Westerbeke 55B-FOUR, 55C- FOUR Service Manual

SERVICE

MANUAL

55B-FOUR

and

55e-FOUR

MARINE

DIESEL

ENGINE

PUBLICATION NO. 049970

2ND EDITION

SEPTEMBER 2006

~

WESTERBEKE CORPORA

TION.

150 JOHN HANCOCK ROAD

I MYLES STANDISH INDUSTRIAL

PARK'

TAUNTON MA 02780

WEBSITE:

WWW.W£ST£RB£KE.COM

----

AlMM'"

Metn«f

National

Marin~

Manufacturers Association

-~

CALIFORNIA

Exhaust gasoline its

constituents)

the

State cancer, reproductive

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

-

Weakness

IF

YOU

GET

OUT

seek

medical

until

it

PROPOSITION

WARNING

gas

from

engines

of

California

birth

defects,

harm.

gasses

gas.

Carbon

can

include:

and

OR

ANYONE

INTO

THE

attention.

has

been

contain

65

diesel

and

(and

some

of

are

known

to

cause

and

other

AWARNING:

Carbon

Monoxide

and

death.

Sleepiness

ELSE

FRESH

Shut

inspected

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

• Inability

EXPERIENCE

AIR

IMMEDIATELY. down

and

ANY

the

repaired.

of

Carbon

Twitching

to

OF

unit

an

odorless

and

in

Temples

Think

THESE

If

symptoms

and

do

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

A

WARNING

should

be

generator. WESTERBEKE

MONOXIDE of

your

vessel.

obtainable

DECAL

is

provided

fixed

to a bulkhead

also

recommends

DETECTORS

They

at

your

in

are

local

by

WESTERBEKE

near

your

engine

installing

the

/iving/sleeping

inexpensive

marine

Engines & Generators

store.

and

easily

and

or

CARBON

quarters

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

11Ul1Iual

carefully.

Most

accidents

are

! caused

by

failure to follow fundamental

rules

and

precautiJJns.

Know

when

dangerous

conditions exist and

toke

the

necessary

precautiJJns

to protect

yourse1/,

your

personnel,

and your

machinery.

The

following safety instructions

are

in

comp1iance

with

the American Boat and

Yacht

Council

(ABYC)

stondards.

PREVENT

ELECTRIC

SHOCK

A

WARNING:

Do

nut

touch

AC

electrical

connections

while

engine

is

running,

or

when

connected

to

shore

power.

Lethal

voltage

is

present

at

these

connections!

•

Do

not operate this machinery without electrical

enclosures and covers

in

place.

• Shut off electrical power before accessing electrical equipment

•

Use

insulated mats whenever working on electrical

equipment.

• Make sure your clothing

and

skin are dry, not

damp

(particularly shoes)

when

handling electrical equipment

•

Remove

wristwatch and

all

jewelry when

working

on

electrical equipment.

•

Do

not connect utility

shore

power

to

vessels

AC

circuits, except through a

shiJ>-to-shore

double

throw

transfer switch. Damage

to

vessels

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:

Do

not

touch

hot

engine

parts

or

exhaust

system

components. A running

engine

gets

reryhot!

•

Always

check

the

engine coolant

level

at

the

coolant

recovery

tank.

A

WARNING:

Steam

can

cause

injury

or

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:

Fire

can

cause

injury

or

death!

• 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 cleaner/silencer

removed.

Backfire

can

cause severe injury or

death.

•

Do

not smoke or permit

flames

or

sparks

to

occur

near

the

fuel

system.

Keep

the compartment

and

the

engine/generator clean and

free

of

debris

to

minimize

the

chances of

fire.

Wipe

up

all

spilled

fuel

and

engine

oil.

•

Be

aware - diesel fuel will

burn.

PREVENT

BURNS -EXPLOSION

A

WARNING:

Explosions

from

fuel

vapOIS

can

cause

injury

or

death!

• Follow re-fueling safety instructions.

Keep

the

vessels

hatches closed

when

fueling.

Open

and

ventilate

cabin

after

fueling.

Check below for fumes/vapor

before

running

the

blower.

Run the blower for

four

minutes

before starting your engine.

• All

fuel

vapors

are

highly

explosive.

Use

extreme

care

when

handling and storing

fuels.

Store

fuel

in a well-

ventilated

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

environment.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAl

A

WARNING:

Dr

death!

• Disconnect generator. it

last.

•

Make starting.

•

Make certain re-installed before starting the

BATTERY

A

WARNING:

STARTING

Accidental

the

battery

Remove

certain

the

all

personnel are clear

all

covers,

EXPLOSION

Battery

cables

negative lead

ordeath!

•

Do

not smoke or being serviced. highly explosive arcing or equipment

during

• Never connect positive (+) connection terminal

Do together. Ventilate accumulation of explosive disturb is

being

•

Avoid bums or sparks that could cause wristwatch,

the

•

Always the and

BATTERY

A

WARNING:

severe

by

servicing.

not test

Sparks any

the

charged.

contacting

battery.

tum

battery

reconnect it last

ACID

injury

allow

Lead

acid

gas,

which

lit

tobacco

in

the

vicinity

the

negative

the

battery condition

could

ignite

compartment containing batteries

battery charger connections

the

terminals

rings,

and any

the

battery charger off before disconnecting

connections.

when

Sulfuric

Dr

death!

starting

guards,

explosion

an

open

batteries emit

can

products. Shut off

to

prevent electrical

(-) battery

gases.

other jewelry

Remove

disconnecting

acid

can

cause

before servicing

first

of

the

and

hatches

engine.

can

cause

flame

near

hydrogen,

be ignited

cable

of

the

starter

by

shorting

battery

gases

To

avoid

while

with

tools,

an

explosion.

the

negative

in

batteries

and

engine

are

injury

the

by

all

to the

or

sparks,

etc.,

before

the

battery.

can

injury

the

engine!

reconnect

before

battery

a

electrical electrical arcing

the

solenoid.

terminals

fuel

vapors.

to

prevent

do

the

battery

to

prevent

Remove

handling

lead

first

cause

not

TOXIC

• Ensure

•

• For additional information refer

• Do not

•

AVOID

EXHAUST

A

WARNING:

that discharged regularly manifolds/water-injected

Be

sure

the

Run

blowers

Do

not

run equipped detector boat builder detectors.

(educational information

A

odorless nausea

fumes systems. copper

Do through exhaust enter flow

Although exhaust gas symptoms poisoning

Vomiting Dizziness Headache Nausea

that

WARNING:

gas.

or

death!

use

can

Exhaust

tubing

not install exhaust outlet

portholes,

discharge

the

exhaust

of

exhaust.

fumes

is present

MOVING

GASES

Carbon

the

exhaust system

from

the'

for

leaks

unit

and

when

the

generator

with

a functioning marine

complies

or

dealer

Carbon

Inhalation

copper tubing in diesel

rapidly

destroy

sulfur causes rapid

resulting in exhaust/water

outlet

discharge

Avoid

diesel

engine exhaust

from

in

diesel exhaust

or

sigus

are:

Inability Throbbing in Muscular twitching Weakness

PARTS

monoxide

engine.

and

its

running

Check

make

sure

elbow

surroundings are

the

set

or

with

ABYCA-24.

for

installation

on

Carbon

monoxide

produces

copper

where

vents, or air

is

near

outlet

overloading

gasoline engines,

of

carbon

monoxide

to

think

temples

and

sleepiness

(CO)

is a deadly

is

adequate

the

exhaust

the

exhaust

is

securely

well

generator engine

to

(CO)

"u·like

tubing

conditioners.

the

and

gases

fumes.

coherently

set

unless

carbon

Consult

of

approved

ABYC

T-22

Monoxide).

is

an symptoms,

exhaust

in

exhaust

deterioration

leakage.

exhaust

waterline,

close

the

craft.

are

not

carbon

Some

inhalation

gas!

to

expel

system

attached.

ventilated.

or

engine.

the boat

monoxide

your

invisible

systems.

of

can

be

If

the

water

or

restrict

as

toxic

monoxide

of

the

gases

is

Diesel

drawn

engine

could

the

as

or

•

When

servicing

level,

wear rubber protection. Batteries destructive. off at once into

the

eyes inadvertently

caps.

If

with

the

battery or checking

gloves,

contain

it

comes

in contact

water.

Acid

a rubber

sulfuric

with

may

splash

when

removing electrolyte

the

apron,

acid

your

on

electrolyte

and

eye

which

is

skin,

the

skin

A

or

wash

it

or

Engines & Generators

•

ii

WARNING:

death!

Do

not service

situation

make touching components.

arises

operating

moving

Rotating

the

in

adjustments,

engine

which

parts

it

and

can

while

it

is

absolutely use

extreme

hot exhaust

cause

running.

necessary

system

injury

If

care

to

a

to

avoid

SAFETY

INSTRUCTIONS

• Do not

equipment;

jackets,

could

• Make

Keep

places at all

• Do

the

• Stay clear of when

be caught

HAZARDOUS

I

~WARNING:

• Never operate

• Do

removed.

• Do not run

open.

A

,.",."

wear

loose clothing or jewelry

tie back long hair

shirts,

sleeves,

be

caught

in

sure

all attaching

protective

not

check

engine is

the

shields

times.

fluid

operating. the

drive

engine is

in

these rotating parts.

NOISE

High

an

engine

not

run

an

engine

engines

WARNING:

fIT

Do

p/JysIt:al"

and

rings,

necklaces

moving

levels or

runuing;

for

not

hardware and

shaft

noise

without

with

long

nt

parts.

guards

the

and

hair

levels

the

periods

lin

Incapacifatetl

when

avoid

wearing

or

is

properly

in

their

drive

belts

the

transmission

and

clothing

can

C81/S8

its

muffler

air intake

with

(silencer)

their

macIJinlll1

by

fatigue!

servicing

loose

bracelets

tightened.

respective

tension

coupling

can

easily

hearing

installed.

enclosures

when

ytlU

that

while

are

ABYC,

INSTALLING

Read for recommendations

ABYC

"Safety Order

NFPA

"Fire Order

USCG "USCG

Order

NFPA

AND

DIESEL

the

following

safety

codes

and

when

(American

Standards

from:

ABYC

3069 Solomon's Island

Edgewater,

(National

Protection

from:

NfPA

II

Tracy

Avon

Industrial

Avon,

MA

(United

33CFR183"

from:

U.S.

Government

Washington,

MD

Standard

Drive

02322

Slates

D.C.

Boat

for

21037

Fire

Park

USCG

PUBLICATIONS

ENGINES

ABYC,

NfPA

standards.

installing your and

Yacht

S!1IaU

Craft"

Rd.

Protection

for

Motor Craft"

Coast

Guard)

Printing

20404

Office

and

USCG

Follow their

engine.

Council)

Association)

FOR

publications

)

OPERATORS

Many

of

the in your notes carefully,

procedures.

()peratOIs

to

highlight critical

GASOUNE

Preparations to

thorough

Council's combination

Sections

All Regulations

examination

of

H-2 P-l P-4

E-9

installations

MANUAL

preceding

Manual

maintain your

ENGINE

(ABYC)

of

the

Ventilation

Exhaust

InboanI

DC

Electrical

(FCR).

AND

instaII

an

of the

standards. These

sources

ABYC

Systems

Engines

must

comply

safety

tips

and

warnings

along

with

other

information.

equipment,

Read

and

GENERATOR

engine should

American

standards

including

standards

Systems

the

USCG

of particular interest

with

the

are

repeated

cautions

your

follow

manual

all

safety

and

INSTAllATIONS

begin

with

a

Boat

and

Yacht

are

a

and

the

NfPA.

are:

Federal

Code

of

)

Engines & Generators

iii

INSTALLATION

When installing

WESTERBEKE

engines

and

generators it is important

that

strict

attention be paid

to

the

following

infonnation:

CODES

AND

REGlIATIONS

Strict

federal

regulations,

ABYC

guidelines,

and

safety

codes

must

be

complied

with

when installing

engines

and

generators

in a marine

environment.

SlPHON-BREAK

For installations

where

the

exhaust

manifold/water

injected

exhaust

elbow

is

close

to

or will be below the vessel's

waterline,

provisions

must

be

made

to

install a

siphon-

break in the

raw

water

supply

hose

to

the

exhaust

elbow.

This

hose

must

be

looped a

minimum

of

20"

above

the vessel's

waterline.

Failare to use a siphon-breok

when

the

exhaust

manifold injection port is at or

below

the load

waterline

will

result in

mw

water

dDmoge

to the engine

and

possible

flooding

of

the

boat.

If

you

have any

doubt

about

the

position of

the

water-injected

exhaust

elbow

relative

to the vessel's waterline

under

the vessel's

various

operating

conditions,

install

a

siphon-breok.

JIOIE:

A

siphon-break

requires

periodic

inspection

and

cleaning

to

ensure

proper

operation.

Failure

to

properly

maintain a siphon-break

can

result

in

catastrophic

engine

damage.

Consult

the

siphon-break

manufacturer

for

proper

maintenance.

EXHAUST

SYSTEM

The exhaust

hose

must

be

certified

for

marine

use.

The

system

must

be

designed

to

prevent water

from

entering the exhaust

under

any

sea conditions

and

at

any

angle

of

the

vessels

hull.

A

detailed

40

page

Marine

Installation

Manual

covering

gasoline

and

diesel,

engines

and

generators,

is

available

from

your

WESTERBEKE

dealer.

,.~/WESIJ:RBEKE

I Engines & Generators

iv

AVAILABLE

FROM

YOUR

WESTERBEKE

OEALER

TABLE

OF

CONTENTS

Parts

Identification

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

2

Introduction ........................................................

.3

Engine

Specifications

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

..4

Testing

for

Overhaul

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

5

Alternator Inspection ........................................ 5

Engine

Troubleshooting

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

6

Engine

Disassembly

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

10

Engine

Measurements

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

11

(Prior

to

Disassembly)

Transmission

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

11

Injection

Pump

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

11

Engine

Disassembly

(Exploded

View)

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

12

Engine

Inspection

and

Repair

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

15

Engine

Assembly

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

25

Sealants and Lubricants .................................. 25

Bolts and Fasteners ......................................... 25

Engine

Assembly

(Exploded

View)

...•...................

28

Engine

Assembly

(External

Parts)

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

.34

Engine

Assembly

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

38

Engine Tuning ................................................ 38

Lubrication

Diagram

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

39

Cooling

System

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

.40

Fuel

System

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

.43

Governor Drawing ......................................... .46

Engine

Adjustments

..•........................................

50

Testing Compression ..................................... .50

Oil Pressure ....................................................

50

Valve Clearance ..............................................

51

Injection TIming ............................................. 52

Warning

Lights,

Alarms, & Circuit

Breakers

....

53

Starter

Motor

.... , ................................................

54

Dual

Output

Alternators

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

58

Wiring

Schematic

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

60

Wiring

Diagram

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

61

Tachometer

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

62

Alternator

Testing

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

63

Torque

Data

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

70

Nut

and

Bolt

Tightening

Method

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

73

Tightening

Torque

Standard

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

.........

74

Metric

Conversion

Formulas

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

76

~

WESTERBEKE

Engines & Generators

1

PARTS

IDENTIFICATION

INTAKE/AIR

AlTER

OIL

~UUI"'~'

PRESSURE

CAP

CONNECTION

THERMOSTAT ASSEMBLY

RAW

WATER

D"'.D-----

REAR

FRONT

PREHEAT

"u,.<NU"U,

AIR

INTAKE/AIR

rlLltH,~

FUEL

UFT

PUIRP-~

2DACIRCUIT

BREAKER

Fua

AlTER

----~

HaTEXCHIANGJ:R-------~~

SHIFT

lEVER

Oll

..

'T1'·

.....

WATER

INJECTED

EXHAUST

OIL

COOLER

Oll.~~~SSURE

SENOOR

RIGHT

SIDE

Engines & Generators

2

1c~~~,

~~

___

EWXiATERir.U:iliNJECTED

ElBOW

1.0.

PLATE

:\.......:.Jf---HI:AT

EXCHANGER

REAR

ANODE

COOlER

LEFT

SIDE

All

THERMOSTAT

::'\...-_".

AlTERNATOR

fRONT

PUllEY

OIL

All

MOUNT

INTRODUCTION

PRODUCT

SOFTWARE

Product

software,

(technical

data,

parts

lists,

manuals,

.

brochures

and

catalogs),

provided

from

sources

other

than

WESTERBEKE

are

not

within

WESTERBEKE'S

control.

WESTERBEKE

CANNOT

BE

RESPONSIBLE

FOR

mE

CONTENT

OF

SUCH

SOF1WARE,

MAKES

NO

WAR-

RANl1ES

OR

REPRESENTATIONS

WITH

RESPECT

THERETO,

INCLUDING

ACCURACY,

TIMEliNESS

OR

COMPLETENESS

mEREOF

AND

WIUIN

NO

EVENT

BE

liABLE

FOR

ANY

TYPE

OF

DAMAGE

OR

INJURY

INCURRED

IN

CONNECTION

WIm

OR

ARISING

OUT

OF

THE

FURNISHING

OR

USE

OF

SUCH

SOF1WARE.

WESTERBEKE

customers

should

keep

in

mind

the

time

span

between

printings

of

WESTERBEKE

product

software

and

the

unavoidable

existence of earlier

WESTERBEKE

product

software.

The product

software

provided

with

WESTERBEKE

products,

whether

from

WESTERBEKE

or

other suppliers,

must

not

and

cannot

be

relied

upon

exclu-

sively

as

the

definitive

authority

on

the

respective

product

It

not

only

makes

good

sense but

is

imperative

that

appropriate

representatives ofWESTERBEKE or

the

supplier

in

question

be

consulted

to

determine

the

accuracy

and

currentness

of

the

_ product software

being

consulted

by

the

customer.

SERIAL

NUMBER

LOCATION

The

engine's

model

number

and

serial

number

are

located

on

a

nameplate

mounted

on the

side

of

the

engine's

manifold.

The

engine's serial number can

also

be

found

stamped

into

I

the

engine

blOck

on

the

flat

surface of

the

block

just

forward

of the

number

one

cylinders injection

pump.

Take

the

time

to

enter

this

information

on

the illustration of

the

nameplate

shown

below,

as

this

will

provide-a

quick

reference

when

seeking

technical

information

and/or

ordering

repair

parts.

ORDERING

PARTS

Whenever replacement

parts

are

needed,

always

provide

the

engine model.number and

serial

number

as

they

appear

on

the

silver

and

black nameplate

located

on

the

manifold.

You

must

provide

us

with

this

information

so

we

may

properly

identify

your

engine.

In

addition,

include a complete

part

description

and

part

number

for

each

part

needed

(see

the

separately

furnished

Parts

List).

Insist

upon

WESTERBEKE

packaged

parts

because will fit or

generic

parts

are

frequently

not

made

to

the

same

specifications

as

original

equipment.

RAW

WATER

CODLING

SYSTEM

Siphon-Break

For

installations

where

the

water

injected

exhaust

elbow

is

close

to

or

will

be

below

the

vessels

waterline,

provisions

must

be

made

to

install a siphon-break

in

the

raw

water

supply

hose

to

the

water injected

exhaust

elbow.

The

siphon-

break

provides

an

air vent in

the

raw

water

cooling

system

to

prevent

raw

water

from

filling

the

exhaust

system

and

the

engine's

cylinders

when

the

engine

is

shutdown.

A

CAUTION:

Failure

to

use a siphon-break

when

the

exhaust

manifold

injection

port

is

at

or

below

the

load

waterline

will

result

in

raw

water

damage

to

the

engine

and

possible

flooding

of

the

boat.

If

you

have

any

doubt

about

the

position of

the

water-

injected

exhaust

elbow

relative

to

the

vessels

waterline

under

the

vessels

various

operating conditions, install a

siphon-

break.

This

precaution is necessary

to

protect

your

engine.

The

siphon-break

must

be

installed

in

the

highest

point

of a

hose

that

is

looped a minimum

of

20

inches

(51cm)

above

the

vessels

waterline.

This

siphon-break

must

always

be

above

the

waterline

during all

angles

of

vessel

operation

to

prevent

siphoning.

NOTE:

A

siphon-break

requires

periodic

inspection

and

cleaning

to

ensure

proper

operation.

Failure

to

properly

maintain a siphon-break

can

result

in

catastrophic

engine

damage.

Consult

the

siphon-break

manufacturer

for

proper

maintenance.

SIPHON-BREAK

WITH

STAINLESS

LOOP

FOR

3/4"

HOSE

PART

NO.045368

SIPHON·BREAK PART

NO.

033327

"flY'

WESTERBEKE

Engines & Generators

3

SPECIFICATIONS

558

ENGINE

SPECIFICATIONS

Engine

Type

Displacement

Combustion

Type

Combustion

System

Bore & Stroke

Max.

Angle

of

Installa~on

Max.

Angle

of

Rota~on

Rring

Order

Direction

of

Ro~on

Propeller

Shaft

Compression

Ra~o

Aspimtion Engine

Speed

Fuel

Consump~on

Dimensions -inches

(mm)

Engine

Only

Weight Air

Row

Diesel,

water

cooled,

four

cycle,

four

cylinder,

in-line

overhead

valve

type

133

cubic

inches

(2.179

liter)

In-direct

injection

Swirl

chamber

3.35 x 3.78

incheS'(85 x 96

mm)

Notto

exceed

14'

Not

to

exceed

30'

for

30

minutes 1-3-4-2 Counterclockwise,

when

viewed

from

flywheel

Right

hand

direction

of

rotation 21:5:1 Naturally

Aspirated'

Idle

speed:

850-1000

RPM

CruiSing

Speed:

2000-2500

RPM

No

load

speed:

3200

RPM

(neutral)

1.5

U.S.

gph

running

at

2500

RPM

(approx.)

when

the

propeller

used

allows

the

engine

to

tum

at

3000

RPM

at

full

open

throttle

underway

in

forwam

H~ght

23.3

inches

Width:

18.6

inches

Length:

27.0

inches

448

Ibs

(203.2

kgs)

(592

mm)

(472

mm)

(687

mm)

Engine

Combu~on:

116

cfm

(3.3

cmn)

Engine

Cooling:

200

cfm

(5.6cmm)

TUNE-UP

SPECIFICATIONS

Compression

Pressure

Valve

Timing

Intake

Opens

Intake

Closes

Injection

Timing

Nozzle

Injector

Pressure

Valve

Clearance

(engine

cold)

441

psi

(3.04

MPa)

Open

at

15'

BTDC -Close

29'

ABDC

Open

at

40'

BTDC -Close

16'

ATDC

16"

BTDC

1920

psi

(13.2

MPa)

0.0157

inches

(0.4

mm)

ELECTRICAL

SYSTEM

Starting

Battery

Capacily

DC

Charging

Altemator

Starting

Aid Starter Cold

Cranking

Amps

Altemator

Regulator

Exhaust

Elbow

Exhaust

Hose

Size

Exhaust

Gas

Flow

Muffler

Size

(min.)

12

Vott,

(-)

negative

ground

400 -600

CCA

(min.)

50

Amp

rated,

bett-driven

-12V

Glow

plugs,

12V

sheathed

12

von,

1.8

KW

w~h

solenoid

175 -200

Amps

Intema!

regulator,

buitt

into

altemator

EXHAUST

SYSTEM

45'

elbow

3.0"

1.0.

hose

265

cfm

at

3000

RPM

14" x 14"

Fuel Fuel

Injection

Pump Injectors Fuel

Rner

Air

cleaner

Fuel

Uft

Pump

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

System

Capaclly

Sea

Water

Row

at

3000

rpm

Diesel

fuel

I?

