require

SIZE

(HPJ

1/6

114

113

112

314

1

In

Ihe

some

js

Ihallhe

larger

is

required

if

If

difficulty is experienced in starting motors, turn

Operating

MOTORS

to

start an electric motor

much

more

than

if

generator.

Capacitor

from 2 to 4 times

to

it.

An

electric

to

AMPS

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

above

lable

Ihe

small

molors

Ihan

hardesl

slaning

current

other

as

to run, their use should be

the electric motor is

and

as

much

motor

start

115-

FOR

maximum

for

larger

types

is

considerably

to

start

them

than

types.

They

are

to

be dri-

repulsion-induction

current

connected

\bIt

Amps for Starting is

(Splil-phase)

to

start

to

an

motors connected

AMPS

FOR

(~TARTIN~)

AMPERES

6.4

to

22.4'

9.2

to

32.2'

10.4

to

72.8'

14.4

to

29.2'

20.4

to

40.8'

26

to

52

ones.

The

reason

are

sizes.

of

current needed for starting

for

only

an

instant,

it can bring the motor up to speed in a few

the

generator

if

possible, reduce the load

will

Speed

to

its full capacity

If

an AC

com-

as

air

nol

not

as

of

INFORMATION

Generator

Frequency

cated by the following:

o When the generator

output frequency is

Therefore, to change the generator's frequency/voltage, the generator's drive engine's speed must be changed using the dips witch on the

generator

sensing PC board changed.

Generator

o Maintaining reasonable cleanliness is important.

Connections corroded, and insulation surfaces salts, dust, engine build up. Clogged ventilation openings may cause excessive heating and reduced life

o For unusually severe conditions, thin rust-inhibiting petro-

leum-base coatings, should be sprayed surfaces to reduce rusting and corrosion. Typical materials suggested are Daubert Chemical Co. and Ashland "Tectyle 506"

o

The checked periodically and for any evidence should not be allowed accelerate cracking. The bolts which fasten the drive disc to the generator shaft must be hardened steel 8, identified by 6 radial marks, one at each ners

o The rear armature bearing is lubricated and sealed;

maintenance

noisy

o Examine bearing at periodic intervals.

of

shaft should be detected when force is applied.

motion

shaft

Repair must be made quickly or major components

rub

,-----

WESTERBEKE recommends mounting a carbon monoxide detector in the vesssel's Jiving quarters. Monoxide, even in

The presence of carbon monoxide indicates an exhaust leak from the engine

exhaust hose,

entering your boat.

If

air and correct the problem immediately!

Frequency

is

a direct result

ECU. The

changed

Adjustment

of

engine/generator speed,

is

run at 1800 RPM, the AC voltage

60 Hertz.

AC

output configuration

and

the

connections

on

the

of

voltage

Maintenance

of

terminal boards and rectifiers may become

may

start conducting

exhaus~

drive discs on single bearing generators should be

of

the head.

is

required.

or

rough-sounding, have it replaced.

is

detectable,

of

bearing socket outside bearing has occurred.

and

cause

major

Carbon

or

generator or from the exhaust elbow/

or

that

carbon monoxide is present, ventilate the area with clean

carbon, etc. are allowed

of

windings.

or

brushed over all

"Non-Rust AC-4!o"

or

equivalent.

if

possible for tightness

of

incipient cracking failure. Discs

to

become rusty because rust may

However,

bearings

damage

Monoxide

small

amounts,

fumes

if

the

are

wearing

to

generator.

Detector

is deadly.

from a nearby

of

SAE

of

the 6 cor-

bearing

No

side movement

or

wear

-----,

vessel

screws

grade

becomes

if

are

as

indi-

the

if

to

no

side

on

wiJI

Carbon

Eng/nes & Generators

83

(SERIES

WYE)

SERIES

STAR

TWELVE

L

2

3

LEAD

N

WINDING/TERMINAL

AND

(NOMINAL)

(PARALLEL

PARALLEL STAR

WYE)

VOLTAGES

BOARD

N

CONNECTIONS

L

12 1

10

11

'v

SERIES

DELTA

L9

10':11 2-3

0 0 0

;

5 9

)