(catane

rating

of

45

or

higher).

BOSCH,

PFR

type

Throttle

type

Primary,

full

flow,

spin-on

element

Replaceable

paper

carlridge.

Solid

atate

with

extemal

fitter

COOLING

SYSTEM

Fresh

water-cooled

with

tube

and

shell

type

heat

exchanger.

170

-190' F

(77

- 88'

C)

Centrifugal

matal

impeller

type

belt-driven.

Positive

displacemen~

rubber

impeller,

ben-driven.

7.25

US

qts

(6.861~ers)

8.0 -8.5

gpm

(30.2 -32.1Ipm)

(measured

before

discharging

into

water

injected

exhaust

elbow)

LUBRICATION

SYSTEM

General Oil

Rtter

Sump

Capeclly

(not

including

fitter)

Opemting

Oil

Pressu

re

(engine

hot)

Oil

Grade

Oil

Cooler

General clutch

Gear

Ratio

(atandam)

Forced

lubri~on

bY

Trochoid

type

pump

Full

flow

spin-on

8

U.S.

qts

(7.61~ers)

43

-

85

psi

(290 -590

KPa)

API

Specifi~on

CF

or

CG-4,

SAE

30,

15W-30

Fresh

water

cooled

TRANSMISSION

ZF

Marine

Transmission,

case

hamened,

helical

gears,

with

a

servo-operated

multiple

disc

1:88:1

(ZF25M)

Propeller

Recommenda~ons

18 x 13P-2blade

(RH)

or

18 x l1P 3 blade

(RH)

(Propeller

used

should

allow

the

engine

to

reach

its

full

rated

RPM

(3000 + 000

-100)

at

full

open

throttle

while

underway

in

forwarc

gear)

Lubri~ng

Ruid

Transmission

Sump

Capacity

Automatic

transmission

fluid,

type

Dexron

II

or

III

0.75

U.S.

qts.

(0.79

liters)

~

WESTERBEKE

Engines & Generators

4

HOW

TO

DETERMINE

Cause

Genenilly, is

power output,

fuel is not sometimes wear. many or inspection is a good caused symptoms

These

can tion by

starter

optimum

pressure

oil

)

under

compression pressure, incomplete combustion

take

properly. important larly.

surement because The engine

crankshaft.

of

Low

Compression

the time at which

determined

and

neoessarily

The

factors.

causes

symptoms

result

timing,

defective electrical devices such

and

consumption.

sufficient compression pressure.

place even

At the same time, the engine speed at

by

various conditions

decreased compression pressure, and increased

oil

consumption. The lowered engine power output

due to trouble

caused by injector nozzle

decrease

It is, therefore, necessary

on

the basis

and maintenance. Oil analysis

means

of

by

worn

cylinders or piston

will

occur:

1

Low

engine power output

2

Increased fuel consumption

3 Increased oil consumption 4

Hard

5

Noisy

often

also

from excessive fuel injection, improper injec-

and wear

glow

plugs. Therefore it

engine overhaul time by the lowered compression

caused by worn cylinders

Satisfactory combustion

if

other parts

1b

detennine the

to

measure the engine compression pressure

of

compression pressure is made should

the compression

rpm

can be measured at the front end of

ENGINE

in compression pressure

of

data produced

monitoring engine internal

engine starting

engine operation

appear

of

the injectors. They are caused

period

pressure

OVERHAUL

an

engine should

with

rings,

together. Symptoms 2 and 4

is

and

of

the engine are operating

of

varies

TESTING

PERIOD

be

overhauled

such

as

lowered engine

the engine itself, but is wear

or injection

is

caused

to

determine a cause

by

periodic

on a seasonal

wear.

the following

as

the battery, alternator,

desirable

pistons plus increased

is

obtained only

If

an engine

of

engine overhaul, it

which

with

engine

When

to

judge the

lacks

fuel

the be

checked rpm.

the

pump

by

also

will

regu-

mea-

FOR

basis

is

OVERHAUL

Compression engine until Thereafter,

of

these

When

limit,

the engine must be overhauled.

The engine requires blowby below.

DISASSEMBLY

1. Before disassembly

defects cleaning.

2.

Drain

3.

Clean

4.

Do disassembly.

5. Perform Keep sary. intrusion of dust

6.

Parts which

parts

its

component,

reproduced

7.

Pay

parts for their positions necessary,

S.

Carefully

faulty tell accurately

CONDITIONS

pressure

piston

it

decreases

parts.

decrease of

evident,

not

Take

must must

attention

you

and

which

cannot

water,

fuel

or

wash

remove

disassembly

disassembled

special care

be

restored

they

were

be

set

so

at

assembly.

to

aid

check

condition

how

it

during

tends

rings

gradually

compression

overhaul

compression

558

FOUR

441

PSI

SPEED

44.1

and

the

engine

or disassemble the

parts

and

removed

aside

that

the

marks

assembly

each during

acted

or

removal

to

increase a little

and

valve

seats have

with

the

pressure reaches

when

oil

consumption

values

are

COMPRESSION

(3.04

MPa)

NORMAL

OF

250

RPM.

PSI

BETWEEN

cleaning, carefully

be

found

oil

in

a proper order

to

dirt.

to

their

separately

same

on

or

part or component

removal

what

CYLINDERS

after

disassembly

before

disassembly.

exterior.

parts

in

order.

Apply

keep the

at

assemblies,

directions. Put

..

or

fuel

respective·components

disassembly.

in

groups,

combination

or

cleaning.

was

abnormal

cleaning.

in a new

been

broken

progress

PRESSURE

AT

that

using systern

This

components

fore

of

the

at

minimum

CRANKING

check

require

proper

oil

when

parts

means

each

marl<ed

or

set

can

on

marks,

any

The

about

wear

repair

is

high,

for

and

no

tools.

neces-

from

that

be

and

if

sign

part

it

more

in.

or

all

for

of

will

NDlE:

To

test engine compression see the

ADJUSTMENT

section

of

this

manual.

ASSEMBLY

1.

Wash

all parts, except for oil seals, O-rings, rubber sheets,

etc.,

with

cleaning solvent and dry

2.

Always you job.

3.

Use of

4.

Be torques

5_

Ant time the engine is assembled, O-rings

use

tools that

understand

only

good

oil,

grease

sure

to

use

are specified.

must be installed.

are

in

how

to

use

them before perfonning any

quality lubricants.

or sealant

a torque

to

parts

wrench

good condition and

Be

as

to

tighten parts

)

ENGINE

them

with

sure

specified

new

gaskets

pressure

be

to

apply a coat

..

for

and

...

ALTERNATOR

When

rebuilding the

and

inspected.

and

the

alternator

wire

air.

sure

which

brush.

wiring

connections that connect

Thm

the

Depending brushes send

it

to

For additional

ALTERNATOR SERVICE

WESTERBEKE

Engines & Generators

5

INSPECTION

engine,

The

housing

terminal

Make

certain

rotor

pulley

by

on

when

the

may

need

replacing.

a service

in

shop

information

TROUBLESHOOTING

this

manual.

the alternator should

can

be

wiped

studs

should

the

studs

are

tight

to

the

wiring

hand.

It

should

alternator for

on

was

last

If

the alternator

testing

and

alternators refer

off

with

be

cleaned

and

harness.

tum

smoothly.

serviced,

is

at

overhaul.

to

and

MANDO

be

cleaned

a solvent

with

clean

the

all

suspect,

the

a

the

The

following problems these

problems,

these

problems.

the

need

troubleshooting

relating

and

This

for

an

engine

to

engine

service,

the

recommendations

chart

may

oveIhaui.

chart

be

of

ENGINE

describes

the

assistance

certain

probable

to

overcome

in

TROUBLESHOOTING

causes

of

NOTE:

The

determining

ampere mounted

engine's

1IIl11IJJo1

on

the

electricol reset same

circuit

breaker.

bracket.

system

is

protected

The

preheat

by

a

20-

solenoid

is

lIARD

PROBLEM

STARTING

lOW

CRANKING

1.

Engine

oil

2.

Run-down

3.

Worn

battery.

4.

Battery

terminals

5.

Defective

DEFECTIVE

1.

Airtrapped

2.

Clogged

3.

low

4.

Inadequate

5.

Injection

6.

Injection

MAIN

1.

low

2.

Burnt

3.

Faulty

4.

Incorrect

slarter.

INJECTION

fuel

injection

pump

too

ENGINE

compression.

a.

Incorrect

b.

Inadequate

c.

Valve

d.

Broken

e.

Compression

I.

Piston

g.

Worn

glow

governor

PROBABLE

SPEED

viscosity

stem

piston

too

battery.

loosely

SYSTEM

in

fuel

passage.

fmer.

pressure.

spray.

delivering

earty.

TROUBLES

valve

clearance. conlact seized.

valve

spring.

leaks

ring

seized.

ring

and

plug.

plug

operation.

lever

CAUSE

high.

connected.

insufficient

of

valve

seat.

through

cylinder

cylinder.

position.

fuel.

head

gasket.

1.

Replace

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

a. b.

c. d. e.

I.

g.

2.

Replace

3.

Correct

4.

Set

lever

VERIFICATION/REMEOY

engine

oil

w~h

less

viscous

battery.

terminals

air or

injection

or

or injection

Adjust

lap

Replace Replace

Repl~ce

Replace

Overhaul

or

replace

from

replace

valve

valve.

valve valve gasket piston

glow

lead

wire

to

slarting

and

correct

slarter.

fuel

system.

filler.

pressure.

nozzle.

injection

timing.

clearance.

and

valve

spring.

and engine. plug.

connection.

position.

cables.

pump.

guide.

piston

oil.

ring.

LOW

OUTPUT

LOW

COMPRESSION

INJECTION

1.

Incorrect

2.

Insufficient

3.

low

injection

INSUffiCIENT

1.

Airtrapped

2.

Clogged

3.

Contaminated

INSUffiCIENT

1.

Clogged

SYSTEM

injection

injection.

pressure.

FUEL

in

fuel

fitter.

fuel

INTAKE

air

cleaner.

OUT

OF

timing.

system.

tank.

AIR

~

ADJUSTMENT

WESTERBEKE

Engines & Generators

6

See

1.

Adjust

2.

Repair

3.

Check

1.

Check

2.

Clean

3.

Clean

1.

Clean

HARD

injection or

injection

and or lank.

or

STARTING

timing.

replace

injection

nozzle

retighten

replace

connector.

filter.

air

cleaner.

and

pump. adjusl

pressure.

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

LOW

OUTPUT

EXCESSIVE CONSUMPTION

(ooM.)

OIL

PROBABLE

OVERHEATING

1.

Low

coolantlevel.

2.

Loose

V-be~.

3.

Incorrect

4.

Low

OIL

1.

Defective

2.

Broken

3.

Loose

4.

Loose

5.

Loose

6.

Broken

7.

Loose

OIL

1.

Incorrectly

2.

Displaced

3.

Worn

4.

Worn

OIL

1.

Defective

2.

Worn

injection

engine·oillevel.

LEAKAGE

oil

seals.

gear

case

gear

case

drain

hose.

oil

pipe

rocker

cover

LEVEL

RISING

positioned

or

twisted

piston

ring.

piston

or

LEVEL

FALLING

stem

valve

and

timing.

gasket.

attaching

connector. cover

gasket.

attaching

piston

connecting

cylinder.

seal.

valve

guide.

CAUSE

bolts.

ring

rod.

gaps.

VERIFICATION/REMEDY

1.

Add

coolant.

2.

Adjust

or

3.

Adjust

injection

6.

Add

engine

1.

Replace

oil

2.

Replace

gasket.

3.

Retighten

4.

Retighten

5.

Retighten

6.

Replace

gasket.

7.

Retighten

1.

Correct

ring

2.

Replace

connecting

3.

Replace

ring.

4.

Replace

piston

1.

Replace

stem

4.

Replace a valve

replace

V-belt

timing.

oil.

seals.

bolts. hose. oil

connections.

attaching

gap

positions.

and

rebore

seal.

and

bolts.

rod.

valve

cylinder.

guide.

EXCESSIVE CONSUMPTION

SMOKY

FUEL

EXHAUST

ENGINE

1.

2.

3.

4.

5.

6. INSUFFICIENT

1. NOZZLE

1.

2.

IMPROPER

FUEL

WHmSH

1.

2.

BODY

Noisy

knocking.

SmokY

exhaust

Moving

parts

Poor

compression. Improper Improper

Air

Seized Worn

Excessive Excessive

a. b. c.

valve valve

intake

obstructed.

mOUBLES

nozzle.

FUEL

LEAKS

OR

engine rise

Poor

piston Seized Excessive

mOUBLES

INTAKE

PURPLISH

piston

nearly

seized

or

excessively

timing.

clearance.

AIR

oil.

of

oil

into

combustion

contact.

ring.

piston-to-cylinder

worn.

chamber.

clearance.

1.

See

KNOCKING.

2.

See

SMOKY

3.

Repair

4.

See

LOW

5.

Adjust.

6.

Adjust.

1.

Remove

1.

Replace.

2.

Replace. Replace Find

fuel

1.

Correct

a.

Check.

b.

Replace

c.

Replace

EXHAUST.

or

replace.

COMPRESSION;

obstruction.

with

proper

fuel.

leaks.

oil

level.

or

clean.

or

correct.

HARD

STARTING.

~

WESTERBEKE

Engines & Generators

(continued)

7

ENGINE

TROUBLESHOOTING

PROBLEM

PROBABLE

CAUSE

VERIFICATIONJREMEDY

SMOKY

EXHAUST

(em.)

WHmSH

OR

PURPUSH

(conI

••

)

d.

Worn

valve

stem

and

valve

guide.

d.

Replace.

e.

Low

engine

oil

viscosity.

e.

Replace.

f.

Excessive

oil

pressure.

f.

Correct.

3.

Injection

timing

is

too

late.

3.

Adjust.

4.

Insufficient

compression.

4.

See

LOW

COMPRESSION;

HARD

STARTING.

BLACKISH

OR

DARK

GRAYISH

1.

Engine

body

troubles.

a.

Poor

compression.

a.

See

LOW

COMPRESSION;

HARD

STARTING.

b.

Improper

valve

clearance.

b.

Adjust.

2.

Insufficient

intake

air

(air

cleaner

clogged).

2.

Clean

air

cleaner.

3.

Improper

fuel.

3.

Replace

with

proper

fuel.

ABNORMAL

SOUND

CRANKSHAFT

AND

MAIN

BEARING

OR

NOISE

1.

Badly

worn

bearing.

1.

Replace

bearing

and

grind

crankshaft.

2.

Badly

worn

crankshaft.

2.

Grind

crankshaft.

3.

Melled

bearing.

3.

Replace

bearing

and

check

lubrication

system.

CONNECTING

ROD

AND

CONNECTING

ROD

BEARING

1.

Worn

connecting

rod

big

end

bearing.

1.

Replace

bearing.

2.

Worn

crankpin.

2.

Grind

crankshaft.

3.

Bent

connecting

rod.

3.

Correct

bend

or

replace.

PISTON,

PISTON

PIN,

AND

PISTON

RING

1.

Worn

cylinder.

1.

Rebore

cylinder

to

oversize

and

replace

piston.

2.

Worn

piston

pin.

2.

Replace

piston.

3.

Piston

seized.

3.

Replace

piston

and

rebore

cylinder.

4.

Piston

seized

and

ring

worn

or

damaged.

4.

Replace

piston

and

rings.

VALVE

MECHANISM

1.

Worn

camshaft.

1.

Replace.

2.

Excessive

valve

clearance.

2.

Adjust.

3.

Worn

timing

gear.

3.

Replace.

4.

Worn

fan

pulley

bearing.

4.

Replace.

ROUGH

OPERATION

INJECTION

PUMP

SYSTEM

1.

Uneven

injection.

1.

Adjust

injection

or

replace

paris.

2.

Control

rack

manunctioning.

2.

Disassemble,

check

and

correct

injection

pump.

3.

Worn

delivery

valve.

3.

Replace.

4.

Inadequate

injection

nozzle

spray.

4.

Replace

injection

nozzle.

GOVERNING

SYSTEM

1.

Governor

lever

manunctioning.

1.

Check

governor

shaft

and

correct

operation.

2.

Fatigued

governor

spring.

2.

Replace.

(continued)

-..v:

WESTERBEKE

Engines & Generators

8

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMITTENT EXHAUST

OVERHEATING

SOUND

ENGINE

1. a. b.

2.

3.

4. KNOCKING

1.

2.

3.

1.

2.

1.

2.

3.

4.

5.

6.

7.

KNOCKS

Main

engine

Overheated

Carbon

deposits

Too

early

Too

high

Improper

WITH

Poor

compression.

Injection

Improper

Fuel Water

V-belt

Damaged Lack

Low KnOCking. Moving Defective

pump

a.

Poor

b.

Poor

c.

After·injection

d.

Nozzle

fi~er

mixed

slackening

of

coolant

oil

level

parts

PROBABLE

WITHOUT

troubles.

cylinder.

in

cylinder.

injection

fuel.

nozzle. spray. chattering.

clogged.

water

thermostat.

timing.

pressure.

DARK

malfunctioning.

drip.

needle

valve

in

fuel

or

slippery

pump.

or

poor

oil

seized

or

CAUSE

MUCH

SMOKE

seized.

wnh

quality.

damaged.

SMOKE

oil.

--

a.

See

OVERHEATING;

b.

Clean.

2.

Correct.

3.

Correct

4.

Replace

1.

See

LOW

2.

Adjust/Repair

a.

Clean

b.

Repair

c.

Repair

d.

Replace.

1.

Clean

or

2.

Replace

1.

Adjust,

replace

2.

Replace.

3.

Add.

4.

Add

or

change.

5.

See

KNOCKING.

6.

Replace.

7.

Replace.

VERIFICATION/REMEOY

LOW

OUTPUT.

wnh

proper

fuel.

COMPRESSION;

or

replace

or

replace

or

replace

replace.

fuel.

or

clean.

HARD

nozzle.

STARTING.

LOW

OIL

PRESSURE

1.

Wom

2.

Relief

3.

Clogged

4.

Diesel

Bearings.

valve

malfunction.

oil

cooler.

dilution

of

the

oil.

1.

Engine

2.

Overhaul

3.

Repair.

4.

Injection

overhaul

oil

pump.

pump

repair.

replace

bearings.

"~/WESIERBEKE

I

engines

& Generators

9

ENGINE

DISASSEMBLY

PROPll.SION

Switch off the batteries and disconnect the battery cables from the engine and tape over the tenninals.

or

Drain

from the engine Unplug

ttansmission fluid and the ttansmission oil cooler hoses. Detach the oil cooler hoses and unbolt the the engine.

NOTE:

the instnnnent panel wiring harness. Drain the

Lobel any

TRANSMISSION

If

the

ttansmission is not being rebuilt

inspected

replace linkage

the IIlInsmission For

transmission your

transmisdoD

the coolant hoses. Inspect and lubricate the and the propeller shaft coupling. Clean and repaint

transmi

WES1ERBEKE

ENGINE

pump out all the engine oil and drain the coolant

and

engine hoses.

ttansmission from

lines.

hoses

or cables as you separate them

.

it

should be visually

Flusb

out

and

pressure test the oil cooler and

gear

and

cbange the IIlInsmission fluid.

ssi

9n

service

manual

service

DAMPER PlATE

and

maintenance

To

rebuild a transmission

dealer

or

an

authorized

center.

BROKEN

COOLANT

DRAIN

refer

OAMPER

BOLTS

INSPECT PLATE

THE

FOR

SPRINGS

to

your

contact

PLATE

DAMPER

WEAR

AND

shift

ENGINE

Take the following precautions:

•

With the following step by step procedure to disassemble the engine.

I.Remove

2. Remove

3. Remove

4. Remove

5. Remove

6.

7. Remove

.8.

9.

COOLANT

10.Remove 1l.Remove

12.Unbolt

13.

14.

DISASSEMBLY

Clean

the

exterior

dirt

and

oil.

Be

careful

Arrange label reassembly. Keep

Mount disassembly.

engine flywheeL

hose connections from the oil cooler

one end

preheat

Remove Label the wires and cables.

complete

WA:rnR

With housing sender in place.

Remove

parts

the

ttansmission separated from the engine. begin the

the

of

each hose connected to the part being removed.

the

solenoid

the the

the

with

PUMP for parts breakdown.

the

hoses disconnected,

and

the

CIRCULATING

the the

engine

its entirety.

block.

the

Remove injection pipes and fuelleak-off pipe from the fuel injection pumps and nozzles.

Fuel

pipe,

the

injection

a. Loosen the sleeve nuts

on the injection injection pipes.

b.

Disconnect the leak off pipe together with gaskets.

c.

Remove the eye bolt, and then disconnect the fuel

pipe.

of

the

engine

not

to

damage

in

the

as

needed

parts

engine

on a suitable

transmission

engine oil

engine

bell

housing

mounting engine start

motor,

engine

its

adapter

housing

coolant

the

order

to

insure

clean.

damper

cooler

heat

exchanger.

and

back

plate. drive

mounted

mounting

gasket, leaving the temperature

circulating

PUMP

air

intake

silencer

oil filter

elbows

fuel

Injection

and

the

and

remove

injection

pump

\ Leak off pipe

pumps.

pipe,

and on

side, and then disconnect the

pipe

of

any

deposits

disassembled

of

disassembly.

proper

engine

plate

and

oil hoses. Note oil

to

If

the

circuit

bracket.

belt

and

raw

water

plate.

remove

pump.

parts.

Mark

mating

stand

from

the engine.

possible. leave

breaker!

the

alternator.

pump,

See

the

thermostat

Refer to

ASSEMBLY.

and

the

intake

mounting

the

leak

the nozzle holder side and

bracket

exhaust

Disconnect the fuel

off pipe.

manifold

of

or

and

for

the

RAW

manifold.

from

the

in

Engines & Generators

10

~~~

\..:J~.

~~

O.

....

~...--

\

0 .

/'

/

Fuel pipe

Nozzle

holder

~r~

~.-

Injection pump

ENGINE

DISASSEMBLY

Injection

pump

MEASUREMENTS

.

1.

Align

the

hole

of

the

fuel

cut

lever with the

hole

of

the

governor

cover, and then insert a pin

(6!!)

into

tliis

hole

to

hold the fuel

cut

lever.

PRIOR TO

MAIN

ENGINE

DISASSEMBLY

2.

Check

to

see

if

the

groove

of

the control link is at

the

center

of

the injection

pump.

3

..

Remove the injection

pump,

and then take

out

the

shim.

NOTE:

Fuel

cut

lever

--,..~

Pin(6

~)

Governor

cover

Control link

\

I

Injection pump

1/

center position

"

(n,ection pump

rack

pm

1.

Mark

each

injection

pump

as

to

which

cylinder

it

was removed from.

2. Do

not

reuse

the

shim,

replace

it

with

the

same

thickness

that

was

removed.

___

Injection pump

ASM

Shim

Cylinder block

Backlash

oftiming

gear

STANDARD

CRANK GEAR!

0.04

IDLER GEAR

(0.0017)

CAM GEAR!

0.03

IDLER GEAR

(0.0012)

IDLER GEAR END PLAY

STANDARD

0.058 - 0.115 (0.0023 - 0.0045)

CRANKSHAFT END PLAY

STANDARD

0.058 - 0.208 (0.0023 - 0.0082)

""'"

WESTERBEKE

Enginds & Generators

11

mm

(in.)

LIMIT

0.2

(0.0079)

0.2

(0.0079)

mm

(in)

LIMIT

0.2 (0.0079)

mm

(in)

LIMIT

0.3 (0.0118)

INTERNAL

PARTS

DiSassembly

Steps

(11

Rocker Bracket Assembly

(21

Push Rods

(31

Rear Hanger

(41

Front Hanger

(51

Cylinder Head Assembly

(61

Cylinder Head Gasket

(71

Tappets

(81

Oil Pan

(91

Oil Strainer

(101

Oil Pipe

(111

Crank Pulley (12) Flywheel (131

Flywheel Housing (14111ming Gear

Case (15) Oil Pump Assembly (16) Idler Gear and

Shaft

(171

Cam Gear

(181

Camshaft

(19) Rear

Seal Retainer (20) Piston Assemblies (211

Crankshaft

00

nat

pull out

-"'=,""

this bolt.

\

t

191

ENGINE

DISASSEMBLY

111

~

Rocker bracket

Push rod

1.

Remove the rocker bracket assembly.

(M6 x 1

.....

5 bolts and 6 nuts)

2.

Pull out the push rods

(8

pes.).

nuts

(6)

"'

..

{

Cylinder head

1.

Remove the rear and

front

hangers.

2.

When removing the cylinder head bolts, loosen them slowly, a little at a time, starting with

the

outside, working in a circular pattern inward.

3.

Remove the cylinder head assembly and the head gasket.

4.

Pull

out

the tappet

from

the cylinder body.

E!19ines & Generators

12

ENGINE

DISASSEMBLY

5

hanger--,

Rear

Cylinder head

ASM

Valve mechanism

1.

Before disassembling the valve mechanism, remove the connector, sembly.

2. Compressing the lar, spring seat, valve spring and valve.

~

4

3 2 1

"Head

glow

plug and nozzle holder

valve spring, remove the split col-

bolt

(M12)

as-

Timing gear

1.

Remove the idle gear and the idle gear shaft.

2. Pull out the sleeve from the tip end

3.

Remove the lock remove the

nut

flyweight

of

the cam shaft gear, and then

assembly and the cam gear.

of

the cam shaft.

lo

w

connecto~r

Nozzle

holder

..,lll="'"A

(3)---..

... G ....

..

,r

;1

~:~~,

~

\

e~

t

Hot

plug

:::~

~udsare

sealing

Do

appHed

agent.

not

pull

(5

locations)

wfih

them

out.

F1I

~...:::..

Split

Spring

collar

seat

'10"'

~

;

11\

~lveSprlng

(4)

151

lSI

@@

\

Seat;

valve

insert

®

~~'J

'.

.!:t:-,

Camshaft

1.

Remove bearing

cylinder block.

2.

Pull out together

the

snap ring which holds down

of

the

cam shaft from the ring groove

the

cam shaft

with

the bearing.

Snap

ring

from

the

front

of

the

the cylinder block.

Engines & GelJerstors

13

ENGINE

DISASSEMBLY

Piston and Connecting Rod

(\

_

Connecting

rod

~ap

Piston and connecting rod

1.

Turning the crankshaft, position the piston

to

be

removed

at

the

bottom

dead center.

2. Loosen the cap nut

of

the

connecting rod, and then

remove it.

3. Give another rotation

to

the crankshaft to position

the piston

at

the

top

dead center.

4.

With the handle

of

a hammer placed at the

bottom

of

the connecting rod, push the piston assembly

upward

out

of

the cylinder block.

Notes:

1.

Before removing

the

piston, scrape

the

carbon

deposit

off

the

cylinder wall.

2. When pushing

out

the

piston

assembly, care should

be taken

not

to

damage

the

cylinder wall.

3. Attach a

tag

with

a cylinder

number

to

the

removed

caps and bearings

to

keep

them

in order.

Piston

ring

(4)

r..

:"1

ri

~

'--'

""

~

Piston

--

......

_1'<;'"

Con'rod

bolt

(The drawing·out

ofthe

con'rod bolt

must be limited to only

when

replaced.)

Connecting

rod

(7)

--

......

"i~~\,c.k

~

Snap r;n9

(5)

Bearing (3)

Piston ring Remove the piston ring

with

a ring pliers.

Brass

bar

Piston pin

1.

Remove the snap rings

with

a commercially avail·

able tool.

2. With a brass bar attached

to

the piston pin, push

it

out by hammering

it

lightly. Note: Keep

the

pistons, piston pins and connecting rods in

order

for

each cylinder.

Engines & Generators

14

ENGINE

INSPECTION

AND

REPAIR

Cylinder block Check

the cylinder block

defects. Use

the

hydraulic gauge

Cylinder

Measurement position: 13mm

bore

for

to

check the

(Measure y-y

directions.)

(Near the

compression ring)

X X

wear, damage

water

below

the

top

in

X-X and

No.1

y

or

any other

jacket water

Cylinder Body

Use a straight edge

the

four

sides and the

body

upper face.

Regrind the values are greater than the specified the

maximum

If

the measured values exceed the

allowance, the

Cylinder

Body Upper

Standard

0.075 (0.0029) 0.15 (0.0059)

Upper

cylinder

grinding allowance.

cylinder

Face Warpage

<D

and a feeler gauge ®

two

body

upper face

body

must

Face

Warpage

Limit

diagonals

be replaced.

of

the cylinder

if

the

limit

but

maximum

Maximum

Allowance

0.3 (0.0118)

to

measure

measured

less than

grinding

mm

Grinding

(in )

Engine

Cylinder The grade

.

cylinder head).

Engine

Limit

Perform boring and

0.2

(0.0079)

bore

diameter and grade

mark

is stamped on the

block (on the mating face

Bore

grade

(Stamp

Bore

85.000 - 85.010

(3.3464-

85.011

(3.3468 - 3.3472)

85.021

(3.3472 - 3.3476)

honing

diameter.

mark

position)

Diameter

3.3468)

- 85.020

- 85.030

mm

Repair method

of

the inner

top

surface

with

the

cylinder

mm

Grade

A

B

C

of

(in.)

the

(in.)

If

the

measured value is less than the limit, the cylinder

body

may

be reground.

EI

B

Cylinder Body Height ® (Reference)

Engine

Standard

307.94 - 308.06

(12.123

-12.128)

IF

mm

(in.)

~

WESTERBEKE

Engines & Generators

15

ENGINE

INSPECTION

AND

REPAIR

Cylinder head inspection

of

measure

the

mea-

limit

but

the

Remove carbon deposit on the bottom surface

with

care

not

to

head Leakage: Water pressure test 5kg/cm' (for 3 minutes)

Cylinder Head

1.

Use a straight 'edge and a feeler gauge

the

head lower face.

2.

Regrind the cylinder head lower face sured values are greater than the specified

.less than the maximum grinding allowance.

four

Lower

sides and

--

,I

EI

damage

Face

the

-~

_______

~

L~-

- B

the

valve seat.

Warpage

two

diagonals

A ....__--·1

~~

to

of

the cylinder

if

IF

,

~

HOT PLUG Hot Plug Depression

1.

Clean

the

cylinder head lower face, taking care

to damage the

2.

Use a straight edge and a feeler gauge the

hot

No.1

hot

If the measured value exceeds the specified the hot plugs

rot

PI

ug Depression

Combustion Chamber Inspection

1.

Remove the carbon adhering combustion chamber. Take care not hot

plug fitting positions.

2.

Inspect the combustion chamber, and

the

other damage. If

cracking

. must be replaced.

Note:

Be

absolutely prot!lberances on which

will

be stalled. These seating correctly.

hot

plug surfaces.

plug depression in a straight line from

plug

to

the

No.3

hot plug.

must

be replaced.

Limit

0.05

(0.002)

to

the inside

the

hot

plug machined faces

or

damage is present,

certain

in contac;t

flaws

that

the

combustion

with

will

there are

the

prevent

the

chamber

hot

plug

the

for

no

to

measure

limit,

mm

of

to

damage

hot

plug hole,

cracking and

cylinder head

scratches

surfaces

after

it

is in-

hot

plug

from

nO\

the

(in.)

the the

or

If the measured values exceed the

the

allowance, Cylinder Head Lower

standard

0.075 (0.0029)

Cylinder Head Height ® (Reference)

Engine Standard

.

If

the

cylinder

depression

cylinder head

,

.

head

must

be checked.

Face

0.15 (0.0059)

Warpage

Limit

lower

must

be replaced.

63.90 - 64.10

(2.515 - 2.523)

face

maximum

Maximum

Allwance

0.3

(0.0118)

is

reground,

,.y:

grinding

mm(in)

Grinding

mm

,

(in )

valve

WESTERBEKE

Engines & Generators

16

Hot Plug Replacement

Hot

Plug Removal

1. contact

2. plug free.

Insert a bar into

Lightly

3.0

- 5.0

the

nozzle holder fitting hole until

with

the

hot plug.

tap

the bar

mm

(0.12 - 0.20 in) diameter brass

with

a hammer

to

drive the

it

makes

hot

ENGINE

INSPECTION

AND

REPAIR

Hot Plug Inspection

Inspect the

e.

' e discovered.

Hot Plug Installation

1. Align the

head groove ® and tap with

hot

plugs

Replace the

a plastic hammer.

hot

plug knock ball

for

excessive wear and other dam-

plugs

if

either

of

these conditions

A

CD

with

the cylinder

it

temporarily into position

Heat Shield Replacement Heat

Shield Removal

After

removing

brass bar

shield

@ and drive

Heat

Shield Installation

Install the heat shield to zle holder installation hole side. shield flange

, The heat shield flange side

Note:

Always install a

heat

shield.

®

into

the

to

lightly tap

it

place

new

hot

plugs, use a

the

free

..

the

cylinder head

with a hammer

must

heat

shield. Never reuse

hammer

lower

side

from

Ughtly

be facing up.

tap the heat ,

and a brass bar.

CD

of

the heat

the noz-

the

and a

old

2.

Place a metal plate @ approximately

thick

over

the

hot

plug

upper

3.

Use a bench press ® 5,000

kg

(8,819 - 11,023 Ib/39,227 - 49,033 N) on

metal plate covering the

will

This

4.

Lightly tap the firmly

5.

Repeat the procedure (Steps 1 hot plugs.

Do Damage

6.

Use face protuberances.

The the cylinder head

7.

After grinding, make sure are completely free

The sions.

Once again, sure

drive the

hot

seated.

not

apply to

the

cylinder head will result.

a surface grinder

hot

plug surfaces

hot

plug surfaces

lightly

that

they are

to

exert a pressure

hot

plug into position.

plug head

~(er

pressure

lower

firmly

greater

to

grind

must

face.

that

of

protuberances.

must

tap the

seated.

hot

r+;;:::@,

hot

25

mm

surface

to

be perfectly flush

also be free

@.

of

4.000 -

plug upper surface.

make sure

4)

for

~~f,;\

than

off

any

the

hot

plug heads

that

the remaining

that

specIfIed.

hot

piug sur-

plug surfaces

of

depres-

to

(1

in)

the

it

is

••

with

make

VALVE,

Inspection

,.

2.

VALVE

of

A - Contact

B - Valve depression

Contact Valve depression

width

---

SEAT

valve

width

INSERT AND

seat

VALVE

Standard

2.0 (0.0787) 2.5 (0.0984)

0.7 (0.0276)

1.2

SEAL

mm(in.)

Limit

(0.0427)

Engines & Generators

17

ENGINE

INSPECTION

AND

REPAIR

Valve thickness

Nominal Limit

Repair method

1.0

0.7

Replace

(0.03937) (0.0276)

t:

...-I

'-

J

. .

Valve Stem OutsIde DIameter

t

Measure

the

valve .stem diameter

at

three points.

If

the measured value

is

less than

the

specified limit,

the

valve must

"e

replaced.

Valve

Stem Outside Diameter

Standard

Intake Valve

7.0

(0.2756)

Exhaust Valve

7.0

(0.2756)

+

Valve Seat Insert Replacement Valve

Seat Insert Removal

mm

(in)

Limit

6.85

(0.2697)

6.80

(0.2677)

1.

Arc weld the entire inside circumference (j)

of

the

valve seat insert

®.

2.

Allow

the

valve seat insert

to

cool for a

few

minutes.

This

will

invite contraction and make removal

of

the

valve

seat

insert easier.

3.

Use a screwdriver ®

to

pry

the valve seat insert

free.

Take care not

to

damage

the

cylinder head

@.

4.

Carefully remove carbon and other foreign material from

the

cylinder head insert bore.

@

Valve Seat Insert Installation

1.

Carefully place the attachment (j) (having a small . outside diameter than

the

valve seat insert) on t

valve seat insert

®.

Note: The

smooth

side

of

the

attachment

must

contact

the

valve

seat

insert.

2.

Use a bench press ®

to

gradually apply pressure

to

the

attachment and press

the

valve seat insert

into

place. 4,000

kg

(8,819 Ibs.) Note: Do

not

apply

an excessive

amount

of

pressure

with

the

bench press. Damage

to

the

valve seat

insert

will

result.

Valve

Seat Insert Conection

1.

Remove the carbon from

the

valve seat insert sur-

face.

2.

Use a valve cutter (15', 45', and

75'

blades)

to

mini-

mize scratches and

other

rough areas. This wi:

bring

the

contact width back

to

the

standard value.

Remove only the scratches and rough areas. Do

not

cut

away

too

much. Take care

not

to

cut away

unblemished areas

of

the

valve seat surface.

Valve

Seat Angle degree

45

Note: Use an adjustable valve

cutter

pilot.

Do

not

allow

the

valv ..

cutter

pilot

to

wobble

inside

the

valve guide.

3. Apply abrasive compound

to

the valve seat insert

surface.

4.

Insert the valve into

the

valve guide.

~

WESTERBEKE

Engines & Generators

18

ENGINE

INSPECTION

.-

"

!

5.

Apply

light

pressure

fit

the valve seat insert .

. 6. Check

7. Check

8. Clean the head and valves

VALVE

Valve

Use a surface plate and a square spring

If

the measured value exceeds the specified limit, the

valve spring must be

Valve Spring Inclination

that

the valve contact

that

the valve seat insert surface is in contact

the

with

compound and metal particles.

entire circumference

SPRING

Spring Inclination

inclination.

to

the valve while turning

width

of

the valve.

to

remove

to

replaced.

Standard

1.8

(0.0709)

is correct.

the

measure the valve

Limit

2.5

(0.0984)

it

to

abrasive

mm

(in.)

AND

Valve

Use a vernier caliper to measure the valve

length. If the measured value is less than the specified limit,

valve spring must be replaced.

TAPPET

AND

TAPPET

Inspect

abnormalities.

Use a micrometer to measure

REPAIR

VALVE

••

'ilNr.:"'--

Spring Free Length

-

Exhaust and Valve Spring

Length

PUSH ROD

the

Tappet Diameter

Intake

Free

(Cam

tappets

Standard Limit

42.1 40.0

(1.6575) (1.5748)

Follower or Valve Lifter).

for

excessive wear, damage and any

the

tappet diameter.

Standard

20.967 - 20.980

(0.82547

- 0.82598)

spr{ng

mm

free

the

(in)

(in.)

Valve Spring Tension

Use

a spring tester

If the measured value is less than

valve spring must be replaced.

Valve

Spring

Tension

Set Length ,f'-'}

at

29.9

to

measure the valve spring tension.

the

Standard

mm

VALVE

'~~I

SPRING

17.0

(37.479)

_______

TESTER

specified

~~

________

limit,

the

mm(in.1

Limit

15.0

(33.069)

~

-J

WESTERBEKE

Engines &

19

Use a dial indicator the

tappet and cylinder body tappet travelling bore.

-

Tappet and Tappet Travelling Bore

Clearance

to

measure

(0.00079 - 0.00213)

the

Standard

0.020 - 0.054 0.08

~

r

(.)

~~

.

Generators

clearance between

mm

(in)

Limit

(0.00315)

~.

:--

)

(.)

c

.,..

PUSH

ROD

ENGINE

INSPECTION

AND

REPAIR

Use a filler Roll

the

tion).

gauge

push

Push Rod Run.()ut

CAMSHAFT

Inspection

Check

damage Note:

With

with

in

with

see

each bearing.

of

the

joumal

or

any

the

front

ball

bearings,

roller

if

the

camshaft rotates

to

measure

rod

along a smooth flat surface (illustra-

cam

shaft

and the cam

other

defect.

and

rear parts

and·with

bearings

_ .•

-PUSHROD

as

the

valve push rod runout.

Limit

. 0.3 (0.0118)

for

evidence

of

camshaft pressed in

the

cylinder

center bearing, check

smoothly

block

with

mm

of

wear,

pressed

no play

(in.)

to at

3. Uneven wear

Nominal Limit Repair method

52

III

(2.0472)

4. Runout

Nominal Limit Repair method

0.02

(0.008)

ROCKER

Inspect all disassembled parts abnormalities.

of

journal

0.05 (0.002) Replace

of

cam shaft

0.1

(0.004)

ARM

SHAFT AND ROCKER

for

wear, damage and any

mm

Replace

ARM

(in)

'~~'/"

_

..

Measurement

1.

Cam

Intake

Exhaust

2. Center journal diameter

Nominal Limit

52

(2.0472) (2.0441)

of

height

III

journal and cam

(A -

B)

Standard

6.13

(0.2413) (0.2295)

6.43 6.13

(0.2531) (0.2413)

51.92

I

~

. ,'8 . +

'.

Limit

5.83

III

,

Repai r method

Replace

Repair method

Replace

mm

(in)

(in.)

- Rocker

Use a micrometer to measure the rocker arm outside

diameter.

If the measured value is less than the specified shaft must be replaced.

Arm

Rocker Arm Diameter

Shaft

Outside Diameter

Standard

11.935-

(0.4699 - 0.4707)

limit,

mm

11.955

the

(in.)

Engines & Generators

20

ENGINE

INSPECTION

AND

REPAIR

Rocker

I

1.

2. Measure the rocker arm shaft outside diameter.

Rocker and Rocker Arm Shaft Clearance

3.

Rocker

Inspect the rocker arm valve stem contact surfaces for ridges@

If the surfaces have light ridge honed

If the ridge

Arm

Shaft

and Rocker

Use a vernier caliper bushing inside diameter.

Arm

Rocker Inside Diameter

Replace either the rocker arm

if

the

Check tions.

If necessary, use compressed air arm oil

...

t"'-"'x'"':"':

with

Bushing

clearance exceeds the specified

Arm

Bushing

that

the rocker arm oil

POl"'.

-"'-:'"'

..

"'::=-=;::::"":.-'"'_:.:::._==-:"'-=_1"::-:..:::_-"'_:'"':"':"':::::>::::=:::"":"'Y.::_::a~'

ROCKER

Arm

Correction

and

scoring®

an oil stone.

or

scoring

to

measure

Standard

0.005 - 0.045

(0.0002 - 0.0018) (0.0079)

ARM

SHAFT

is

severe, the rocke'r arm must be

Arm

Clearance

the

rocker arm

Standard

11.960-

(0.4709

or

the rocker arm shaft

11.980

- 0.4717)

limit.

ROCKER

Umit

0.2

port

is free

to

clean

of

the

J.

1"

or

scoring, they may

mm

(in.)

ARM

mm

(in)

obstruc-

rocker

0.0.

be

PISTON, PISTON PIN

Clearance between

1. Measure the outside diameter of the piston

60 mm from the

(in the

unit

of

1",000

2. Calculate the clearance based on the measurements

of

the cylinder bore and the outside diameter

piston.

Clearance 0.015 - 0.035

Outside diameter

The grade mark is stamped on the piston.

Model

of

Outside diameter

AND

PISTON RING

piston

and

cylinder bore

top

in a right angle

mm).

piston

and grade

of

84.975 - 84.985

(3.3454 - 3.3458)

84.986 - 84.995

(3.3459 - 3.3462)

-85.005

3.3466)

'_''''''oe

mark

at

about

to

the piston pin

of

mm

(0.0006-

top

piston Grade

0.0014)

",,,,oUl

mark

(Stamped!"

60

surface

of

mm

A

B

C

the

(in.)

the

(in.)

,.

--.~

RIOGES'(li'r"---...----...

( ---

\\

-=-]--

SCORING

®

~

Model

WESTERBEKE

Engines & Generators

21

Nominal

25.0

(0.9843)

Limit

24.97

(0.9831)

Remarks

Replace

beyond

mm

if

worn

limit

(in.)

-

..

--------.--------------------------------~-----

Clearance

Piston

With with the

ring. If

worn

1st compression ring

2nd

compression

ring

Oil

Clearance Measure ·clearance

ence. If

worn

between

ring

gap

the

ring

inserted

the

piston head so

cylinder, and

beyond

the

----

ring

between

beyond the

piston

into

that

then

measure

limit,

replace

0.2-0.35

(0.0079 - 0.0138)

0.35-0.5

(0.0138 - 0.0197)

(0.0079

piston

ring

at

several places

limit,

replace

ENGINE

and

piston

(0.00008 - 0.00047)

the

cylinder

it

becomes a

the

Standard

0.2-0.4

- 0.0157) (0.03937)

groove

the

INSPECTION

Standard

0.002

- 0.012

bore, push

right

gap

of

rings.

and

ring

on

the

rings

or

hole

mm

angle

the

piston

mm(in.)

Limit

1.5

(0.0590)

1.0

circumfer-

piston.

mm(in.)

(in.)

it

in to

AND

REPAIR

CONNECTING

ROD

BEARING

Torsion If

Clearance and

and

worn

beyond

100

Per Torsion

Parallelism

piston

Clearance

diameter

Inside

mm

between

pin,

ROD

parallelism

the

limit-repair

(3.94)

small end

inside

diameter

AND

of

connecting

or

Standard

0.05

(0.002)

0.05

(0.002)

of

Standard

0.008 - 0.020

(0.0003

25 (0.9843)

CONNECTING

rod

replace.

mm(in.)

Limit

0.2

(0.0079)

0.15

(0.0059)

hole

of

connecting rod

bushing

mm

Limit

- 0.0008)

(0.0020)

(in.)

0.05

Standard

1st 0.085 - 0.105

----

compression ring 2nd

compression ring (0.0020 - 0.0033) 0.15 Oil

ring

(0.0033 - 0.0041) (0.0078)

0.050 - 0.085

0.030 - 0.070

(0.0011

- 0.0027)

Limit

0.2

(0.0059)

Engines & Generators

22

MEASURING BUSHING

W

PISTON

CONNECTING

INNER

ROD

DlAMmR

ENGINE

INSPECTION

AND

REPAIR

Connecting· Rod Bearing Inspection

\1.

Fit

the

connecting rod bearing lower half into the

) connecting rod bearing

2. Check

. 3. Tighten

the

connecting rod bearing

If

the tension is insufficient, the bearing must

replaced.

the

connecting rod and the bearing

the

specified torque.

Fm1NG

cap.

THE

LOWER

BEARIIIG

Tightening

torque

Clearance ameter

Clearance

,

between

with

bearing installed and

bearing and crank

without.

Standard

0.035 - 0.073

(0.0014

- 0.0029)

)

lower

kg·m (ft. Ibs.)

7.5-8.5 (54-61)

pin,

half tension.

be

cap

to

inside

(0.0039)

di·

mm (in.)

Limit

0.10

CRANKSHAFT

Outside diameters If worn beyond the limits-replace

Crank journal

.

Crank pin

-

AND

CRANKSHAFT BEARING

of

journal and

60.0 (2.3622) 59.86 (2.3567)

49.0 (1.9291) . 48:87 (1.9240)

Standard Limit

mm

(in.)

mm(in)

When there

replace Clearance between journal and bearing inside diameter

with

bearing installed and

Clearance

Engines & Generators

.

23

occurs

it

with a new

an

uneven wear to the crankShaft.

one

without

0.029 - 0.072 0.11

(0.0011 0.0028) (0.0043)

grinding

Standard Limit

it

for

reuse.

mm

(in)

ENGINE

INSPECTION

AND

REPAIR

Runout Replace

Crankshaft gear Check the crankshaft gear visually

other

Oil seal

When

with a

Installation Use

crankshaft

of

crankshaft

if

beyond

Standard

0.025 (0.001)

defects.

the

lip

new

one.

the

crankshaft

front

limit

of

an oil seal is found defective, replace

front

oil seal installer to install the

oil

seal.

Limit

0.05 (0.002)

for

damage and any

mm

(in)

it

Ring Gear

1.

2.

TIMING

Uneven wear

Installation

Heat the ring gear evenly with a gas burner thermal expansion.

Do not exceed 200·C (390·F).

Use a hammer ficiently heated.

allow

the

temperature

to

install the ring gear when

of

GEAR

of

idle gear

Nominal Limit

45.0 (1.7717)

shaft

0.1

REMOVING RING

the gas burner

(0.0039)

THE

GEAR

to

invite

it

is suf-

mm

to

(in.)

FLYWHEEL

Ring Gear Replacement

Ring Gear Inspect the ring gear. Ifthe

ring gear teeth are broken orexcessively

ring gear must be replaced. Ring Gear Removal

Strike around and chisel

AND

the

to

remove it.

RING

edges

GEAR

of

the ring gear with a

worn,

the

hammer

Engines & Generators

24

Clearance between idle gear bushing and shaft

Standard Limit

0.025 - 0.085

(0.001

- 0.0033)

0.2

(0.0079)

mm

(in.)

ENGINE

ASSEMBLY

GENERAL

•

Be bolts

• During are correct direction pistons,

•

Apply Insure that moving parts, rotate

excessive

•

If

reference

•

Use

•

Tighten to

•

When bolts

• Most

make certain

Torquing

Prevent mechanical damage

three

yield torqued

brought center damaged care.

INFORMATION

careful

not

to

mix

bolts

and

are

used

on

various

assembly,

being

assembled in their proper order and

piston

lubricating oil

or

slide and are not subject

tension.

there

are

them

new

gaskets, lockwashers, O-rings, packings

the

specified torques using a reliable torque

required,

and

gaskets. Refrain

gaskets

recheck clearances

in

rings, bearings

mating marks scribed during

correctly for

bolts and nuts

use

and many bolt washers are asymmetrical,

they

are

engine assemblies.

relation

liquid sealants

to

moving

when

assembly.

on

from

positioned properly.

Hardware

by

running fasteners steps-II2, bolts and rocker

bolts

See

213,

and

III

torque.

arm

shaft fasteners. The former

as

indicated. The latter-rocker shaft fasteners-should

down

in

very

small increments, working

out.

Gaskets, especially head gaskets, might

during

assembly,

TORQUE

they

should be positioned

SPECIFICATIONS

nuts.

Metric and

and

insure that

faCing

the

engine

block,

and

bearing

parts during

assembled

to

important parts of

when

using tape sealants.

Exceptions

caps.

on

binding

disassembly,

wrench.

required

thru out

assembly.

the

or

down

are

from

this

S.A.B.

parts in

the

such

as,

engine,

and

seals.

the

engine

on

nuts,

in

torque-to-

are

the

be

with

great

manual.

be

Bolts

and

Fasteners

Lightly them. should be sealed

When LOCTITE

LITInUM bearings and

Antiseize LOCTITE protect threaded components yet come lOCking

Heavily

use

PISTON

Piston Pin Snap Ring

1.

2.

oil

head bolts

Bolts

and

assembling

blue. based

stuffing

compounds

apart

when

according

oil

all

clean engine

AND

Use a pair snap ring.

Check that the piston moves pin.

and

other fasteners

other plugs that penetrate

with

PERMATEX

the

flywheel,

grease

is

boxes.

and thread locking adhesives

necessary.

to

the job.

sliding

and

oil.

coat the

waterproof,

LOCTITE

reciprocating components,

CONNECTING ROD

of

snap ring pliers

SNAP

RING

PLIERS

#2 or

bolt

ideal

offers

to

install

smoothly

\

as

you

assemble

the

water jacket

mGH

TACK.

threads

for

water

allow

levels of

the

on the piston

with

pump

such

as

them

to

always

piston pin

Sealants

Oil

based excellent any coating of gaskets

LOCTITE hoses

Coat Sll.JCONE

When passages,

Do

not

mGH-COPPER ADHESIVE ing

a gasket

Specialized gasket sealers such applications requiring non-hardening properties. is

particularly effective

resists

NOTE:

fitting

and

Lubricants

PERMATEX

all

purpose sealers.

joint

in

contact with coolant,

oil

or LIQUID TEFLON

and

o-rings.

hydraulic red sealant should be

and

the

oil

both surfaces

SEALER.

installing gaskets that seal

coat

both

use

sealant

in

position during

fuel,

oil

, and

TAPE

SEALANTS

that

connect

#2 and

filter

assembly.

of

the

oil ..

sides

with

when

installing a

on

copper cylinder-head

water.

should

water cookmt

its

mGH

They

are

effective in just about

raw

water,

can

pan

gasket with high

around

WHITE

SPRAYS

assembly.

SILICONE

new

as

HYLOMAR

be

used

passages.

TACK

oil, or

be

used

water (coolant)

gasket.

are

useful

on

pipe plugs

equivalent

fuel.

A light

on

rubber

on

oil

adapter

temp

RED

GREASE.

for

hold-

work

well

in

HYLOMAR

gaskets

and

are

Piston Ring

1.

Use a piston ring installer

ril1~s.

Install the piston rings in (1)

Oil

ring

(2)

2nd compression ring (3) 1 st The marked side

be facing up.

The undercut side will

As

either direction.

2.

Lubricate the piston ring surfaces

3.

Check that the piston rings rotate

piston ring grooves.

compression ring

of

be

facing down.

the

oil ring has no any facing mark,

the

two

of

the second compression ring

~\

to

install the three piston

following

compression rings

"="--~)

order.

it

with

engine oil.

smoothly

I

st

2 st

may

face in

in

the

Engines & Generators

25

BOil

ENGINE

ASSEMBLY

CYUNDER

Nozzle

holder

HEAD

ASSEMBLY

Glow

Ii

plug

(7)

~5eal;VaIVe(1)

,

(6)~

.

@

~

Seat; Valve insert

Valve

Stem

Oil Seal

1.

Lul1ricate the oil seals and valve stem sealing are

with

engine oil.

2. Use a valve stem

seal.

INSTAlLER

Intake and Exhaust Valves

1. Place the cylinder head on a flat wooden surface.

2. Lubricate valve stems with engine oil.

3. Install the valves

Install the valves

oil

seal installer