,

Ll

50

60

l2

Hz

6

L2

L-L 400 volts L-N 230 volts L-L480

L-N 277 volts

Ll

PARALLEL DELTA

L

10-12 2-4 6-8

1 3 5 7 9 11

6-7

0

L3

L

L3

volts

5

L

5

~12

N

L

o

11

L

9

10-12

1-3

0

2-4

5-7

(

,

Ll

L

10-12

1

N

L2

50 Hz L-L 200 volts

50

Hz

L-N 60 Hz L-L 240 volts 60

Hz

L-N 138 volts

2-4

,

3 9-11

5C 7

1.1

l2

6-8

9¢11

1

L3

liS

N

volts

6-8

~

0

L

0

3 L

91'

-:8:--N-7-'~

L

10-11

o

1-12

)

Ll

50 50

60 60 (Refer to Note

THREE

PHASE

ZIG-ZAG

lOt

L •

8-10

0 0

~

II

I

L2

Hz

L-L 230 volts

Hz

t-N

Hz

L-L

Hz

L-N 138 volts

L~

~2

'11

~L

2-12

5

9

I

,

L2

6-7

o

9-8

)

L3

115 volts

277

volts

#

1)

N

4 6 5

4-6

0

9

(

L3

L

o

3-7-11

i

,

N

50

Hz

60

Hz

DOUBLE DELTA

7

L

4

8-11

o 0

1

10

50

Hz

50

Hz

60

Hz

60

Hz

L-L 115 volts L-L 138 volts

2-3

5 12

N

1-L 1-N 115 volls

L-1. L-N

6-9

7 4

t

Ll

230 volts

240 volts

120volts

10

1 L

o

50

Hz

50

HzL-N

60

Hz

60

Hz

(Refer to Note #1)

Note

#1

TI,e nomillal vallie.

Nole

The

0.866.

Single

phase

current

#2

1711-ee

rated

power

Engines & Generators

L-L 230 volts

ll5

volts

L-L 277 volts

L-N 138 volts

phase

ampemge

must

110/

phase zig-zag cOl/nection.

must

be

load.

exceed

nwZlip/ied

the

by

84

50 50

60 Hz

60

(Refer

DOUBLE DELTA

2-WlRE

7

L

8-11

0

C

1

10

N

Hz

L-L

Hz

L-N

L-L4IS

Hz

L-N 240 volts

to

4

2-3

~

5

50

Hz

L-N

60

Hz

L-N

346

200 volts

Note #2)

6-9

0

7 4

12

II

230 240

volts

10

N

0

volts

vollS

ELECTRONIC

ADJUSTABLE OVERLOAD

THRESHOLD

PROTECTION

REGULATION

SR7-2G

AVR

AMP

FUSE

ADJUSTABLE

OF

UNDERSPEED

PROTECTION

THRESHOLD

INTERVENTION

""Hertz--,'jo~(-\-):E°O

DESCRIPTION

The

voltage regulator performance. circuitry protection to guard against operating conditions could

be detrimental information details connections. qualified technician.

TERMINAL

#1.

Excitation

#2.

Exciter

between S and

#3.

Exciter #3A.

Supply voltage

#4.

Sensing voltage.

#5.

Supply voltage

#6.

Jumper

#7.

Not

#5B.

Npt

#5C. Sensing

POSSIBLE

Exciter Field: The exciter connected

dark

blue

yellow) Supply: There

1.

The supply coincides SR712 (in case of three-phase generators, connected be is

also sensing. This connection

generator

the

2.

The supply generator equipped supply. of the

TIlis

These

CONNECTIONS

field

to used. used.

voltage.

CONNECTIONS

to

terminal 1 of the electronic regulator

or

black), while

should be connected

supply should

Witll

connected

does

regulator.

Supply

regulator.

(AVR)

ensures

advanced

to the procedures should

field

jumper

3A

DC positive.

SA

for

are

two

the star point). Ternnnals 3

to

each otller

1I0t

and

sensing separate. Tins

is

always connected

design

AVR

the

AC

generator.

voltage regulators adjustments

DC negative.

to

3 if

the

is

less

than

to

regulator (Ae).

to

regulator (Ae).

60

Hz

operation.

field

negative should

the

positive (nonnally

to

terminal

possibilities.

with

the

sensing.

be

connected

in

such a way

in

have auxiliary

with

auxiliary winding

optimum

is

equipped

The following

be

performed

regulator

160

VAC.

3.

In

tllis

to

tenninals 3

terminal S is

that

necessary

winding

is

the

to

terminals 3 and

AC

generator

with

and

by

AC

supply

be

(normally

red

or

case

the

and

normally

and 4 should

the

supply

when

the

for supplying

case of a

for

regulator

a

..

o

tllat

S

5

DO

1;!a1--tCDI~NEICT

rn---l

REMOVE

EXCITER

o

In

both

of

these

cases,

tlle

SR7/2

supply

270

VAC.