~~~

to

the intake

to

their

to

install

the

or

exhaust guides.

original lapped valve seats.

oil

t.~

~

e>

~

I

~

dj

~/c:

..

. ,

Split

Spring seat

Valve spring

'.

:/"')

.

../

collar

(5)

(4)

(3)

Intake and Exhaust Valve Springs Install

the

pitched end) facing down.

'J(~~~

valve springs

~:::--P~/M1'FD

with

their

painted end (the close

PORTION

Engines & Generators

26

ENGINE

ASSEMBLY

Spring Seat

Split

Collar

1.

Use

a spring compressor

to

push

the

valve spring

into position.

2.

Install

the

spring seat split collar.

3.

Set the spring seat

split

collar

by

tapping

lightly

around

the

head

of

the collar

with

a rubber hammer.

Spring Compressor:

Nozzle

holder

assembly

Before assembling

the

nozzle holder assembly, check

to

see

if

the spray condition and

the

spray pressure

of

the

injection nozzle are appropriate, (Refer

to

"INSPECTION

AND SERVICE.") .

Assemble

to

the

cylinder head

the

gasket (heat shield),

heat

shield,

corrugated

washer

and

gasket

(nozzle

holder)

in

this

order.

Install the nozzle holder assembly, and then tighten

it

to

the specified torque.

kg·m (ft. Ibs.)

TIghtening

torque

4.0

- 5.0 (29.0 - 36.0) I

~

Nozzle

holder

ASM

~......

Gasket

~

Corrugated washer

'-_

~

Heat

shield

t Glow plug

I

~

~GaSket

Connector

Glow

plug

and

connector

Assemble

the

glow

plug

to

the cylinder head, and then

tighten

it

to

the

specified torque.

Install the connector

to

the

glow

plug, and

~hen

tighten

.

until snug.

kg·m

(ft

Ibs)

.

...

Parts

TIghtening torque

Glow

plug 1.5 - 2.0 (11.0 - 14.0)

Piston

ring

(5)

.,.

~

-

•

....

--'

~

"snap

ring

(4)

Piston (1)

--_-I~'J

Piston pin

(31~

~

*

~.

* Rod

bolt

removed

for

clarity.

Capnut(B)_

~

Bearing (6)

PISTON

AND

CONNECTING

ROD

Piston Use a piston heater to heat the pistons

to

approximately

100°C

(212°F).

Connecting Rod

USING A PISTON HEATER

1.

Install the connecting rod

to

the piston

with

setting

the marks

as

illustrated.

2.

Install the piston pin into the piston and the connecting rod bushing.

(Hot plug side)

Front

mal'K

__

Engine

~

front

..

di,ectio

v

~

Isuzu

..

m~;'~'lk:e,./o(;~~~t

Cylinder

nl

stamped side

mark

~

WESTERBEKE

EngInes & Generators

27

ENGINE

ASSEMBLY

Reassembly

(1) Crankshaft

(2)

Piston Assembly

(3)

Rear

(4)

Camshaft

(5)

Cam

(6)

Idler

(7J

011

Pump

(8)

TIming

(9)

Flywheel Housing

(10)

Flywheel

(11) Crank Pulley (12)

Oil Pipe

(13) Oil

(14)011

(15) Tappets

(16)

(17)

(18)

(19) Rocker Brac;ket Assembly *

(20)

Strainer Pan

Cylindar Head Cylinder Head Assembly Push

Engine

Seal

Gear

gear

and

Assembly

Gear

Rods

Hangers

Steps

Retainer

Shaft

Case

Gasket

INTERNAL PARTS

121

(11)

Engines & Generators

28

r--'-'-'-'-'---'-'-'-'-'--, I

. i

I I

I

L._._._._._._._._._._._._.~

ENGINE

ASSEMBLY

Reassembly Steps

,

)

111

,

Crankshaft

121

Piston

(31

Rear Seal

(41

Camshaft

151

Cam

(61

Idler

(7J

Oil

(81

TIming

(91

Flywheel

(101

Flywheel

(111

Crank

(121

011

(131

Oil

(141

Oil

(151

Tappets

(161

Cylinder

(171

Cy6nder

1181

Push Rods

(191

Rocker

(201

Ei>glne

Assembly

Gear gear

Pump

Gear

Pulley Pipe Strainer

,Pan

Bracket Hangers

Retainer

and

Shaft

Assembly

Case:

Housing

Head

Gasket

Head

Assembly

INTERNAL

PARTS

)

Engines & Generators

29

ENGINE

ASSEMBLY

Installation

of

retainer

After applying engine oil

to

the

lip

of

the oil seal. install

the retainer.

Apply

sealant.

Tighten bolts on the retainer

to

the specified torque in

the order

as

shown in the figure left.

kg·m (ft. Ibs.)

Tightening torque

0.8

-1.2

(6.0 - 9.0) I

'<D

Camshaft assembly

1.

Apply

engine

oil

to

the inside

of

the bearing

of the cylinder block. and then install the camshaft assembly.

Note: When installing

the

assembly. care should be taken

not

to

damage

the

bearing.

2.

After

installation

of

the snap ring

to

the outside

of the

front

bearing. check

to

see

if

the

camshaft

rotates smoothly.

Cam

gear and sleeve

1.

Install

the

cam gear

to

the camshaft so

that

the

tim-

ing

point

(a

dot

mark

".")

comes

to

the

front

side.

2.

With the flyweight installed. tighten the cam gear with

a lock nut.

kg·m (ft. Ibs.).

Tightening torque

7.0-9.0(51.0-65.0)

I

Cam

gear

-"'!><'l~

Timing

pOlnt

.... .-:

Sleeve

Flyweight

3.

Apply engine oil

to

the shaft

of

the sleeve and the

slide

of

the flyweight.

4.

With the lip

of

the sleeve placed in the cavity

of

t

flyweight. insert the shaft

of

the sleeve into the

til-

end

of

the camshaft. Note: Check

to

see

if

the sleeve moves smoothly.

Idle Gear Install the idler gear shaft

with

the oil hole facing up-

ward. Lubricate the shaft

with

oil. Install the idler gear. Align

the timing marks

as

shown in the illustration.

Install the

thrust

collar and tighten the bolts

to

the

specified torque.

kg·m (ft.

lb'

Tightening torque

2.1 -3.1

(15.2 - 22.4)

Idle

gear

Engines & Generators

30

ENGINE

ASSEMBLY

Crankshaft bearing Note

that

there is an oil hole and an oil groove in the

I upper bearing (on the block side),

but

not

in

the

lower

bearing (on the bearing cap side). Fit the bearing tang

firmly

into

the

slot machined on the

cylinder body bearing

archEls.

WITH

OIL

HOLE

FIT

CORRECTLY

'~~

·11

0NO

OIL

GROOVE

AND

HOLE

(LOWER)

Crankshaft and bearing Lubricate

the

bearings with engine oil, install the crank-

shaft, install the, thrust bearings

with

the

groove facing

the crankshaft.

Thrust bearing

~

~-

V Crankshaft

"'"

'\

p\)" V~

P\)

~-"-,,

---'"

Crankshaft Bearing

Cap

1.

Lubricate the bearing cap bolts with engine oil.

2. InstalHhe bearing caps

to

the crankshaft.

The arrow mark

must

be pointing

to

the

front

of

the

engine.

3. Tighten the bearing cap bolts

to

the

specified torque

a little at a

time

in the numerical order shown in the

illustration.

Crankshaft Bearing

Cap

Bolt

Torque

kg.m (ft. lbs.)

8.5 - 9.5 (61.0 - 69.0)

4.

Check that the crankshaft

turns

smoothly

by

manu-

ally rotating it.

LUBRICATE

WITH

ENGINE

OIL,

fl-::=:;:;;:;::::::::::-':-:;:::::::;:,,;:;,;::::::::o;:;

Arrow mark

10

• 6

..,

•

[9

::::::~~::::=~:.:::.J8

q

Front

151

2st

Ojl

Position

the

rings

as

shown making sure the ring gaps

are away

from

the

thrust

side.

Piston and Connecting Rod Lubricate

the

piston, the piston rings, and the connect-

ing rod bearings

with

engine oil.

Position

the

piston

front

mark towards

the

front

of

the

engine.

Use the piston ring compressor

to

compress

the

piston

rings. Use a

hammer

grip

to

push

the

piston in until

it

makes

contact

with

the crank pin.

At

the same time, rotate the crankshaft until the crankpin

reaches its highest point.

Set the bearing cap cylinder

number

marks and

the

con-

necting rod cylinder number marks. .

The marks

must

be faCing

the

injection

pump

side.

Special tool

Cylinder

No,

Tightening

torque

Note:

4LEl

kg·m

(ft. lbs.)

7.5-8.5

I

(54-61)

After installation, confirm

that

the

crankshaft rotates

smoothly.

Engines & Generators

31

ENGINE

ASSEMBLY

Oil

pump

assembly

PrO

not

TIghtening torque

Front

oil

Install

the

Installation shown in the figure.

to

the cylinder block.

provided

Cylinder block

seal

front

oil seal

is

made according

Install

1.9-2.9(14.0-21.0)

_..I"-1'!~~

to

the timing gear case.

to

the

L dimension

60.2 - 60.8 (2.370 - 2.384)

the

oil

pump

kg·m (ft. Ibs.)

"L

n dimension

mm

(in.)

I

Governor cover

4.

Assemble the gasket and the

top

of

the gear case, and then tighten them ·to

specified torque.

tightening torque

Cover

Flywheel housing Install the flywheel housing

Tightening torque 4.2 - 5.6 (30.0 - 40.0) I

governor

0.8 - 1.2 (6.0 - 9.0)

to

the cylinder body.

cover

kg·m (ft. Ibs.)

to

the the

Front

oil

seal

TIming gear case

case

to

the cylinder block.

1.

Put the link plate the gear case through the connecting injection

2.

Apply ends

of

3.

Apply

sealant

the cylinder block

Case

tightening torque 1.9 - 2.9 (14.0 - 21.0) I

(with

governor)

of

the governor incorporated in

pump

in advance.

engine

the main spring lever

oil

to

the bushes provided on both

to

the gear case, and then install it

or

the front plate.

. Install the

of

timing

hole

the governor.

kg.m (ft. Ibs.)

of

gear

the

to

Flywheel Lubricate bolts with engine oil.

Tighten a

illustration.

little at a time in the 'sequence shown in the

Tightening torque

(ft. Ibs.)

kg.m

9.0 - 11.0 (65.0 - 80.0) .

Apply

engine oil

~

WESTERBEKE

Engines & Generators

32

Crank

pulley

Lubricate Instal.l

the

Oil pipe and

1.

2.

the

the crank pulley, lock the crankshaft and tighten

front

bolt.

Tightening torque

oil

Install the

tighten the bracket ing cap.

the

cylinder block and .tighten the sleeve nuts.

Install

the

Tightening torque

lip

of

the front, seal

17.0

strainer

oil pipe from the oil

oil strainer

to

the

of

the strainer

1.9-2.9

ENGINE

with

qil

kg·m (ft.lbs.)

-19.0

(123.0

-137.0)

pump

assembly

oil pump, and then

to

the

No.2

bear-

kg.m (ft. Ibs.)

(14.0-21.0)

ASSEMBLY

Tappet and head gasket

1.

Install the tappet

2.

When installing the head gasket,

mark

of

between

I

Cylinder head assembly Lubricate the bolts

Tighten the bolts in the sequence shown in the iIIustra-

.

tion

to

the specified torque.

Bolt

size

to

I

M12xl.5

(8

each)

M8x

1.25

(4

each)

to

the cylinder block.

turn

the

parts number (last 4 digits) which is

the

No.2

and

No.3

cylinders

Parts

with

number

Stamp

oil.

8.5-9.5 (61

- 69)

(Last 4 digits)

mark

position

Tightening torque

-

2.5-3.5

(18

-25)

..

.11

up the stamp

of

the gasket.

kg·m (ft

60'-90'

Ibs)

To

2nd

bearing

cap

Oil pan

1.

Apply sealant

2.

Install the oil pan

fixing

bolts evenly.

Tightening torque 0.8 - 1.2 (6.0 - 9.0) I

to

the

oil pan.

to

the cylinder block and tighten

kg·m (ft. Ibs.)

Push rod Install the push rods.

Rocker arm bracket assembly Apply liquid gasket

bracket groove around

Install the rocker arm bracket assembly making sure push rods align specified torque.

Apply stem

assembly, being careful not

Tightening torque

of

sealant

to

the the bottom

the

oil galley as shown in

with

the

rocker arms and tighten

of

to

the

0.8 -1.2

Rocker

ROC~

r

Avoid

1l1~>-

~groc\le.

~

of

seQlant

Oil

the application

to

this

gallery

I

the

rocker arm

get any in

illustration.

kg·m (ft. Ibs.)

(6.0 - 9.0) I

arm

to

.......

",~

the

the the

~

WESTERBEKE

Engines & Generators

33

(Rocker

bmcket

bottom

s~r.ace)

ENGINE

ASSEMBLY

ADJUST

THE VALVE

CLEARANCE

Refer to the ENGINE ADJUSTMENTS section

in

this

manual.

EXTERNAL PARTS (Right-hand Side) EXTERNAL

PARTS

(Left-hand Side)

, .

11)

Dipstick

(9)

Water

Pump

12)

Oil Filter

110)

Thermostat

and

Water

Outlet

Pipe

13)

Injection

Pump

111)

Cylinder Head Cover

14)

Injection

Pump

HouSing Cover

112)

Exhaust

Manifold

15)

Fuel Pipe

113)

Starter

16)

Leak Off Pipe

114)

Generafor

17)

Fuel Hose

115)

Pulley

18)

Injection Pipe

116)

,Belt

.....

,!jJ..-! (3)

14)

Front hanger and rear hanger

Dipstick Oil filter (cartridge)

Tiglmln them to the specified torque shown below.

1. Insert the dipstick.

kg·m (ft. Ibs.)

Tightening torque

1.9-2.9

(14.0-21.0) I

2.

Rear hanger

IO'_-Front

hanger

..-v:

WESTERBEKE

Engines & Generators

34

(11)

113)

ENGINE

ASSEMBLY

Injection

Align ernor and lock into place

This tion

Install a that shim selection).

pump

the

two

(2)

holes in the fuel cut lever and the gov-

with

a pin.

will

center and hold the control link

of

the

injection pumps.

Injection pump

center

position

.

~

'Y~'

new

shim

with

was

removed. (Refer to the maintenance section on

___

_

Fuel cut

,.~

'--~..,J.4

the same thickness

Injection pump ASM

....

.-_Sh

im

for

lever

the installa-

as

the one

Housing

cover

Apply portion

About

About2mm

around

the bolt

Injection After applying sealant

install pump.

The

applied are and

pump

housing cover

(TB1207C)

it

to

the cylinder block by the side

Tightening torque 0.8 - 1.2 (6.0 - 9.

areas

of

the

housing cover

about

4

mm

In

width

about

2

mm

around

the

bolts.

4mm

hole.

to

which liquid gasket

from

of

sealant

in width

from

the cover

the housing cover,

of

kg·m (ft. Ibs.)

the

edge

the injection

0)

is

cover edge

I

Cylinder block

the

Install the injection

Remove the rack pin cut lever. and then confirm that the fuel cut lever moves smoothly

injection

groove

Tightening torque

of

pump

.

pump

making sure the rack pin is in

the

control

to

the specified torque.

(6_)

rack before tightening

which is inserted into the fuel

1.9-2

(ft. Ibs.)

kg.m

.9 (14.0 -21.

the

0)

I Injection pump

I center position

. Control

link

-~RackPin

Solenoid ASM

. Solenoid assembly

1. Apply sealant

in which the solenoid is installed.

Note

:

Avoid

the

application of sealant

2.

Screw in

. block (the rear

then tighten

Tightening torque

(TB1207C)

the

solenoid from the rear

of

the No. 3 injection

it

to the specified torque .

SolenOid

ASM

-,--.:..-..../

to

the surface (bite groove)

to

the

screw thread.

of

the cylinder

pump

rack), and

kg.m (ft. Ibs.)

1.

5-2.5(11.0-18.0)

lnsmlled

Apply

(

ofsealilnt

surface

SUrface)

I

)

Engines & Generators

35

Screw

thread

Av

oid the

apPlica

(

of

sealant

tion )

(not adjustable, pull to run)

ENGINE

ASSEMBLY

Leak

off

pipe

?

'''''~'''

Fuel pipe Leak

off

pipe

Fuel hose

1.

Install

the

fuel pipe

to

the injection

pump

and then

tighten

it

to

the specified torque.

2. Install the leak

off

pipe

to

the nozzle holder and then

tighten

it

to

the

specified torque.

kg.m

(ft. Ibs.)

Tightening torque

Fuel pipe

2.0 - 2.5 (14.0 18.0)

Leak

off

pipe

2.5-3.5

(18.0-25.0>"

When

tightening

it.

hold

the

pipe securely

by

hand so

that

it

will

not

rotate.

3. Connect

the

fuel pipe and the leak

off

pipe with the

fuel hose and

fix

them with clips.

In;8ct;on

pipe

Install

the

injection pipe

to

the

injection

pump

and

the

nozzle holder and tighten them

up

with sleeve nuts. .

kg·m

(ft. Ibs.)

Tightening torque

1.5-2.5(11.0-18.0)

I

.

-~~

\...

_ .

Nozzle

holder

Injection

pu~~~

~/

"~

~

Set

the

thread

of

the

sleeve

nut

securely before

tighten-

ing

it

up_

Water

pump

assembly

1.

Put sealant on

the

water

pump

where

it

contacts the

block and head.

2. Tighten

to

the

specified torque.

kg.m

(ft. Ibs.)

Tightening torque

1.9-2.9

(14.0-21.0)

I

Thermostat Water

outlet

pipe

Assemble the thermostat.

install the gasket and the

water

outlet pipe. and then tighten

it

to

the

specified

torque.

kg·m (ft. Ibs.)

Tightening torque

1.9-2.9

(14.0-21.0)

I

Adjust

the Valve Clearance

Refer to the ENGINE ADJUSTMENTS section in this

manual .

Cylinder head cover

1. Install the gasket

to

the cylinder head cover.

Notes:

1. Much care should

be

taken

for

the

gasket

not

to

get

dislocated

or

twisted

when

installing

the

head

cover.

2. Avoid

the

application

of

sealant

to

the

rubber gas-

ket.

2.

Install the cylinder head cover

to

the

rocker arm

bracket, and tighten

it

to

the specified torque.

kg·m (ft. Ibs.)

Tightening torque 0.2

-0.4

(1.4-

2.9) I

Cylinder cover

Gasket

Rocker arm bracket

~

WESTERBEKE

Engines & Generators

36

ENGINE

Air

inlet

pipe

1.

Apply

sealant (TB1207C)

air

inlet pipe is installed.

2.

Install the air

and tighten

Tightening

inlet

it

to

the specified torque.

torque

Cylinder head

cover

Exhaust manifold Assemble the gasket

exhaust manifold along the stud bolts and tighten

the specified torque.

Tightening

torque

pipe

to

the surface

to

the cylinder head cover,

0.8-1.2

the

cylinder head, install the

1.9-2.9(14.0-21.0)

in

kg.m

(6.0-9.0)

Air

inlet

kg.m (ft. Ibs.)

which the

(ft. Ibs.)

ASSEMBLY

Alternator

1. Tighten the adjustment plate together with the water pump, and then install them temporarily.

2. Install the bottom of the alternator to the timing gear case, and then tighten it temporarily with bolts and

nuts.

3. Install the fixing bolts onto the top

through the adjusting plate (temporary tightening).

Drive pulley and belt

1.

Install the drive pulley to the water pump and then tighten

2. Set the drive belt to each pulley.

pipe

it

I

to

I

it

up

Tightening

(2

locations).

torque

Water

of

the alternator

pump

kg·m (ft. Ibs.)

0.8 - 1.2 (6.0 - 9.0) I

Gasket

Exhaust

Starter Install the starter

to

the specified torque.

Tightening

For starter motor disassembly and repair, refer to the

starter motor section

to

the

torque

in

flywheel

this manual.

housing, and tighten

9.5-11.5(68.7-83.2)

kg·m (ft. Ibs.)

it

I

Drive belt tension should

deflection at mid-point.

For alternator disassembly and repair, refer to the MANDO ALTERNATOR

be

very tight, about

SECTION

in

this manual.

1/2"

Engines & Generators

37

ENGINE

ASSEMBLY

NOTE:The exhaust manifold, which was disassembled from the cylinder head, should be inspected before reassembly.

a. Remove the exhaust elbows from the lower surface

of

the manifold. Clean and inspect for cracks and

defects. Replace as needed.

b. Remove the exhaust nipples, elbows and plugs from

the manifold and heat exchanger.

c.

Remove water connectors from the ends manifold. arrangement

d. Examine all parts

and replace as needed.

f.

Flush out the coolant recovery tank and clear its hose passage.

Be

sure to note the proper location and of

each for proper alignment.

for

defects, corrosion and wear

Set aside to re-install

of

on

the boat.

the

HEAT EXCHANGER

Install the heat exchanger, replace the heat exchanger zinc and aUach new hoses with new clamps to the cooling system. Refer manuall

for

HEAT EXCHANGER SERVICE.

to

the COOLING SECTION in this

MARINE TRANSMISSION

1.

Assemble

2.

Reinstall

ATF

NUIE:

Some

Drive

require pressure transmission oil cooler hoses should Refer

to

the

Dextran

transmissions,

oil

tested

and

the text

on

damper

marine

III.

coolers.

repainted at

Heat

Exchangers.

plate

to

transmission

such

as

the

Oil

coolers should

engine

also

the

flywheel. and

Borg

overhaul.

be

fill

with

Warner

be

Velvet

cleaned,

The

inspected.

ENGINE TUNING OPERATION

After reassembly, the engine must be tuned. This will ensure efficiency. mixture and the engine oil sump with lube oil (API spec. CF

1.

2.

3.

4.

5.

6.

7.

B.

9.

10.Check

11.

12.Check

13.

14.Check

15. 16

17.Adjust 1B.Stop

Refer to the following pages for details sub-assemblies. These sections also include:

Wiring Diagrams, Engine Specifications, Torque

Diagrams, Starter Motor, Alternator, Raw Water and a detailed Troubleshooting Section.

that

the engine operates at its maximum

Fill the engine cooling system with antifreeze

or

CG-4)

Mount the

Connect

DIAGRAM.

Connect Connect Manually

to Bleed Crank

operation)

pre-lubricate the engine internal components. Start

rpm

Remove

is

circulating

through If

sluggish, stop the engine and make the appropriate repairs

Reinstall the cylinder head cover. Increase

engine intake

Check

When 75°C (167°F) to

seconds.

This operating time.

specified procedure.

the

fuel

the

running.

there is no oil circulation or

2000

engine

lines.

the the

the

operate

engine.

the

fuel

the

engine

for

the

engine

for

five

the

that

the from

the

or

adjustments.

the

warming-up

the

engine

leakage. for

abnormal

for

abnormal

the

engine

the

engine

rpm

will give the engine the essential run-in

the

engine

value.

the

engine

on a electrical air

intake

exhaust

the

lines

with

about

and

minutes.

cylinder

engine

the

cylinder

engine

for

fastening

coolant

or

more,

and

allow

operation

to

complete

test

bench

wiring.

line

to

pipe.

fuel

feed

of

air. the

starter

twenty

allow

head

oil

head.

speed

operation.

oil,

noise electrical

seconds.

it

cover

oil

is

continuously

pump

to

fuel,

and

parts

temperature

increase

it

to

run

and

Refer to the WIRING

the

air

pump

(non-ignition

to

run

while

to

the

if

the oil circulation is

1500

coolant,

odor.

charging.

for

the

for

speed

the

tuning

of

connect

cleaner.

to

feed

This will

at

750

the

valve

rpm

to

and

looseness.

reaches engine twenty

to

the

Pump,

fuel

to

BOO

engine

rockers

do

air

speed

the

Adjust

Refer to the ENGINE ADJUSTMENTS section manual.

Engines'& Generators

38

.

the Valve Clearance

in

this

LUBRICATION

SYSTEM

Valve opening

Valve

opening

pressure

4.5kg/crn'

(64.0

PSI)

-----

pressure

lkgtcm2 (14.0 PSI)

Oil

filter

H '"jectiO"

L.G:Jllton

, ,

i~i

:-~--~

iii

Pressure feeding

1

pump

h

------,

:

Oil

pan

Oil

gallery

Gov~mo,

I

+mO:~'"1

, ,

----------_.--_

, ,

,

, ,

,

, ,

,

, ,

Non pressure feeding

,

OIL

'LUBRICATING

Body; Oil pump

PUMP

OIL

CIRCULATION

·the

Clearance between the

Clearance between

DIAGRAM

Inspection and replacement When there is

found, repair Clearance between

pump

0.040 - 0.085 (0.0016 - 0.0033) 0.15 (0.0059)

pump

body

0.10 - 0.185 (0.0039 - 0.0073) 0.4 (0.0157)

Standard Limit

0.17 (0.0067) 0.2 (0.0079)

wear, damages

or

replace the rotor.

the

outer

cover

Standard Limit

the

periphery

Standard Limit

the

inner

rotor

or

any other defects

or

inner

of

the

outer

and

the

outer

rotor

mm

rotor

mm

and

(in)

and

(in)

~

WESTERBEKE

Engines & Generators

39

COOLING

SYSTEM

WATER

PUMP

DISASSEMBLY

Cover

1.

Loosen

2.

Remove

Note: The cover

moving

deform

. center

the

is

applied

the

cover, much care should be· taken

it

by

applying an excessive force

set screw.

cover.

with

4---

Seal unit

Seal

REASSEMBLY

unit

-Cover

Bearing

Body

@~setscrew

sealant (TB1207B). When re-

not

to

it. Impeller

Seal

Cover

Setscrew

Impeller

unit

Bearing

unit

With

body, lock

Set

Impeller Seal

1.

2. Press in

Cover

1.

2. Apply Screw-lock

Clearance, play and tightening

1.

2. Play in the water

0.008 - 0.010 (0.0003 - 0.0004)

3. Tightening allowance between center and

unit

a hole in the bearing

screw tightening torque

Apply

specified value.

Clearance between the

the

BELCO

seal

unit

assemble the seal unit.

between the

Apply

liquid gasket

is installed, and then install the cover.

and then tighten them.

Standard

bearing shaft

Standard

unit

the

bearing

unit

comes into contact

the

unit

with

bond

No.4

impeller with a press until

pump

impeller and the

to

the surface

to

the cover installation screws,

allowance

pump

0.53

- 2.17 (0.0209 - 0.0854)

pump

ball bearing.

-

0.026

0.061

set in line

a setscrew.

0.8-1.2

Cover

to

the

surface where

with

the body, and then

body

to

which the cover

between

impeller and

Limit

0.2

(0.0079)

(0.001

with

one in

kg·m (ft. Ibs.)

(6.0

-9.0)

the

clearance

gets

to

parts

the

body

mm

- 0.0024)

the

(in.)

-'

(in)

(

Engines & Generators

40

Maintenance

The

filter

should

be

the cartridge with

compressed

oily,

replace

on a flat

air.

it

cleaned

surface

If

the

every

to

dislodge

cartridge

100

is

COOLING

operating

dirt or

badly

hours.

clean

contaminated

Tap

off

SYSTEM

or

A

CAUTION:

Impeller,

/hey

cooling

<1=11.

mhanger.

"any

IIIDSf

They

HAW PART

Df

be

fDrmd

DflBn

WATER

NO.

11361

the

can

PUMP

VIIJIBS

fD

pment

be

hare IIml"

IIIDCkageln

fDtmd

In

tire

..

heat

uff

tire

Heat

Exchanger

After

approximately

and

pressure

automotive

heat

exchanger.)

TO

TRANSMISSION

test

the

radiator

COOLER

!:;!~~~I)S

Service

1000

hocrs of

engine's heat

shop

should

~NC

PART

NO.

operation,

exchanger.

be

able

to

11885

clean

remove, (A

local and

clean

test

the

RAW

WATER

PUMP

~

WESTERBEKE

Engines & Generators

41

THERMOSTAT

ASSEMBLY

19

CIRCLIP

2QPLATE

(INTERN,ALL_

RAW

WATER

PN.4612D

PUMP

OVERHAUL

Disassembly

The

pump

when

removed from attachment nipple the

pump along with a drive pulley

the

pump. Remove these attachments

before starting

1. Remove the four cover plate

and sealing O-ring #10.

2.

Remove the impeller the

~ub

mobon.

3. Remove the screw

cam

in place. Remove the

behind

4.

Remove dust plate

S.

Support the pump body press the shaft and bearing assembly out the pulley end

the pump.

6. Remove the

7. Support the outer bearing #18 and the bearing.

8.

Remove the spacer #17

it

threaded into the inlet and outlet pons

the

pump

and pulling it out

#4

#20

O-ring

from

the

engine

will

have

attached

noting

to

the

their positions

disassembly.

screws

#12,

cover plate

#9

using a pair of pliers, grasping

of

the

pump

with

a twisting

and

seaIing

cam

and circlip

on

the shaft.

and

washer #3 that hold the

#2

and

inner wear plate #8

#19.

an arbor

circlip

press

push

the shaft out

#13.

and

with

the

shoft

a drift,

hese

of

#11

of

LIGHTLY PUMP

AND

GLYCERIN.

GREASE

CHAMBER,

IMPELLER

INSPECT ANa IF OF

THE O'RING,

WITH

THE

IMPELLER.

THEY

SHOW

WEAR.

Inspection

Inspect all parts

and

replace

those

showing wear

Reassembly

1. Install a

glycerin

2. Install the circlip #13

bearing bearing contacts circlip.

3. Install spacer

bearing

contacts the

4.

Apply some glycerin onto the shaft approximately

S.

Support mobon, install the shaft and bearing assembly into

shaft seal body. the pump body boss for circlip #19.

6. Install circlip #19 and push the shaft and

assembly so the outer bearing

7. Install

8. Install wear plate #8, washers

9.

Apply housing, impeller inner surface of the cover plate O-ring

to.With a

pump. #11

ll.~tall

mto pulley alignment Attach the raw water

new

shaft seal #5

to

the lip

#18

and push the shaft into the bearing

#17

#16

and push the shaft into the bearing spacer.

~e

pump body

#5

until

Then

with

the

dust plate

and

screw #4.

some

glycerin

#10.

twisting

Install the

with the four

the pulley

the

pump.

Mount the

in

the pump

of

the seal.

on

the shaft. Support the outer

against

the

circlip. Support

the

O-ring

1/8"

away

on

an

arbor press.

the inner bearing contacts the

the push shaft and bearing,

so

that

the

outer

#18

body.

#6

from

the inner bearing.

bearing

just clears

contacts the circlip

#20.

cam

32

and secure it

to

the

surface

motion,

install

O-ring.

#10

screws

#12.

on

the shaft and the hose

pump

of

the impeller

and secure the cover

on

the

engine. hoses.

and install it

bearing

a-RING

REPLACE

SIGNS

or

corrosion.

Apply

some

until

the

inner

until

it

on

With a twisting

the

pump

assembly

in

place

#9

into

nipples

the

with

#11

the

plate

back

Check

into

#19.

and

~

WESTERBEKE

EngInes & Generators

42

FUEL

SYSTEM

GOVERNOR

1.

The adjustments

of

the governor-related parts require

the

engine performance test.

2.

Before disassembling the governor, measure the dimensions

"A"

and

"B"

given in

the

structural

drawing

to

ensure the same dimensions in reassembly.

3.

Do not disassemble the governor when the performance test cannot be conducted after reassembly.

STRUCTURAL

DRAWING

OF

GOVERNOR

Idle speed screw

Start

spring

Governor shaft

Set

spring

Injection

pum~

[===~]t:===~~~~~~~~~

Governor

cover

Main

spring

lever

.......

·<...:S

Guide lever

Timing gear esse

Tensioner lever

Angleich

Sleeve

Full/oad stopper

Shifter

~

WESTERBEKE

Engines & Generators

43

FUEL

SYSTEM

Reassembly

(1)

Assemble the

(2)

After

assembly, confirm

(3)

Also,

confirm

Reassembly

Assemble the related Pijrts such as

the

idle spring

(1)

When assembling

sliding

(2) Set both ends

notched groove bent-up

(3)

After the

(4) When assembling the

nor illustration

parts

The bled after performance test.

-A-

portion

arm

reassembling the

governor moves smoothly.

cover, tighten the • A n dimension shown in the

given in

dimension

of

to

of

shifter

that

2 - 3

the

to

the

shifter shakes smoothly.

of

governor cover

to

the

governor cover.

the

shaft, apply engine oil

with

the

governor cover.

of

the

retum spring securely

at

the

bottom

the

lever respectively.

govemor

timing

mm

temporarily. .

square indicated

(When

2 - 3 (0.0787 - 0.0118)

guide lever, put the shaft through it, and then assemble the snap ring.

that

the shaft moves smoothly.

Guide lever

the

fuel cut lever and

to

the

to

the

of

the

cover and the

cover, confirm that

gear case

assembling temporarily)

by

to

the gover-

(")

are assem-

mm

(in.)

Shifter

Governor cover

(Notched groove)

[Stop) [Operate]

I~:"·

I

Snap

'::::::

Gasket

Idle

screw

Idle

spring

ring

above)

(ll!)

Governor

lever

:

L

Washer

view

""--L

Z

of

the

drawing

.

...v

WESTERBEKE

Engines & Generators

44

FUEL

SYSTEM

REASSEMBLY

(1)

Put the lever (main spring) through

Note: Before

lever respectively. .

(2)

(3)

Note: When

hammering

Put

the

return spring

Assemble

assembling

the

in

the

bushes,

ofthe

bushes.

bush

of

the lever (main spring) first, and then the control lever bush.

the

bushes, apply Loctite (#601)

OF

CONTROL

Protrusion

the

hole

put

both

shafts

control lever through the shaft

LEVER

ofthe

of

to

timing

the

lever through

the

periphery of

Main

Bush

Apply

loctite

(

to

the

peniphery

gear

case

of

the

I.ever

the

PARTS

spring

No.SO'

lever.

the

)

holes

(main spring).

bushes.

of

the

timing

gear case

(4)

Hook

both

ends

of

the

return spring (control lever) securely

(main spring)

Assemble the control lever. Assemble the O-ring

and the

respectively.

to

the groove

control lever before tightening

of

the

up

I Control lever tightening torque 11.2 - 1.8 (9.0

a-ring.

Bush

~u-~--t~

Notes:

1. TIghten

(Do

2. After assembly, confirm

not

the

control lever after locking

tighten

the

control

to

the protrusion and

bushes (control lever) first, and then assemble the washers

the control lever

kg.m (ft.

Ibs.)

with

a nut.

the

of

the lever

-13.0)/

Control

lever

Spring

washer

the

that

lever

the

after

locking

control

control lever

the

lever moves smoothly.

firmly.

main spring lever.)

'~IWESTERBEKE

i Ellfllnes & Generators

45

FUEL

SYSTEM

STRUCTURAL

"DRAWING

OF

GOVERNOR

Start

spring

Set spring

~

Sn.p

p;n

Guide

tever

I

\ t

Control link

Floating

fever

\

Link

plate

Copnut

~

...

@l

Flyweight

~

WESTERBEKE

Engines & Generators

46

FUEL

SYSTEM

Reassembly

of

full-load stopper

Install the full-load stopper to

Full load stopper

the

timing

Timing gear

gear

case

case,

and then tighten

Lever

it

with

a nut temporarily.

shaft

Eye;

start

Guide

piece

Link

spring

plate

Main

Floating

spring

lever

Mainspring

Set spring

Reassembly of governor lever related components

Assemble each lever and spring to the

Notes

(1)

When assembling components, apply engine oil to each slide (such hole in

(2)

Install

its

(3)

Confirm

(4)

After assembly, confirm And also confirm that each spring operates properly.

when

the

assembling governor related components

shaft, and

set spring securely

the

assembling direction.

that

each lever moves

periphery

to

by

that

each

of

the shaft).

the groove

its dead

of

the

weight

pin connecting

before installing the start spring.

lever moves smoothly.

as

the end face

the

floating lever,

timing

of

the lever, the

with

much care to

gear case.

~

WESTERBEKE

Engines

& Generators

47

FUEL

SYSTEM

THE

IJ.RING

GASKET

ONlY

NESJS

ro

BE

FIEP/ACED

IF

IT

SHOWS

SlSNSOFWEAR

Changing

the

Fuel

Filter

Element

Refer to the

illIIstratWn

above.

L Shut off the fuel

supply.

2. 'Ibm the

fuel

filter

bowl countercIockwise to

remove.

3. Pull the

filter

eIemeut

SlIaight

down

and

off.

4.

InsJ!ecl

both

O-rings and replace

if

worn.

5. Wipe the O-rings with clean fuel and snap the

new

filter

up

into place over the

small

O-ring.

6.

Clean

off

the

filter

bowl and threads. (The

bowl

can

be

pro-filled with

fiicJ).

Screw

the bowl inta place

when

the

O-ring

contacts the

bousing.

TIghten

the

bowl

fumly

by

hand

7. TIle key-on

preheat

sequence will allow the lift

pump

to

.

fill

the

fuel

filter.

8.

Run the engmes

and

inspect

for

leaks.

FUB.INJECTION

PUMP

The

fuel

injeCtion

pump is a very important component of

the

di.escJ

engine, requiring the utmost care in handling.

The fuel injection

pump

bas

been

thoroughly bench-tested

and

the

owner-operator is cautioned not

to

attempt

to

service

it

If

it

requires servicing, remove it and

take

it to an

authorized

fuel

injection pump service facility. Do not

attempt to disassemble and

repair

it

FUEL

UFT

PUMP

Periodically check the fuel connections to and out

of

the

pump

and

make sure that no leakage is present and that the

fittings

are

tight and

secure.

The

DC

ground connection at

one

of

the

pumps

mounting bolts should

be

clean and

well

secured

by the mounting bolt to

ensure

proper pump

operations. When enetgized thru the preheat circuit, the fuel lift pump

will purge air

from

the fuel system and provide a continuous

flow

of

fuel

as

the engine is running.

A

small fuel filter has been added to the incoming fuel

line

to ensure that filtered fuel enters the fuel

lift

pump.

FROM PREHEAT

NOZZLE ASSEMBLY

Inspection and replacement

Place the removed

nozzle

in

the clean light oil, disas-

semble

it

into the nozzle body and the needle valve and

clean them thoroughly. Then check to

see

if

the valve

moves smoothly in the body.

When

it

does not move smoothly, repair or replace the

nozzle.

Injection

pipe

Leak

off

pipe

DISASSEMBLY

Packing

Injection

pump

\~o

\ \ /

~

He.tsh/eld

L.-

/ Ev

Al

--

Gasket

• fdP'

"'t)IY"

WESTERBEKE

EngInes ~ Generators

48

FUEL

SYSTEM

INJECTION

1.

Using the nozzle tester, check tion starting pressure limit, adjust or replace the nozzle. When using nozzle tester,

a.

If

replace

b.

Set the nozzle tester dust or dirt

Co

Mount the nozzle and nozzle holder on the nozzle

tester.

d.

Use the fuel at the approximate temperature of

e. Operate the hand lever

bleed the lever ing the injection starting pressure.

A

of

such

skin

enters

TESTING

take

thefol\owing precautions:

the diesel fuel

it

68' F

(20'

at intervals

CAUTION:

velocity

of

ffngers

the

bloodstream,

At

air

the

C)

in

the

The

that

and

of same

of

hands,

the

spray pattern and injec-

of

nozzle and,

the nozzle tester is discolored,

time, clean or replace the filter.

in

a clean place where there is

of

nozzle tester several times to

nozzle line, then move the hand

one

stroke

INJEtnON

1920

NOZZlE

TESTER

spray

injected

It

may

penetrate

destroying

it

may

if

it exceeds the

per

second while read-

PRESSURE

PSI

from

the

deeply

tissue.

cause

blood

nDZZle

Into

If

poisoning.