But

it

should be

should be bridged for supply

160

VAC,

while

the

voltage Sensing: Sensing should

and phase alternator

Operation and low

FUNCTIONS

Volt: voltage generated the screw

Stab:

If

time turned voltage

In using

1.

2.

is

between

can

vary

only

and

phase.

at 6 should frequency protection correctly regulated.

A

WARNING:

present.

against

screw

turned

order

The generator

and the potentiometer must be at

(turned Slightly

filament potentiometer stabilizes.

Take

electrical

Witll

this potentiometer, it

is

turned

This

potentiometer optinlizes altemator

clockwise,

decreases but

cOllnterclockwise,

tends

to

adjust

the

following

fully

tum

160

from

80

therefore

60

Hz:

be

connected

all

OF

THE

by

tumed clockwise,

counterclockwise it

the

to

be

more

tlIis

must

counterclockwise).

clockwise

lamp

oscillates, slowly

noted

that terminals 2

with

same

terminals

and

270

VAC.

be

connected

to

350

VAC.

is

normally

When

operating

to

each

Be

aware

that

necessary

hazards.

precautionms

REGULATOR

is

the alternator

the

stability

voltage

potentiometer

metllod.

be

counterclockwise

tends

the

response

stable.

working,

until

at

this

decreases

tlle

FOR

60Hz

FOR

50Hz

FIELD

can

vary

from

80

and

3

voltage

high

should

to

The

sensing

connected

at

60

other

in

voltages

between

be

terminals 4 and

order

left

Hz,

to

80

and

open

is

single

to

one

terminals

to

keep

may

be

safe

guard

if

POTENTIOMETERS

possible

in a very

voltage

starting

light

point,

to

increases,

decreases.

and

to

be

less

time

increases

cOlTectly,

frolll

maximum

generated tUIll

until

adjust

the

simple

way.

if

performance.

the

response

stable.

If and

we

advise

zero

load

stability

by

tlle

light

If

tlle

to

the

S

SA

tlle

the

Engines & Generators

85

ELECTRONIC

Hertz:

With

this

potentiometer, pre-calibrated to

adjust

recalibrate this protection. you must take the generator nonnal zero load condition, tum the potentiometer

clockwise the

nominal counterclockwise decreased

When

the

value,

the generator overheating. protection

possible

Amp:

With

intervention level of

system

overload, necessary

applications. To

modify

by

15% minimum (counterclockwise) During this period condition the

generator voltage value

At

this voltage increases

Fuse: The electronic regulator protects malfunction. The

replaoed

then

sealed

the

low

frequency

until

the

limit

speed

by

10

and

measure

by 5 volts. speed

decreases

voltage

to

has

of

and

point,

the

easily.

also

decreases proportionally,

Even

at

10%

of

the

calibrate the threshold

this

potentiometer,

the

an

intervention

when

this

protection,

the

normal

while

alternator

load,

of

time

turning

the

initial overload

to

the

from

fuse

(250V-5A,

overload protection. This protection

nominal

INTERNAL

12

WIRE

which

is

normally

by

the

manufacturer,

protection intervention.

position

%.

nominal

is

reached,

Then

turn

the potentiometer

the

voltage

by

more

than

if

we

advise

value,

at

other

it

is

possible

delay,

which

starting

you

the

motors

must

overload the generator

turn

the

potentiometer

and

wait about

voltage

the

at

10%

overheating in

value

potentiometer clockwise,

less

than

is

value.

is

equipped

quick acting, F

WIRING

it

then

value

10%

of

calibrating

it

is

obviously

values.

to

adjust

permits a

or

similar

twenty

decreases.

the

being

removed,

with a fuse,

cases

DIAGRAM

RECDNNECTABLE

is

possible To

decrease

until

the

blocking

temporary

to

nominal

of regulator

type)

REGULATION

to

a

it

has

nominal

this

the

SR7-2G

TO CONNECTIONS

REFER

TO WIRING IN

DIAGRAM

THIS

MANUAL.

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seconds.