It

is

the

no

Body

Nozzle holder

GLOW PLUGS

The

glow plugs

When PREHEAT is solenoid begin to

get

should

hot.

are

wired through

pressed

"click" on

Inspection

To

inspect nections, cylinder threads remove

examine the

eroded

the

plug,

then

unscrew

head.

Thoroughly

with a soft

ali

the

carbon

tip

too

for

much,

remove

brush

and

wear

replace

Testing

An

accurate Touch the

other

good

glow plug

This

method

engine. You can also use

drain (5 - 6

one

way to

prod to

to

the

can

amps

test

the

glow plug's wire connection,

body of

will

have a 0.4 -0.6

be

used

per

plug).

RETAINING

ASM

the

at

the

and

the

or

unclamp clean

and

cleaning

oil

deposits.

and burn erosion; if

the

plug.

glow

plugs

the

glow plug,

with

the

an

ammeter

preheat

control

glow plug should

electrical terminal

each

plug's tip

solution to

While cleaning,

is with

as

ohm

plug

in

to

Shim

Nozzle

spring

Spring Spacer

NozzleASM

panel

plug from

an

shown.

resistance.

or

test the -power

seat

NUT

solenoid.

this

con-

the

and

it

has

ohmmeter.

and

A

out

of

the

No

good No good

10

I

good No good

!=.JI

'01

I .

r

(,

f..I\

./11\

.,

I

!

About 4°

Check to see are normal. Adjust when they adjust the injection pressure.

if

the spray condition and the injection pressure

them

to the specified value respectively

do

not

meet

the standard value. Use shims to

T

Engines &

49

GLOW

PLUG

llGHTENING

1.0·

Generators

TORQUE

1.51of.l(G

(7

-11

FT-LB)

USIIIGA

TESTUGHT

+

ENGINE

ADJUSTMENTS

TESTING

Make certain

and must

1.

2. Disconnect the wire to

3.

Note:

Compression cylinder is very measured

Therefore, this

pressure

ENGINE

the air

intake

also be in

Warm

the

Remove

the

cylinder

way,

all

compression gauge/adapter

On

and important

in

start

you

in

each

COMPRESSION

the

oil

level

filter is

good

condition.

engine

to

normal

the

glow

which

the

pressure

in

no

each

will

may

particular cylinder order. However,

that

cylinder.

at

the

No. 1 cylinder

be

sure

cylinder.

(dipstick)

clean.

the

plugs

is at

The

battery

operating

fuel

shutdown

from

the

correct

and

temperature.

engine

combination

compression

be

the

to

is to be

measured

compression pressure be

measure

starting

and

the

level

starter

motor

solenoid.

and

install

to

the

measured.

at

work back.

compression

any

it

In

Low

Compression

When

low

compression applying a small plug

hole.

Allow

Install

the

pressure compression rings. with

the

A slight

both

the

DlL

PRESSURE

Low

Oil

The

specified gradual For

additional

the

ENGINE

Testing

To

test

install a

warming the

oil

reading

If

the

compression

valves.

rise

in

rings

Pressure

safe

loss

of oil pressure

TROUBLESHOOTING

Oil

Pressure

oil

pressure,

mechanical

up

the

pressure

is

amount

the

oil

to

gauge

rises

compression

and

the

valves.

minimum

information

remove

oil

pressure

engine,

set

gauge.

found,

determine

of oil

in

the

settle.

and

repeat

dramatically,

valve

does

would

indicate a problem

oil

pressure is 5 -

usually

on

the

low

oil

indicates

oil

pressure

'gauge

the

engine speed at

cylinder

the

above

the

not

rise,

pressure

chart.

in its

the

cause

thru

test

fault

the

10

worn

readings,

sender

place.

idle

by

the

glow

If

the

is

with

problem

with

psi.

A

bearings.

then

After

and

the

is

see

read

4. Oose the

5.

6.

NOTE:

•

7.

S.

Compression

raw

water seacock

Crank

the engine

maximum reading,

Repeal:

this

If

the

readings

an

overlraul.

55B 441 SPEED

44.1

Re-install

the threads)

Open the raw water

the

and

then

process

are

FOUR

COMPRESSION

PSI

(3.04

MPa)

OF

250

PSI

BETWEEN

glow

plugs

and

reset the

ga.Jge' ....... \

allow

record that

for

each

below

NORMAL

RPM.

CYLINDERS

(use

fuel

seacock

(thru-hull).

the

gauge

reading.

cylinder.

the

limit,

PRESSURE

AT

CRANKING

anti-seize

shut-off to

(tbru-hull).

to

reach

the

engine

compound

the

run

a

needs

on

position.

558

FOUR

43

TO

65

PSI

MECHANICAL OIL

PRESSURE

GAUGE

OIL

PRESSURE

(290

TO

590

KPa)

NORMAL

~

OIL

PRESSURE

SWITCH

Engines & Generators

50

VALVE

The valve clearance must hours or whenever the valve rocker Valve Cold engine valve clearance

NOTE:

"Angular to elearanees.

CLEARANCE

adJustment

The

cylinder head bolts have

1ightening

retighten

the

ADJUSTMENT

be

adjusted every 500 operating

should only be done

is

O.OI5in

Method".

cylinder head bolts

There/ore,

ENGINE

is

abnormally

when

engine is

(O.4Omm).

VALVE

been

tightened

it is not necessary

before

adjusting

ADJUSTMENTS

noisy.

cold.

CLEARANCE

with

the

valve

3.

In

accordance

sure

and

marked

Cylinder

Valve arrangement I

When No.1 cylinder

in

the

compression stroke Np. 4

When in

the

compression stroke

4.

On

completion

mark alignment as

in the

normal

clearance of the other

A

CAUTION:

aluminum.

adjusting

with the conditions of cylinder

adjust

if

with

eiiher @

No.

cylinder

of

direction. Then

Therefore,

screw

No.1,

required the clearance

or

• in

the

table

1

is

at

TOe

•

is

at TOe

I:

Inlet

E:

Exhaust

the valve clearance alignment

in 1 by

giving a

measure

valves.

The

rocker

ann

be

careful

to

excess.

of

the

below.

2 3 4

E I E I E I E

•

@

turn

to the

and

adjust

is

made

of

die-cast

not

to

tighten

mea-

valves

•

@ @

make

a

crankshaft

the

ADJUSTMENT

TDCMAR~K~

PROCEDURE

f

Q;

"

",Co.

CRANK

V

PULLEY

"".-~

::::7

======

1. Thm the crankshaft clockwise so that

the

crank

pulley is aligned with the

on

the timing gear case

2. Remove the cylinder head cover and der

No.1

is

at

TDC in the compression stroke or at in the exhaust stroke. When the intake are closed, the cylinder is at TDC in stroke,

and

when only the exhaust

TDC in the exhaust stroke.

CYUNOER COMPRESSION

NO.1

cover.

the

TDC

check

and

the

compression

valve

marlc

mark

to see

exhaust

is

open,

groove 0';'

(cast

if

IDC valves

it is

out)

cylin-

at

Adjusbnent

The injection timing forget

to insert a shim in the mounting surface

reassembling the injection pump after

:

of

Injection

may

Timing

not be

re-adjusted.

disassembly.

Take

when

care

not

to

'~/WESTERBEKE

i Engines & Generators

51

ENGINE

ADJUSTMENTS

.

INJECTION

TIMING

Take care

to

avoid

entry

of

dust

or

foreign particles

into

the

pump

interior

when

the

timing

adjustment

is

made.

1.

Remove

the

injection pipe

of

the

No.1

cylinder.

2.

Remove the delivery valve holder

of

the

injection

pump

of

the No. 1 cylinder, and then pull

out

the

delivery spring.

3.

With

the

spring

left

removed, install

the

delivery

valve holder.

oelivery

valve

holder

\

,,/

Injection

pump

4.

Slowly

tum

the

crankshaft pulley clockwise,

at

the

same

time,

continue

to

feed

the

fuel.

When

the

fuel stop flowing

out

from

the

No.1

deliv·

ery

valve holder, stop turning the crankshaft.

This crank angle position is the starting point

of

injection.

5.

In

the

condition

at

Step

(4)

above, confirm

what

degree the

"groove

mark"

of

the crank pulley is at,

when

seen

by

the

"timing

mark", provided in the

timing

gear case.

When

the

value is out

of

the

range

of

the normal

injection

timhg,

adjust

it

accordingly.

Injection

timing

I

BTDC

16·

Note: The injection

timing

varies according

to

the

specifica·

tions

of

the

machine.

6.

Adjust

the injection

timing

with a shim between the

injection

pump

and the cylinder block.

Shim

is available in the

following

9 types, and

"iden·

tification

mark"

is

stamped (or imprinted) on the

top

face.

Identification

mark

of

shim and its thickness (mm)

Mark Thickness Mark

Thickness

Mark Thickness

2

0.2

5

0.5

8

0.8

3

0.3

6

0.6

10

1.0

4

0.4

7

0.7

12

1.2

Note: For each

of

the

injection pumps

of

three

cylinders,

the

shim

adjustment

is

made

at

the

same time.

When a shim is missing

while

overhauling

the

engine

and

the

shim thickness is

unknown,

assemble

the

engine

with

provisional shim inserted. After assembling

the

engine, check

the

injection

timing

and adjust

the

shim

until

the

normal injection

timing

is

obtained.

Reference:

To add

the

0.1

mm

shim thickness corresponds

to

the

1

degree

of

crankshaft angle advance.

Injection

pump

Cylinder

block

Engines & Generators

52

WARNING

ALTERNATOR

The Captain Control Panel indicates alternator low dischaIge

I with a red warning

The

Admiral

perfonnance

COOlANT

A coolant temperature switch housing. the coolant's operating temperature reaches approximately

2100P

(99°C).

WARNINGS

light.

Control Panel

of

the

alternator.

TEMPERATURE

This switch will activate a continuous alarm

uses

SWITCH

is

LIGHTS,

a voltmeter

located

on

to

monitor the

the thermostat

ALARMS

&

LOW

A low oil pressure alarm switch block. This switch's sensor monitors the engine's pressure. Should the engine's oil pressure (0.4 -

alarm.

if

CIR~UlT

OIL

PRESSURE

0.7

kgfcm'), this switch will activate a pulsating

BREAKER

ALARM

SWITCH

is

located

fall

on

the engine

to

oil

5 -

10

OIL

PRESSURE

SWITCH

.,.~

psi

AlARM

TOALAR'M

BUZZE5.~

ENGINE

The DC harness on the engine is protected mounted manual reset circuit breaker Excessive current draw or electrical overload anywhere the instrument panel breaker because the opened breaker disconnects the fuel this After repairing engine.

to

should

TWO

WIRES

CIRCUIT

trip. In

occur,

BREAKER

wiring

this

check and repair the source of the

the

fault,

by

(20

arnps

or engine wiring

event most engines

reset the breaker and restart

will

an engine

DC).

cause

shut

down

supply.

problem.

the

BREAKER

in the

If

~

WESTERBEKE

Engines & Generators

53

STARTER

MOTOR

DESCRIPTION

The sttuter

• A motor section which generates a drive

• An ovemmning clutch section whicb transmits

lUre tmque, preventing motor overrun after starting.

• A switch section (solenoid) whicb is operated wben actu-

ating

supplies load current to

The

high-speed internal-reduction starter. The pinion shaft

3I8Ie

ion

sIIoI4

shaft

exposed smoothly without becoming fouled with dust and grease. The motor

lever

are

identical to conventional ones.

AD.IISIMENT

If

any

should be disassembled and

Piaion

1.

'Connect a battery (12V) between the starter

and and

A

I

·

--

2. tightly

stroke (called pinion

3.

If

2.0 mm), adjust of number

can

be roughly divided into the following sections:

power.

the overrunning clutch through a lever

the motor.

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

ftom

the motor

A reduction gear is installed between the motor

and

a pinion

outside

shaft is supported

mech8!!ism,

almormaIity

shaft;

the pinion

shaft.

The

pinion sliding part is not

the starter so that the pinion may slide

at

both

switch and overrunning clutch inner circuit

AND

REPAIR

is found by the following tests, the starter

ends

slides

on

ball

only on the pin-

bearings. The

repaired.

Gap

Inspection

the starter

stop.

c:AIJID:

body,

IlI1rtI1t

apply

and the pinion drive should rotate out

battery.

w/tage tor

t:III1lImIoIIsI

push

the pinion

shims

on

of

the pinion

gap

it

the solenoid

shims

bsck

and

measure

the return

gap).

is not within the standmd range, (0.5 to

by increasing

increases.

or

decreasing the number

The

gap is decreased

an

arma-

and

whicb

is

called a

is

terminaI

over

10

as

the

sep-

S

No-Load

1.

Connect as illustrated.

2. When the switch the starter must the current or starter semble

r-----------I

A

tighten e'l8ry type

that

starter

In contact

Test

the

ammeter,

the

starter and repair

CAUTION:

starter

of

Use

tetminal

whlt:h

a

dITBCt-dri'18

rotation

wfth

voltmeter,

is

closed, the pinion must protrude and

run smoothly (at

speed

thick

wires

SllCursly.

makes

a

type

at

the

pinion

the

pinion

and

battery

3000

rpm or

is

out of specification, disas-

it

SAnERY

as

mut:h

as

This

is a

rotating

stalter.

gsar when/t

sound

When

dllfflcting

tip, be careful not

protrudes.

SOLENOID

Perform the following satisfactory, replace the solenoid assembly.

1. lnspect the solenoid for continuity between

(+) and

M and the

between between terminals the

(-)

and between terminals S and the body.

terminals

body.

tests.

If

any test result is

There should be

S and

M.

Continuity will

S

and

the

body and

no

continuity

terminaI

to

the

more).

1-----,

possible

solBl/oid

loudsr

to

not

terminals

body

found

be

found

M and

starter

If

and

shift-

than

come

and

GENTLYPUSH

BACK

1.5:2.D

....

PlalOaGAP

NOTE:

Disconnect

2. Connect a battery to and M for The pinion drive should extend

A

CAUTION:

than

10

seconds

,,,,,,,1WESTERBEICE

i Engines & Generators

54

MUlTIMETER

the

wire

the

(-).

Have

a switch

Do

not

apply

when

testing

from

terminal

solenoid's terminal S

in

battery

the

M.

the + lead fully

out

current

solenOid.

and

for

(+)

close

mote

it

') . AT11IACTION

3.

lEST

Holding

minal

S (+)

pinion

fully.

jlYben

released from holding

test.

With

and

to

The

pinion must

a

b8ttery

the starter

~

COIINECTDR

connected

body,

remain

with

to

the solenoid ter-

manually pull out the

at that position even

your hand.

STARTER

MOTOR

4.

OFF

Return

minal M

fully.

pinion when

released

test:.

With

a battery connected

(-)

and

to

the starter

The pinion must return

from

holding

body,

by

hand.

to

the

manually

to

its

original

solenoid

pull

out the

position

ter-

. 2. Loosen

)

STARIER

L

Discon....,.

the

3.

Remove fas1r:ning

4. WlIh

remove the yoke

the

5. Remove washer.

6.

Unscrew same

adjustmeDt will

DISASSEMBLY

the

solenoid assembly.

the

brushes pulled away from

armature

the

time,

~CI)NNECTOR

the

wire from the solenoid terminal M (-).

two screws fastening

two long through bolts and two screws

the

brush holder. Remove the rear bracket

and

brush holder assembly. Then pull

out

cover, pry

the

bolts and remove the center bracket

the

washers

come

the

f~

off.

the

solenoid. Remove

the

armature,

snap

ring out, and remove the

the pinion shaft end play

At

OFF

the

7. Pull out

front

8.

On the

pinionandpinionsrurll

9.

At

a bearing

press-fitted

off,

bracket

pinion

each

replace

the

reduction gear lever and lever

side,

end

of

the

puller.

in the front bracket

the front bracket

RETURN

pry the snap ring

armature.

It

is impossible

TEST

remove the

assembly.

TERMINALM

Ii

to

that

out,

replace

bearing

spring

and

ball

the

from the

pull

out the

bearing

ball

bearing

has

worn

with

WEAR & CfflP"ING.

STARTBI

.

II011IR

SNAPRIUn_-~~""'-Y

LEVER

SPRING

)

PINION

Engine,s & Generators

55

NOTE:

Jnspect,

if

necessary

solenoid,

Jollawing

c/eOJl

brush,

COTTU1UJ!er,

Ql77U2ture,

pages.

and

elc.

replace

See

the

STARTER

MOTOR

STARlER

INSPECTION

Solenoid

Inspect

the

solenoid for continuity

and

between

M be

found

between

Inspecting

L

S

and

Check.the

c:ircuited,

between

insulated,

Tbe

aonature with a growler

repIace

the

repIace

between

tenninals S and

S and

M.

the body and M and the

body.

Continuity

Annature

the

8IlllllIDre.

C(>IIl1IIlloicator

the

armaIlIre.

and

Also

its shaft.

terminals S and

No

continuity should

should

be found

body.

tester.

If

it's

check:

for insulation

If

poorly

short

Brush

1.

Brush Height

StlJlUiard

limit

and

Check the

replace

the

17

6 nun

Brush

Holder

brushes.

nun

(0.669

(0.236

in)

If

worn

in)

BRUSHES

2.

Check the brush spring tension. A spring will cause excessive brush

if

suspect

/CRIICUS

Inspection

out beyond the

weak

or

wear;

replace

CLOTH

service

defective

the

limit,

springs

2.

Measure

Repair

check:

rouglmess.

aocus

the commutator O.D. and the depth

or

repIace4t

the

comm1i1ator

If

cloth.

if

the service limit is exceeded Also

outside

rough, polish the commutator with fine

surlace

CoIlUlUllDr

StiuuIIlrd:

D~

.l·

.....

ce limit: -1.0

ARMATURE

CHECK

of

undercut

for dirtiness and

O.D.

StJuulJzrd

38.7

nun (1.523 in)

nun

(-0.039

3. Check for and holder assembly.

in)

BRUSH

HOLOER

ASSEMBLY

insulation

base.

If

Also

check

between the positive

poorly insulated, replace

the

brush holders for

brush

holder

the

holder

proper

staking.

1~/WES)SFlBEKE

, Engines & Generators

56

Field

Coil

1.

Check coil

and

2. Check of

the

3.

Check

Inspection

for

insulation between

yoke.

for

continuity between

coil

the

poles

and

coil

for tightness.

one

both

end

ends

(brush)

(brushes)

STARTER

of

the

MOTOR

2.

A

terminals,

Greasing.

apply

a.

b. All

c.

d. e.

f. Sliding portion of

Whenever the starter

grease

to

the

following

Armature shaft gear

bearings.

Bearing Bearing sleeves. Pinion.

CAUTION:

shaft

washers

Never

bnIshes,

Slllear

I1r

has

parts:

and

reduction

and

snap rings.

lever.

the

starter fitting

c/JlRlllutatl1r

been overhauled,

gear.

~rface,

with

grease.

.

FIELD

COIL

TEST

STARTER

A

CAUTION:

stalter old

and

Reassemble disassembly,

1.

flange

paint,

depends

cient size

Pinion

gap) washer

. a. Fit

b. Measure end play

I1n

fully

shaft end play adjustment. Set the end play (thrust

to

between

the

ting

to

axiaI increase

ADJUSTMm

IJeforB installing,

and

mollJltfng

aad

IU$I. Starter

the quality

aIJd

grade

tig/ttBn

direction.

to

the

starter assembly in

making sure

0.5 to 2 mm the center bracket

pinion shaft, reduction gear washer and snap

the

center bracket

the

number

AND

REASSEMBLY

thl1lDUghly

SIIrfat:es,

perflJrmanCB

111

the

wiring.

between

the

by

If

the

rellll/nal.

of

the

following:

by

moving the pinion shaft in the end

play

of

adjusting

reml1w

largely

Use

battery

the

inserting an adjusting

and

reverse order

and

the reduction gear .

exceeds

washers

clean

wire

0.5 inserted.

the

alillil,

111

suffi-

starter

of

mm,

3. After again.

WASHER

SNAP

RING

--~I~-O.5

reassembly,

PINION

check

SHAFT

by

conducting a

GEAR

mm

MAX

END

PLAY

no-load

test

..

,.~/WESTmBEKE

I Engines & Generators

57

DESCRIPTION

Dual

outpw

and

high output alternators optional alternators add-on

Dual

balteries

cbarge

equipment

can

equipment

alternators

at

the

each

set

on

be

installed

at anytime.

can be

same time

of

batteries

IISTAl1ATlON

If

an

optional simply engine

If

the

new

the-boat"

instructions

L Disconnect

battery.

2.

Remove output

3.

Install

4.

Attach a alternator's output indicated.

dual

alternator has already

follow

the

WESTERBEKE

installation

instructions.

dual alternator is

engine,

carefully

below:

the

alternator

[positive]

the

new

heavy

alternators negative cable

alternator.

most

WESTERBEKE

during

configured

or,

separately.

being

follow

and

cable.

Do

gauge

terminal

DUAL

are

factory

using a battery

added the

disconnect or

not

output

[s].

assembly

to

charge

been

wiring

to

alternator installation

reuse.

cable[s]

Using

the

OUTPUT

available

engines. These

two banks of

selector

diagram

an

from

tape

as

or

as

switch,

factory installed, .

and

existing ''in-

the

off the

from

the

cable

sizes

TO

the

ALTERNATORS

CABLE

TO

BATTERY

(POSITIVE

I

SPACER BRACKET

DUAL

OUTPUT

[CHARGING

ONE

TO

MOUNTING

PULLEY

ALTERNATOR

BAnERY]

(ALWAYS

S.

Make cable the

positive cable.

6.

Mount location.

a. Connect

alternator.

A

CAUTION:

Ilut

first

b.

Plug

certain it

c.

The the

d..

The which to

WESTERBEKE

connection.

Dual

Pulleys

A

variety chaIging dealer.

USE

FINE

STRAND

CABlEl

certain that the batteries negative post ground

to

the

engine block is

the

regulator to a flat surface

the

black

DIl

nllt

fJ1/Junding

the

red

"battery sense"

batteries

brown

actuates

a switched [+]

the

2-pin connector into is

firmly

positive [+] post [or

wire "keyed ignition"

the

12

WIRING

of

accessory pulleys for

alternators are available

the

wire

to

the

CIInnect

regulatllr.

seated.

wire

regulator,

volt

source.

DIAGRAM

from

same

heavy

gauge

ground

any

pllwer

the

alternator,

in a cool

dry

terminal

stJUTeB

make

should be connected

the

positive

is

the

key

circuit

this

wire

must

connect

Refer

to

the

for the proper

high

powered

and

your

as

on

the

with-

to

cable].

dual

BATTERY 1 ___

TO

--:::;-~

""".!fila"..

~ONNECTS

.

Z.-"",WIJ~E

WIRE OIL

DUAL

OUTPUT

[CHARGING

TO

LEADS.

CONNECTS

PRESSURE

PINK

THE

CONNECTS

BUZZER.

SWITCH.

ALTERNATOR

TWO

BAnERIES]

AND

PINK

TO

THE

TO

THE

BLUE

THE

Engines & Generators

58

DUAL

OUTPUT

ALTERNATORS

TROUBLESHOOTING

NOTE:

Before

troubleshooting,

belts

are

tight

and

the

batteries

Regulator

The

red "battery sensing" wire A connects

must

presen~

The

orange

volts

incorrec~

The blue

voltage load/rpm. key

on, 0 volts

KEY

ON • NO

KEY

OFF·

REGULATOR

Tennlnal/Color

I

Brown

A

Red

S

Orange

F

Blue

Alt.OUlpUi

Testing

always

read

battery voltage.

trace

the

wire

for a bad connection.

wire S should read 0 volts with the

[approximately]

trace

wire F supplies current to the alternator

will

vary

The

VOLTAGE

BATTERY

TEST

with the key

the

wire

depending on the battery charge or actual

readings can vary from 4 to

with

the key off.

REGULATOR

VOLTAGE

POINTS

AND

IgnJUon

011

0

volts

12.6

volls

o

valls

Ovolls

12.6

valls

mrzke

are

for a bad connection.

REGULATOR

PROPER

IgnRion

2

·12

12

vulls

o

valls

10

·11

12

valls

certain that

in

good

If

battery voltage

on.

If

the readings are

IS

DEFECTIVE

IS

DEFECTIVE

VOLTAGE

Engine

On

valls

14.2

6·8

4 ·12volls

14.2

valls

the

condition.

to

the

battery,

key

fields,

12

volts

Running

volls

valls

Valls

volls

drive

is

not

off,

with

12

its

the

it

Alternator

The regulator is functioning properly

are

in

1.

Test the off·key on. the voltage should

2. Hold a

If

.no~

[open

3.

Start the indicate

indic~te

Apply a should

indicates

Testing

good condition.

voltage

The

in

the

read

the

same.

screw

driver close

voltage

the

problem

circuit].

14.2

the

load

maintain

is

present you

engine,

volts

alternator is

such

the

alternator is

at

the

alternator plug with

voltage

at

plug

[blue

should

may

be

the

at

fast idle

[no

load]. A reading

not

as

an

electric bilge pump,

least 13.8

the

wire

[112"]

brushes

the

performing

faulty.

alternator terminal F

to

feel

output terminals should

volts.

NOTES:

o

When

the

engine

is

first

for the

is

a

noticeable

RPM

gauge

o A slight

on

the

aitel71lllOr.

altel71lllOr

change

will

excite.

whine

is

normlll

to

started,

"ldck

in

in"

the

when

it

and

sound

running

and

the batteries

the

F]

from

the

the alternator

the magnetic

[worn]

of

12.6

properly.

13

volts

or

takes

a few

take

the

load.

of

the

engine

with

a full load

engine

regulator

pulley.

field.

or

the

would

the

voltage

less

moments

There

and

If

rotor

the

o

When become

o

When purchase

the alternator is

very

hot.

replacing

and

the

altel71lllOr

replace

producing

dual

belts

high

drive

in

amperage,

belts,

matched

always

pairs.

it

will

t'fllV'IWESTERBEKE

I Engines & Generators

59

+

II

vot

Y

n.

.•.

Ii

IJ

;;

=

"

.n

ft.

, .

SUIT

...

~'"

...

,

:

"~k

...

~

i

'i

lJ.=:J

'1[101[101

SIlIrCti

(

WIRING

SCHEMATIC

STAIIT

~

m.

S1ARTCA

r-,

~@---------

J ' I

1

-----,

~-"

PItHtAl

r-,SOl.

~~:

~-~

...

C.B

•

~

"

i

AtT.

~

"

~

"

..

::f,~

04 02

=

"

~

r,~;

"61'

~~~~

J

G'L'OW';L!G'S

ALttRNA10R

.

~~

LIH

PUMP

P

1 1

1

1 1 1 1 1 1

J.

TH[

'[IIK

WIR[

AT

~LUG

2

IS

InIUUD

AIID

SHOULD

BE

INSUUl(D,

C~"A[N

'ANtl

ONLY

•

4.

THE

GRAY

.IRE

AT

'lUG

2 IS UMusro

UD

SHOULD

lit

INSULAl(D, AOKIUL 'ANEL OIIU.

r---J.-----,

TO

ALT.

I

,

.,,-

TeRM.

I

rU[L

InUl

S~'e-II,!!O.!.._

U

J

~gf~

I

fl~

,I'

I

~L!.

\::::::U-

~

1:

S~~EA

/"":0..

""';::;:

,[IIDU

difcH

X",..I"

1 1

lAC_ora

•

."

VOLTMUtA

+

."

..1.

GAUGE

...

':~M~R

I

""

~

lESf

".

"

n

"

=

1

_I

I

lQBP

1

30B~

ONl'/

I

'.MIIV6i

I

-----------

ADMIRAL PANEL

CAPTAIN PANEL

.'4

LT.

BLU

fl4

PINK

.,0

R[O

.1.4

BRN

@pRESTOI

ITE

72

AMP

AI

T

,,4

8RN

~14

GRA

1114

PINK

414

LT.

8L

@

It

I YfjRSAl

PROPUI

S I

Wr

PR

STO

ITF

51

AMP.

A

51

AMP.

AI

TERNATOR

ST"NOARO AllERtiA10R

ON

TilE

638

01.

63C Il'.. i

IB

IT.

826

IT,

1086

D. & 10SC

~.

",-UN

,

•

WIRING

SCHEMATIC

#39144

,~

AtD

',sruuW::

lWIT~';.'W,)

19

OPT

IONAI

AI

IERNATORS®

'J~A,

1&0.1.,

I!OA.

ltsT[1I

ALHRNAlORi

AVAI'An'{qM

1H!

no

rv

ue

ty

liB

II

UB

ty

,nRD

I

'9MjXIQNI~

~

WESTERBEKE

'Englnes & Generators

60

~

- - - -

YIl-----,_

16'

$[[

HOH

2:~

I$j

1 1

1

·\~v~

aA!.ll!!

NOTE:

An

on-off

swiI&h

should

be

installed

in

this

circuft

to

disconnect

the

slllrterflOm

the

battel}'

in

an

emergency

and

when

leaving

the.boat

Twelve

volt

engine

sIllrte,.

typically

dtaw

200

to

300

amps

when

etanking.

A

switch

with

a

continuous

tating

of

175

amps

at

12

vac

will

normally

serve

this

function,

but a swiJch

must

never

be

used

to

"make'

the

sIllrter

circuit

WIRING

DIAGRAM

&I.'Wf.?A

Q

II

flQSURC

mID

-1+

·~.iI."!H!l''-

+ -+ - --- ---

1

I·

"

ADM I RAL PANEL

r~I'

I~

1 " ,

IU

N

ME

MODELS)

! !

rT

PUlAI'

WIRING

DIAGRAM

#39144

CAPTAIN

PANEL

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

r~~f~~~==R-:

o 1

~

WESTERBEKE

Engines &

Generators

61

1 1

1 1 1 1

TACHOMETEB,IIIOUR

The

tachometerlhour meter used in propulsion engine

ment

panels

contains two separate electrical circuits

common other volts alternator charging voltage supplied on

'The from

.tachometer

the

volts

The

a fault meter.

Hour

Oteck terminals.

L

2.

Tachometer

Check for the proper

terminal

L

2.

3.

4. Check electrical connections

ground.

the

tachometer.

the back

alternator producing battery charging voltage

following

Voltage VolIllge

nections

terminaJ

of

the instrument

tachometer circuit operates

one

of

the

diodes

input terminal while the engine is running,

DC.

are procedures to

in

eithei-

of

meter

Inoperative

for

the

proper

present - meter is defective - repair or replace. not present - trace (+) and

for fault (Jump

to verify

Inoperative

and

(-)

terminal with the engine running.

Voltage

tion

AC

output

Check

ground

minaI

present - attempt adjusting meter through calibra-

access

hole.

voltage

not present - check for proper alternator

voltage.

for

AC voltage

to

alternator connection.

METER

One circuit operates the hour meter

The hour meter circuit operates

to

on

AC

voltage

in

the alternator

the two circuits in a tachometerlhour

DC

voltage between (+)

12

volts

the

operation.)

AC

voltage between tachometer input

No results,

repair

at

tach terminal

and

follow

when

(-)

electrical

DC

to meter (+)

or replace

on

from

tachometer input ter·

TACHOMETER

instru-

with

and

on

12

the (+)

terminal

6-8

volts,

supplied to the

and

13.0-14.8

troubleshooting

and

(-)

con-

meter.

DC

alternator

to

a

the

fed

NOTE:

Cumn! model

dial

10

set

the

tachometer

calibrating

TACHOMETER

NOTE:

the

tachometer

engine's rpm

In

a

screw

new

is

then

CHECK

installntion

may

not always

This

calibration

instal1ntions.

1.

Warm

up

the

engine

Remove

cloth

pulley

2.

Start

3.

Aim confirm tachometer using instrument

is

bring

any

specks

and

place a

to

facilitate

and

idle the

the light of the tachometer

the

engine

reading.

the

instrument

reading

showing.

the

instrument

Then

tachometers

10

used for

(New

use a coarse

the

crankshaft

fine

tuning.

Installation)

having

new

be

comctly

should be

to

normal operating

on

the crankshaft

piece

of suitable

use

of a photoelectric type

engine.

speed.

Check the instrument

Adjust the tachometer

coarse

to

the closest

use

the

fine

to the exact reading

reflecting

onto

adjustment

R.P.M.

calibration

adjustmen!

pulley

insrrumen!

calibrated

checked

pulley

the

in all

temperature.

with a clean

tape

tachometer.

refiecting

in

the

to

calibrate

that

the adjustment as

the

rpms.

The

TERMiNAl

panels.

10

new

on

the

tape

panel

the

photo

to

photo

the

to

by

tach

tach.

Tachometer

1. Check

terminaJ

2.

Check

terminaJ

3.

Check

alternator pivot

Sticking

for

proper

AC

voltage between "tach inp."

and

(-) terminal.

for

good ground connection between meter

and alternator.

that alternator is well

bolt

grounded

Tachom~lnaccurate

a.

With

a hand-held tach

pulley

retaining nut or with a strobe-type tach, read the

front

crankshaft pulley !pm at

b.

Adjust the

driver

the tachometer.

indicated idle

"tachometer

through the calibration

by

the strobe or hand

and

at

high

Zero

speed

the tach

on

the

front

idle.

with a

SmaIl

access

and

tach.

and adjust the

to

engine block at

of the crankshaft

PbilIips type

hole in the rear

bring it

to (Verify tach

as needed).

the

~

!pm

(-)

screw-

of

!pm

at

WESTERBEKE

Engines & Genellltors

62

WESTERBEKE

51A

MANDO

ALTERNATOR

FAN

HOUSING

DISASSEMBLY

REAR

HOUSING

.

ASSEMBLY

COVER

AND

TESTING

A

WARNING:

hot.

Do

A

WARNING

certain away

A

WARNING

DC

and applications. isolate before

made

not

touch

that

everyone

from

sheaves

AC

Circuits

Always

DC

and

AC

performing

without

proper

A

failed

alternator

until

the

alternator

Before

starting

is

clear

and

belts

Multimeters

are

otter

disconnect converters DC

testing.

knowledge

the

of

moving

during

and

DC

mixed

shore

and

No

AC

of

can

become

has

engine,

parts!

test

Circuits

together

power

shut

down

tests

AC

circuits.

very

cooled

down.

make

Keep

procedures.

in

marine

cords,

generators

should

be

EXCITER

TERMINAL

TERMINALP

I

COVER

SENSING

TERMINAL

GROUND

TERMINALE

TESTING

1.

2. Wiggle the engine wiring harness while observing the

NOTE:

alternator

for

tightness and cleanliness, panicu/arly battery clamps and battery terminals. Inspect the alternator drive belt for excessive wear

for proper belt tension.

THE

OUTPUT

Connect the positive voltmeter lead to the output terminal B and connect the negative lead to the ground terminal E on the alternator.

voltmeter, The meter should indicate the approximate battery voltage, and should not vary.

or

if

obtained, output circuit for loose damaged wiring.

Prior

system

the reading varies, check the alternator

to

any alternator

wiring for

CIRCUIT

or

dirty connections

testing,

defects.

and

replace

If

no reading is

or

inspect the

Check all connections

if

necessary. Also adjust

entire

cable

REFER

TO WIRING WIRING

TESTING

1. Connect the positive (+)voltmeter lead to the excitation

2. Tum the ignition switch to the

3.

4.

THE

DIAGRAMS

HARNESS

terminal R on the alternator and the negative (-) lead to the ground terminal E on the alternator.

voltmeter reading. The reading should be volts (see illustration).

If

the

rotor field circuit probably is shorted or grounded. Disassemble the alternator and test the rotor described under CLEAN AND TEST

COMPONENTS in this section.

If

the

field circuit probably and inspect it for worn brushes

Replace the brushes

. long.

tion, disassemble the alternator and test the rotor, outlined under CLEAN AND TEST ALTERNATOR

COMPONENTS

FOR

THE

CONNECTIONS

THE

reading

If

the brushes and slip rings are in good condi-

ABOVE

EXCITATION

is

between .75

is

between 6.0

in

this section.

CIRCUIT

on

and

is

open. Remove the regulator

or

if

they are less than l/4in.

position and note the

1.3

to

1.1

volts, the

as

ALTERNATOR

7.0 volts, the rotor

dirty slip rings.

(6

2.5

mm)

as

Engines

63

& Generators

MANDO

ALTERNATOR

SERVICE

TESTING

5.

TEST

Perfonn this test to determine operating correctly, using a

NOTE:

voltage reading with a battery chargeror allow the engine to run a sufficient length reading.

1. Connect the positive (+) voltmeter lead to the positive

2. Start the engine and run

3.

4.

THE

EXCITER

H

no

reading

aliernator-excitation lead

the regulator. Disconnect the lead from exc terminal

Connect the positive voltmeter lead to the excitation lead and the negative voltmeter lead to ground terminal

E.

If

the voltmeter now indicates an approximate. battery voltage, the voltage regulator replaced. circuit for loose

If

VOLTAGE

The battery

of

time to fully charge the battery before taking a

battery terminal and the negative

the

negative

reaches its normal operating temperature. Adjust the

engine speed to 1500 - 2000 rpm and observe the voltmeter for the highest reading. The reading should be between 13.7 and 14.7 volts.

If

the reading is high, check for a loose alternator ground lead connection. good, the voltage regulator is faulty and must be replaced. attempting to remove the alternator.

If

Be

the reading is low:

LEAD

is

obtained,

no voltage is indicated, check the excitation

or

dirty connections

an open exists in the

or

in the excitation circuit

is defective and must be

or

damaged wiring.

of

REGULATOR

if

the voltage regulator is

0 -

20

volt

DC

voltmeter.

must

be

folly charged to obtain a proper

in this test.

terminal.

sure to disconnect the battery cables before

If

necessary, charge the battery

(-)

voltmeter lead to

it

at fast idle until the engine

or

dirty

If

the connection is

a. Stop the engine and remove the alternator wiring

connections.

b.

Remove the Phillips cover screw from the regulator

cover (see illustration).

c. Remove the nut from the output terminal and the

nut

from

the

sensing tenninal,

(A).

d.

Remove another nut from the sensing terminal, and the nut from the excitation terminal.

and

remove

Jumper

R.

e. Remove the regulator cover.

f.

Temporarily re-install Jumper (A) and all associated nuts. Leave Jumper

g. Remove the plastic plug from the side

regulator.

b.

Connect a jumper between the top brush lead and the ground.

JUMPER

A

(B) installed.

COVER

SENSING

TERMINAL

......

GROUND

\

I

CONNECT

JUMPER

WIRE

..

\

REGUlATOR

PLASTIC

i.

Repeat steps 1 and 2.

NOTE:

j.

If

now obtained, the voltage regulator is faulty and must be replaced.

14.5 volts, inspect the brushes and slip rings for wear, dirt or damage. are good, the alternator is fault internally. Disassemble the alternator and test the components, as outlined in this section. .

PLUG

Do

not

let the voltage exceed 16 volts.

a voltmeter reading

If

LEAD

FROM

BRUSH

of

14.5 volts or above is

the voltmeter reading

If

the brushes and slip rings

of

the

--OUTPUT

TERMINAL

B

is

below

Engines & Generators

64

MANDO

ALTERNATOR

SERVICE

REMOVE

1. Disconnect the negative

I 2. Disconnect the wiring leads.

ALTERNATOR

(-)

battery ground cable.

3. Loosen the screws. Holding the alternator, rotate it

toward the engine and

4. Remove the screws and washers and remove the alternator.

SCREWS

CAPACITOR

ASSEMBLY

~~~~IftRE~~~~~~,,=

COVER

'fff:~ll§A:;;-~

lift the belt

off

the pulley.

~~

TERMINAL

10. Place

11. Use a 7/8 in. box wrench to loosen and remove the

12. Remove the pulley nut, lockwasher, pulley, fan, and

A

more

winding

an

oversized V-belt around the pulley and fasten

the pulley

pulley nut.

spacer.

in

PUUEY

CAUTION:

than

1/16

could

a vise.

AND

DO

in.

(1.6

result

FAN

COMPONENTS

NOT

insert

screwdriver

mmJ.

Damage

from

deeper

blades

to

the

stator

penetration.

DISASSEMBLE

1. Remove the tenninal nuts to remove the jumper (see

illustration).

2. Remove the remaining tenninal nuts.

3. Remove the capacitor.

4. Remove the Phillips screw from the regulator cover.

5. Remove the brush/regulator-assembly cover.

6. Remove the nut from the terminal.

7. Remove the jumper.

8. Remove the !enninal insulators.

9. Remove the two Phillips screws and remove the brush/regulator assembly.

ALTERNATOR

V-BELT

NOTE:

Score the stator. and the

the unit

13. Remove the four through-bolts and carefully pry the

may

be reassembled correctly.

front housing away from the screwdrivers.

'Y';;:::::::::::-/

SCREW

DRIVER

HOUSING

14. Carefully push the rotor assembly out housing and rear housing.

AND

STATOR

front

and rear housings so

rear

housing using two

11.._--

k--FRONT

REMOVAl

of

the front

nl:lln

HOUSING

PUllEY\

REMOVAl

NOTE:

If

the bearing is removed from the housing. a new

bearing

15.

Engines & Generators

must

After removing the three bearing locking screws, care fully press the front bearing

against

65

be installed.

the

inner

race

of

the

out

of

the housing. Press

bearing.

BEARING

DRIVER

MANDO

FRONT

ALTERNATOR

BEARING SCREWS

BEARING

LOCKING

SERVICE

2. Inspect and test the diode-trio assembly:

3.

Using a commercial diode tester, a 12-volt DC test lamp or an ohmmeter, check the resistance between each

of

the three diode terminals and the indicator

light stud.

DIODE

TERMINAL

DIODE

TRIO

ASSEMBLY

light stud

16.

Remove the rectifier assembly by removing the Phillips screw and lifting

RECTJRER

ASSiMBLY

CLEAN

1.

AND

Inspect

brush

.

(6

.

cracked

Test for continuity between I and 2, and 3 and 4 using

3 test lamp

a good brush/regulator assembly; replace the complete assembly,

and test the brush/regulator assembly. The

set

may

mm)

or

if

out

the assembly.

RECTIFIER

TEST

ALTERNATOR

be

reused

longer. The brushes must not

gt"9Oved.

or

an ohmmeter. These checks will indicate

necessary.

REMOVAL

if

the brushes

COMPONENTS

are

be

HOUSING

1/4 in.

oil soaked,

b. Reverse the tester leads and repeat the resistance

checks.

c. A very low resistance should

direction and a very high resistance should

in

cated

If

d.

complete assembly. Do not attempt to replace individual diode.

3. Test the diode-rectifier bridge as follows:

3.

b. Reverse ·the tester leads and repeat Step

the other direction

any diode appears to be defective, replace the

Using a commercial diode tester, check for continuity from each ouput terminal.

TERMINAL

be

indicated in one

if

the diodes are nonnal.

of

three terminals to the

OUTPUT

be

indi-

an

RECTIFIER DIDOES

3.

c. Continuity should exist in only one direction and

all diodes should check alike.

d.

Perfonn the same continuity checks between the three terminals and strap ground terminal. This should show continuity in only one direction

through the diodes and all diodes should check

alike.

If

any diode appears to be defective, replace the

e.

rectifier assembly.

TESTING

BRUSH

ASSEMBLY

Engines

66

& Generators

MANDO

ALTERNATOR

SERVICE

4,

Clean

and inspect

the

front

and

rear housings: 0

a. Inspect the rear

housing

for

cracks or breaks in the

casting, stripped

threads

or a damaged bearing bore.

Replace the housing

if

any

of

these conditions exist.

b. Inspect the front

housing

for cracks, stripped or'

damaged threads

in

the

adjusting

ear,

or

an

out-of-

round

bore in the

mounting

foot.

If

possible,

correct slightly

damaged

threads

using

a tap.

Replace the housing,

if

necessary.

e.

If

the

housings

are

to

be reused, clean them in

solvent and

dry

with

compressed

air.

S.

Clean and inspect

the

rotor shaft bearings:

NOTE:

Do

not

use a solvent

on

the

rear

rotor bearing

since

it is serviced

as

a unil

wilh

Ihe

rOIOr.

a

..

The

bearings should be

wiped

clean with a lint-free

, cloth containing a

moderate

amount

of

commercial

solvent. Do not inunerse a bearing

in

solvent, or

use

pressurized solvent

or

air.

b. Check the bearings

for

obvious damage, looseness

or rough rotation. Replace a bearing

if

any doubt

exists as to its condition.

NOTE:

If

the rear

rolor

bearing

needs

replacement,

rep/oce

the

entire

rolor.

6. Inspect the belt pulley

for

rough

or badly worn belt

grooves or keyway,

and

for

cracks or breaks. Remove

minor burrs

aild correct minor surface damage; replace

a badly worn or damaged

pulley.

0

FRONT

BEARING

7.

Test

the

stator windings

as

follows:

a. Using

an

ohmmeter

or

test lamp, check for

continuity between

all

three

leads

(I,

2,

and

3).

A

lo~

ohm reading or lit test

lamp

should be

observed.

HOUSING

b. Check

the

resistance

from

each

lead

(I,

2,

and

3)

to

the laminations

(4).

There should be

no

continuity

if

the

insulation is good.

e.

Inspect

the

stator windings

for

signs

of

discoloration.

A discolored winding should

be

replaced.

d.

If

a

winding

shows a high resistance or

an

open

circuit between any

two

of

the

three

winding

terminals or indicates poor insulation

between

the

windings

and

the

laminations,

the

stator

must

be

replaced.

8. Check

the

rotor assembly

as

follows:

NOTE:

If

slip

rings

need

10

be

replaced,

you

must

replace

the

entire

rotor.

a. Visually inspect for physical

defects

such

as

dam-

aged shaft threads,

worn

or damaged

bearing

areas,

burned or pitted slip rings or scuffed pole

fingers.

b. Measure the winding resistance across

the

slip rings

(A).

Place the ohmmeter leads

on

the

edges

of

the

slip rings, not

on

the brush contact surfaces. The

correct winding resistance at

70 -80° F (21

-

27° C)

is

4.1

to

4.7 ohms.

c. Minor burning or pitting

of

the slip ring

surfaces

can be removed using a

croCus

cloth.

Thoroughly

wipe

the

slip rings clean afrer polishing,

removing

all grit

and

dust.

.

d.Check

for a grounded slip ring

or

rotor

winding

by

measuting the resistance from

each

slip

ring

to

the

rotor

body

or pole

finger

(B). An

open

circuit should

be indicated in both cases for a

good

rotor.

o

e.

If

the windings are defective or physical

damage

cannot be corrected, replace

the

rotor

assembly.

9.

Use a

comm!,rcial

capacitor checker

to

test

the

capacitor

for

capacity, shorts, leakage,

and

series

resistance.

INTERNAL

CIRCUIT

WIRING

Engines & Generators

67

MANDO

ALTERNATOR

SERVICE

ANGERS

TESTING

ASSEMBLE

1. Carefully press the front bearing inta the front housing,

THE

pushing

Lock the

driver.

TORQUE:

25 -351lrin (2.8 -

ROTOR

ALTERNATOR

agajnst the bearing's outer raoe using a hearing

bearing

in place with screws.

4.0

Nm)

2. Place the rotor (pulley end up) on the bed press, on two steel blocks.

3. Press the front housing and bearing assembly down onto the rotor shaft. race only, using a sleeve driver. Take care to insure that the rotor leads clear the steel blocks.

SLEEVE

DRIVER

ROTOR

INSTAlliNG

4. Install the rectifier assembly into the rear housing.

5. Insert the Phillips screw and tighten

THE

FRONT

Press against the bearing's inner

HOUSING

ON

THE

of

FRONT

HOUSING

BEARING

ASSEMBLY

ROTOR

it.

an

arbor

ASSEMBLY

AND

FRONT

BEARING

ASSEMBLY

FRONT

BEARING

HOUSING

BEARING SCREWS

BEARING

LOCKING

RECTIAER

ASSEMBLY

6.

Assemble the front and rear housings

a.

Put the siator winding in the front housing with the stator leads away from the front housing and the notches in the stator laminations aligned with the four through-bolt holes in the housing.

b. Align the scribe marks you made

front and rear housings during disassembly.

c. Slip the rear housing into place over the rotor shaft.

Align the mounting holes and put the stator leads

through the holes at the top

d. Install the four bolts and tighten them.

TORQUE:

NOTE:

will not

35·

651b·ft

(4.0·

7.3

If

the front housing is

be

tapped.

Nm)

as

follows:

in

the stator, and

of

the rear housing.

new,

the through-bolt

ASSEMBUNG

THE

BEARINGS

Engines & Generators

68

MANDO

ALTERNATOR

SERVICE

7. Install the spacer and the lockwasher and nut onto the shaft. Tum the nut a few turns.

an

8. Place the pulley

9. Use a torque wrench to the tighten the nut.

TORQUE:

10. Carefully install the brush/regulator assembly on the rear housing with the two mounting screws.

11.

install the small terminal insulators.

12. Install the large terminal insulator.

13. Install the jumper.

14. Install the nut on the

15. Install the brush/regulator assembly cover.

16. Install the Phillips screw for the brush/regulator

assembly cover.

TORQUE:

17. Install the capacitor.

18. Install the tenninal nuts.

19. Install the jumper.

20. Install the last terminal nut.

oversized V-belt around the pulley and fasten

in

a vise.

INSTALLING

35·50 Ilrtt (47 - 68

25 -

THE

351b·tt

(2.8 - 5.1

fan.

PULLEY

AND

Nm)

terminal.

Nm)

Then push the pulley,

'OVERSIZEO

THE

FAN

NUT

INSTALL

1. Install the alternator, screws and washers.

2. Connect the wiring leads.

3.

4. Adjust the alternator belt's tension (see

Battery

Maximum

Cutin

Reg. Ambient Ground

ALTERNATOR

Put the belt on the alternator, crankshaft and coolant pump pUlleys.

DRIVE BELT

ADJUSTMENT under

MANDO

Vollage

Speed

Set

Vollage Temp.

ALTERNATOR

Speed

ENGINE

12

von

13500

RPM

Max.

2000

Max.

1500

14.7Votts

-2O'C

·10O'C

Negalive

ADJUSTMENTS).

SPECIFICATIONS

RPM

(at

exc.)

RPM

(at

l2)

Engines

69

& Generators

TORQUE

Kg-m

DATA

(Ib-H)

I

(13.7 -

1.9-2.9

21.01

I

CYUNDER

i

1.5-2.5

~10.8

-18.01

BLOCK

I

AND

2.5

(1B.O

OTHER

-3.5

-25.3)

COMPONENTS

CYUNDER

HEAD

ANo.CYUNDER

HEAD

COVER

7.0-

9.0

- 65.0)

(50.6

~

WESTERBEKE

Engines & Generators

70

POSitiOning)

(

pIn.

0.8-12

15.8-8.4)

.~

TORQUE

Kg-m

DATA

(Ib-H)

CYLINDER BLOCK

~hiS

Don't remove

(

from

connecting rod.

bolt)

1

t

AND

OTHER COMPONENTS

COOLING FAN

AND

WATER

PUMP

17.0

-19.0

1123.0 - 137.4}

(.):

Apply

(Important)

IApplV engine oi'l.I

Locktite No.262

To cylinder head

to

set

up side

of

stud.

t.:..:::::...=",

[(1::~:~OII

Engines & Generators

71

(With

PTO

provided)

TORQUE

Kg-m

(Ib-II)

r--=-I

0.8---=-=-12

.

(5.8-8.7)

~I

----

.

DATA

Q-ring;

control lever

GASKET LOCATION

Corrugated

washer

LOCATIONS

.,.

~.

••

~.

WHERE

----"

18

GASKETS

Gasket;

joint bolt

ARE

=ield~i!!I

Gasket;

water

outlet

pipe

\

USED

''''

Oil

seal;

crankshaft front

O-ring;

Oil

pump

Engines & Generators

72

I plug

Gasket;

exhaust

silencer

1.

Carefully grease.

2.

Apply a

threads

3.

Tighten torque)

4.

Draw a line

5.

Draw to be line

waSh

coat

and

the

with a torque.

~-+--

another

clamped.

(A-B).

ANGULAR

the

nuts

and

of

molybdenum

setting

faces

of

nuts

and

bolts

to

wrench.

CENTER

LINE

(A-B)

across

the

line

(C-D)

on

TItis

line

should

NUT

bolts

to

remove

disulfide

the

nuts

and

the

specified

~--~C

center

of

the

face

of

be

an

AND

all

oil

and

grease

to

the

bolts.

torque

(snug

LINE

l

each

bolt.

each

of the

parts

extension of the

BOLT

TIGHTENING

6.

7.

D

Draw

another line

to

be

clamped.

specified

bolt

Use a socket point

Example'

angle

where

Specified

A B C D E

METHOD

(F-G)

TItis

line

will be

(Q)

across

wrench

the

30· 60·

90·

180·

360·

line

to

tighten

(A-B)

Angle

on

the

is

and

1112

1/6 1/4

112

One

ofa ofa ofa

face

of each of

in

the

center

(E) of

each

nut

aligned

with

Tightening

ofa

tum

tum tum

tum

full

tum

the

parts

direction

the

or bolt

the Rotation

of

nut

to

line

the

or

the

(F-G).

~

E

COMPRESSION

U

VALVE

COINCIDING

ptl

15

GUIDE

GAUGE

SEAL

LINE.

ADAPTER

SmlNG

TOOL

G

TOOLS

CONTACT INFORMATION

AND

TESTING

REAR

OIL

WITH

DRIVE

THE

Apply a coat of molybdenum disulfide grease threads and setting faces

GEAR

IS><

SEAL

SmlNG

HANDLE

WESTERBEKE ON

THESE

TOOL

CORPORATION

AND

OTHER

SPECIAL

FOR

TOOLS

of

the nuts and bolts.

FRONT

DlL

WITH

SEAL

DRIVE

HANDLE

SmlNG

to

the

TOOL

Engines & Generators

73

STANDARD

NOTE:

The torque values given in the following table should be

cation

Bolt

diameter

pitch (mm)

~

M 6 X

M

8X1.25

M10 X

X

1.0

1.25

BOLTS I TIGHTENING

~

0.6 ±0.2

1.3

±0.5

2.8 ±0.7

~

07.+

·

16

·

33

·

0

,2

-0.3

+0.4

-0.6 +0.8

-0.9

TORQUE

appli~d

SPECIFICATIONS

where a particular torque is not specified.

~

08

+0.2

·

-0.3

18

+0.5

·

-0.6

38

+0.9

·

-1.0

~

09

+0.2

·

-0.3 +0.5

2.1

-0.7

4.3 ±0.9

.

kg

m

~

--

2.4 ±0.7

5.1

±1.3

"M10 X 1.5

M12 X 1.25

*M12 X 1.75

1.5

M14 X

*M14 X 2.0

M16 X

*M16 X 2.0

M18 X

*M18 X 2.5

M20 X

*M20 X 2.5

M22 X 1.5

*M22 X 2.5

M24 X 2.0 45.8

*M24 X

1.5

~.5

1.5

3.0

19.2

26.3 ±5.3 30.0

24.3 ±4.9

32.0=1~:~

27.8

43.1

2.7 ±0.7 3.2 ±0.8 3.7 ±0.9 4.2 ±1.0 77

62

+1.3

.

-1.2

5.8 ±1.2 6.3 ±1.2 +2

9.7

-1.9

9.1

±1.8 9.8 ±1.9

13.3

+2.7

12.7

±2.5

19.2

±3.8

±5.6 37.6 ±7.5

±9.2

±8.6

67

+1.4

·

-1.3

10.4

-2.1

15.1

±3.1

14.4

±2.9

+4.4

21.7

-4.3 +4.4

21.8

-4.3 +6.1

27.8

=~:;

40.4

±8.1

47.9=1~::

45.1

±9.0

+2

-6

+1.6

·

-1.5

7.2

±1.4 8.2

11.9

=;:!

11.2

±2.2

17.3

±3.5

16.5 ±3.3 18.8 ±3.8

24.9

±5.0 28.4

25.0

±5.0

34.4

±6.9 39.2

31.8 ±6.4 36.3

=~:;

46.3

43.1

±8.6

54 9 +17.6

·

-11.0

51.7 ±10.3

88

+1.8

·

-1.7 ±1.6

13.6

=;:~

12.8 ±2.5 13.6 ±2.7

19.7

±4.0

±5.7

28.5 +7.9

-7.8 +7.2

-7.3 10

528+

i

·

1

i

I

-10.6

49.1

±9.8

626+20.

·

-12.6

589+11.

·

-11.7

4.9

±1.2

97

+1.9

.

-2.0

9.1

±1.8

14.5

±2.9

20.4

±4.1

19.5

±3.9

29.3

±5.9

29.4

=~:~

±8.1

40.4

37.4 ±7.S

5

.

1

8

54.1

50.3

70.6

66.4

±10.8

±10.1

±14.1

::!:13.3

.

NOTE:

Bolts marked with an asterisk are used

for

female threaded parts made

~

WESTERBEKE

Engines & Generators

74

of

soft materials such as castings.

.

TIGHTENING

TORQUE

SPECIFICATIONS

NOTE:

The

torque

values given

in

the following

table

should

be

applied

where

a particular

torque

is

not

specified.

FLANGED

HEAD

BOLT

kg·m (lb ft!N·m)

~

®f'

~

@!'

marking

Nominal

=.XDitch)

M6

x1

0.5-0.9

0.6-1.2

---

(3.61-a50/4.6

-8.5)

(4.33-8.67/5.88-11.76)

Me

x 1.25

1.1-2.0

1.4-2.9

1.9-3.4

(7.95-14.46/10.78-19.61)

(4.33

-8.67/5.88-11.76)

(13.74-24.59118.63-33.34)

M10x1.25

2.3-3.9

3.6-6.4

4.3-7.2

(17.35 - 28.20/23.53 - 38.24)

(26.03-44.12/35.30-59.82)

(31.10-52.07/42.16-70.60)

""10

x 1.5

2.3-3.8

3.5-5.8

4.1-6.8

(16.63-27.48/22.55-37.26)

(25.31-41.95/34.32

-56.87)

(29.65-49.18/40.20-66.88)

M12 x 1.25

5.6-8.4

7.9-11.9

8.7-13.0

(40.50

-60.75/54.91-82.37)

(57.14 -86.07/77.47

-116.69)

(62.92-94.02l85.31-127.4P.)

"'12

x 1.75

3.5-9.5

7.3-10.9

8.1-12.2

(37.61-56.41/50.99

-76.49)

(52.80

-78.83/71.58-106.89)

(58.58-88.24/79.43

-119.64)

M14 x 1.5

8.5-12.7

11.7-17.6 12.6-18.9

(61.48-91.85183.35-124.54) (84.62-127.301114.73-172.59) (91.13 -136.701123.56-185.34)

.14x2

7.6-11.5

11.1-16.6 11.8-17.7

(57.14-85.34/77.47-115.71 )

(80.28-120.06/108.85-162.79) (85.34-128.02/115.71-173.57)

M16x1.5

11.8-17.7 17.1-26.5

18.0-27.1

(85.34 -128.02/115.71

-173.57)

(125.85-189.50/170.63

-256.93)

(130.19-196.01/176.52

-265.76)

"'16x2

11.2-16.7

16.6-24.9

17.2-25.7

(81.00-120.791109.83-163.77) (120.06-180.101162.79-244.18) .

(124.40 -186.611168.67

-253.01)

A bolt with

an

asterisk 1*)

is

used

for

female

screws

of

soft material such as cast iron.

)

~

WESTERBEKE

Engines & Generators

J.5

STANDARD

AND

LENGTH·DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(It)

x

.305

=

Meters

(m)

Miles

x

1.609

=

Kilometers

METRIC

(mm)

x

.0394

x

3.281

=

Feet

(km)

x

.0621

=

Miles

CONVERSION

=

Inches

DATA

DISTANCE

1 1

EQUIVALENTS

Degree

of

Latitude

Minute

of

Latitude

VOLUME

Cubic

Inches

(in') Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

(US

Quarts

(US

Gallons

(IMP

x

pt)

(US

(IMP

29.573

x

qt)

gal)

MASS·WEIGHT

Ounces

Pounds

(oz)

x

28.35

(Ib) x .454 = Kilograms

PRESSURE

Pounds

Inches Inches Inches Inches Inches

Per

Sq

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

In

(psi)

(H.o)

(fi,0) x

(H20)

= = 1

x

16.387

pt)

qt)

.473

x

.946

x

=

(Hg) (Hg)

60

x gal) gal)

=

3.785

Grams

x

x x

x

Nm

=

111.120

Nm

=

1.852

=

Cubic

.568

=

lfters

x

1.137

=

lfters

x

4.546

=

x

1.201

=

US

x

1.201

=

Millilfters

= lfters(l) x

= lfters (l) x

6.895 .4912

3.377

.07355 .03613

.248

x

=

Liters

(g)

x

(kg)

=

Kilopascals

=

psi

=

Kilopascals

=

Inches

=

psi

=

Kilopascals

km

Centimeters

(l)

x

1.76

(L)

x.88

Uters

(l)

x

Quarts

(US

US

Gallons

.034

=

Ounces

2.113

=

Pints

1.057

=

(l) x

.264

=

.035

=

Ounces

x

2.205

=

Pounds

(kPa)

x

2.036

=

(kPa)

of

Mercury

x

27.684

=

(kPa)

x

.061

=

IMP

=

IMP

.22

=

qt)

(US

gal)

Quarts

Gallons

x

.145

Hg

x

.2961

x

H20

x

4.026

=in'

pt

qt

IMP

gal

x

.833

x

=

13.783

=

.833

psi

=

Hg =

H20

IMP

=

H20

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

(It-Ib)

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUa

CONSUMPTION

Miles

Kilometers

Miles Kilometers

Per Per

(Hp)

Hour

IMP

Per

lfter

Gallons

Per

lfter

x

US

.745

TEMPERATURE

Degree

UQUID

WEIGHTS

Diesel

Fresh Gasoline Salt

Water

Fahrenheft Celsius

Oil

= 1

Water

= 1

US

= 1

US

(OC)

gallon

US

gallon

US

gallon

(oF)

=

(in-Ib)

x

1.609

=

(MPG) (KmIL)

(MPG)

(KmIL)

=

(OC

(OF

-

=

7.13

gallon

=

6.1

=

x

.113

=

1.356

=

Kilometers

Kilowatts

x

.354

=

x

2.352

x

.425

x

2.352

X

1.8) + 32

32) x .56

Ibs

=

8.33

Ibs

8.56

Ibs

Newton

(Kw)

Kilometers =

=

Meters

Per

x

1.34

IMP

MPG

Kilometers

US

MPG

(Nm)

Hour

=

MPH

Per

Liter

Per

(Nm)

x

(KPH)

(Km/l)

Liter

x

8.85

.738

x

.621

(Km/l)

=in-Ib

=

It-Ib

=

MPH

~

WESTERBEKE

,Engines &

76

Ge.nerators

ENGLISH

TO

METRIC

CONVERSION

CHART

Multiply

Dearee Fahrenheit

Multiply

Inch/second'CinJsec'1

MultiDlv Pressure or stress

Inches

Pounds/S...ll!Jare Mulliel-

British Thermal Unit IBtu)

kilowatt-hour (kW·hr)

MuitiDIv Fuel Performance

Gallons/mile (eaVmilel

Temperature

(0",

Acceleration

FooVSecond'(ftlsec')

Multiely

Pound-inch(lb·in.)

Pound-foot Multiply

Horsepower (hpl

Fool:J!.ound (ft·lbl

Mull.iJ!ly

Foot candle (fc)

Miles/aal Imile/oaJ)

Multiely

Mlles/hour (mllelhrl

Toraue

Power

of

water fin. H

Enerav

Vetocltv

IIb·1t)

in.

or

Ught

liMn.')

Work

,0)

By

(OF-32\

By

0.3048

0.0254 By

0.11298

1.3558

By

0.746 By

0.2491

6.895 By

1055

1.3558

3,600,000.

3.6 x

10'

By

1.0764 By

0.4251

2.3527 By

1.6093

: 1.8

or

To

aet eauivalent

Dearee Celsius °C\

To get eouivalent number

Meter/second'(mfs')

Meter/second' Imfs')

To

eel eauivalent

Newton-meters (N·m) Newton-meters

To

eet eaulvalent

KilowaHs

To

g~t

~quivalent

Kilopascals IkPal Kilopascals

To

aet

equivalent

Joules IJ) JoulesJJ\.

Joules

To aet eQuivalent number of:

Lumensimeter'lImfm'l

To

get_eguivalent

Kilometersllner (kmlLl

LHerlkilometer (Ukml

To

oet eauivalent

.

Kilometerslhouf (kmlhr)

(J

IkWI

= one

number

IN·m)

number

(kPll)

number

W/s)

number

of:

Mul!!I!!Y. LenAlh

Inch lin.1

Fool

Iftl

Yard Iydl

Mile (mile)

Mul!!I!!Y

Multiply

'Gallon

Mulliply

.

Multiply

Kiloaram Ike)

Area Inch'lin.') Inch'lin.'l

Foot'ift'l . 0.0929

Yard'Cyd'l

Volume Inch'lin.') Inch'lin.') Inch'lin.')

Quart lat)

iaah

Yard'lvd') . 0.7646

Mass

Pound

Ob)

Ton

/ton)

Ton

lion)

Force

(oz\

Ounce

Pound lib)

By

25.4

0.3048

0.9144

1.609 Kilometers Ikml By

6452

6.45'

0.8361

fa

16387

16.387

0.0164

0.9464

3.785

By

0.4536

907.18

0.907 B.Y

9.807

0.2780

4.448 Newtons

To

aet eaulvalent

Millimeters Imm)

Meters

1m)

Meters Iml

To

aet eauivalent

MilJimeters'lmm')

Centimeterslfcm

Meters'im'l Meters'tm'l

To

oet eouivalent number of:

MiJlimelers'lmm')

Cenlimelers'(cm')

LHers

III

LHers

(Ll

LHers

(Ll

Melers'lm'l

To

aet

eauivalent number of:

Tonne

(ko\

ttl

INl

Kjoorams

Kiloarams Ikol

To

aet equivalent number of:

Newtons INl

number

2

\

of:

Engines & Generators

77

INDEX

A1airms Alternator Alternator Circuit Compression Cooling

Dual

Engine Engine

Air Alternator .

Camshaft Crankshaft Bearing Cylinder Head Assembly Cylinder Head Diagram External Parts Diagram Lubrication Dipstick .

Drive Pulley

Engine Adjustments Engine Tuning External Parts Diagram Filter Flywheel . General Information Idle Gear Injection Pump . Internal Parts Lubrication Diagram . Oil Filter Oil Pan Oil Pipe Oil Pump Piston and Connecting Piston Rings Pump Oil Pump Water Push Rod Solenoid Starter Thermostat Timing Gear Case Transmission Tuning the Engine Water Pump

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

Dual

Output

Thsting

Breaker

System

Output

Adjustments Assembly

Intake Filter

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

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

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

and

Air

Intake

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

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

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

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

and

Strainer

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

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

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

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

and

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

Engine

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

Alternator

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

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

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

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

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

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

Shaft

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

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

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

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

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

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

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

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

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

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

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

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

Repair

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

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

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

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

Rod ................

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

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

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

53 58 63

.53 Crankshaft

50 40

.58

50

25 Piston .41 Piston Ring .37 Piston Pin .30 Timing Gear .31 Timing Gear Backlash

26-36 Transmission

.33 Valve .34 .39 Camshaft

16 Connecting

28,29 Connecting

30 .38 Crankshaft Gear .34 Cylinder Block . .41 Cylinder Head .32 .39

17 Oil Seal

.35 Piston, Piston Pin, Piston Ring

28,29 Piston Ring Gap

.39 .34

. .33

.33

.32

25-27 25-31

.33

.40 .33 .35 .37

36-41

.32 .38 .38 .36

Engine

Camshaft

Idler Gear End Play Injection Pump . Internal Parts Drawing Measurements

Engine

Crankshaft

Heat Shield Hot Plug

Ring Gear Rocker

Tappet Timing Gear . Valve, Valve Seat Valve Spring

Engine Engine Flywheel Front Fuel FuelInjection Fuel Fuel Gasket Glow

Compression Disassembly

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

End

Play

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

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

and

Connecting

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

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

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

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

Inspection

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

Rod

and

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

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

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

Arm

and

Push

Valve Seal

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

Specifications Troubleshooting

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

Oil

Seal

Filter

Lift System

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

Pump

Location

Plugs

and

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

Bearing

Crankshaft Bearing

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

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

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

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

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

Rod .......................

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

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

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

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

Pump

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

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

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

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

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

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

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

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

Rod ...................

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

Repair

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

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

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

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

...........

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

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

.50

10

.13

.11

11

.11

12

11

14

.14

14

.13

11

10 .13 .15

20

22 .15 .23

24 .15 .15

17

16,17

.24

21

22

24

20 .19

24

17

18 .19

.4

6 .30 .32 .48 .48 .48 .43

72

.49

Engines & Generators

78

INDEX

Governor Idler Injection Injection Testing Injection Timing Metric Nut Oil

Pressure

Oil

Seal

Overhaul Parts Pump

Raw

Rocker Schematic Wiring Siphon Specifications Engine Standard Starter Tachometer Tappet Timing Injection Tools Torque Transmission Valve Warning Wiring Wiring

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

Gear

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

Pump

Conversion

and

Bolt Tightening Specifications

........

Identification

Raw

Water

Arm

Break

Torque Specifications

Motor

and

Data

Clearance

Lights Diagram Schematic

Fuel

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

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

Chart

..........

:

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

Testing

Water

Pump

Head

Test

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

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

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

Bracket

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

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

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

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

Gasket

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

Gear

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

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

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

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

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

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

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

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

·

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

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

Assembly

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

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

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

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

........

.43 .30 .48 .49

52

76,77

73

.50

32

5 2

.41,42

41,42

33

60

3

4

74,75

.54

62

.33

52 73

70

10

51

.53

61 60

'""

WESTERBEKE

Engines & Generators

79

)

\

I

i

)