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this

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which

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Engines & Generators

__

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NOTE:

EXCITER

NO

LOAO

FULllOAU

9

COMPONENT RESISTANCE

VALUES

(AT

STATOR

(each

wlndlng)

AUXIlIARY. EXCITER

EXCITER

(each

pair)

ROTOR

__

DC

VOLTAGE I AUXILIARY

7.0

VUC

14.0

VUC

IN

OHMS

86'F)

___

0.041

____

STATOR_ll.3 ROTOR

_

VOLTAGE

215

VAC

222

VAC

0.9

__ . O.

2.7

72

86

GENERATOR

SERVICING

TESTING

Test the speed sensor connector for voltage and resistance values.

If

the values are correct, remove and inspect the magnetic pick up. With the wires disconnected, unscrew the magnetic pick inspect the contact end.

the unit.

NOTE:

provided with the new magnetic pick

SPEED

Voltage

1.5 -2.5

Resistance

WIRES

THE

MAGNETIC

up

from the generator housing and visually

Carefully/allow the installation instructions

SENSOR

(whIle

VAC

TEST

cranking)

(al

rest)

VALUES

950

PICK

UP

COIL

If

any damage

-1000

ohm

~MIPU-I~AGINE1'ICPICK-UP

is

detected, replace

up

coil.

MAGNETIC

The MPU is installed of

the flywheel bellhousing. This positions the MPU over the teeth of the flywheel ring gear. Viewing through this opening, manually rotate the engine crankshaft so as to position the flat gear's teeth directly under the opening. Thread the into the opening until tooth (Thread is 3/8" x 24). Back the opening one tum and then lock it

jam

the approximately 0.030 inches away from the flats of the ring gear teeth.

To

en~ure

the crankshaft by physical contact between the MPU and the ring gear teeth.

If

contact

MPU may be damaged. Remove the MPU and inspect

the it.

Replace installation procedure.

'

. signal to the controller.

NOTE:

MUST

existing wiring cable. Doing so will cause a erratic

PICK·UP

nut. This will position the end

the MPU is positioned correctly, slowly rotate

360" by hand to assure there is no

is

felt between the MPU and the flywheel teeth,

if

necessary and repeat the above

When replacing the Magnetic Pick-Up (MPU) it be

replaced without cutting

[MPU]

in

it

INSTALLATION

the threaded opening

of

one of tlle ring

gently contacts the

MPU

in

this position with

and

on

the side

MPU

flat

of this

out of the

of

the MPU

splicing into the

AC

a

~

0.03010

"""

WESTERBEKE

Engines & Generators

87

GENERATOR

NOTE:

AC

GENERATOR TROUBLESHOOTING

BE

PERFORMED WITH THE ENGINE OPERATING

TROUBLESHOOTING

MUST

AT

60

HZ.

NO

AC

VOLTAGE

RESIDUAL

NO

LOW NO

HIGH 150

UNSTABLE (ENGINE

LOAD

AC

VOLTAGE

LOAD

AC

VAC

OR

SPEED

VOLTAGE

15 • 20

60 • 100

OUTPUT

VOLTAGE

FAULT

OUTPUT

PRODUCED

VOLTS

OUTPUT

VAC.

VOLTAGE

HIGHER.

OUTPUT.

STEADY)

AT

AC.

NO

AT

LOAD.

AT

1.

Short main

2.

Shorted on

exciter

3.

Four

or

open

1.

Blown 6 AMP

auxiliary

2.

Faulty

1.

Reset

2.

Open exciter

3.

Open exciter

1.

Reset

2.

Faulty

1.

STB

pod

needs

PROBABLE

or

open

in

the

stator

winding.

suppressor

rotor.

more

shorted

or

diodes

on

exciter

fuse

circuit

feed

to

voltage

regulator

voltage

potentiometer.

or

shorted

rotor 1 to 3 diodes.

or

short

rotor

voltage

adjustment.

diodes

in

one

windings.

potentiometer.

regulator.

on

regulator

of

rotor.

AVA.

in.

the

three

CAUSE

4.

Open stator

5.

Open field

6.

Shorted on

3.

Shorted

stator

4.

Faulty

5.

Short

6.

Short

2.

Faulty

in

exciter

winding.

in

rotating

winding.

condenser

exciter

or

auxiliary

voltage

in

rotating

in

the

voltage

rotor.

open

winding.

regulator.

exciter

regulator.

main

field

stator.

winding.

AC

VOLTAGE

60

·100

DROP

VOLTS

UNDER

AC.

LOAD

1.

Diode(s) breaking applied

on

exciter

down

when

(inductive)

rotor

load

1·3

is

diodes.

Engines & Generators

88

Westerbeke 65A-FOUR, 26.0 EDER, 33 EDE, 28.5 EDE, 25.5KW EDE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual