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Westerbeke Diesel 55c Four Operator's Manual




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SERVICE and 55eFOUR
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 AlMM Metnf National Marin Manufacturers Association
CALIFORNIA PROPOSITION 65
gas from diesel and
gasoline engines and some of
its constituents are known to
the State of California to cause
cancer birth defects and harm
gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine also recommends installing DETECTORS in the quarters
of your vessel They are inexpensive and at your local marine store
Engines Generators
SAFETY INSTRUCTIONS
INTRODUCTION PREVENT BURNS FIRE
Read this safety 11Ul1Iual carefully Most accidents are
caused by failure to follow fundamental rules and A WARNING Fire can cause injury or death
precautiJJns Know when dangerous conditions exist and
toke the necessary precautiJJns to protect yourse1 your Prevent flash fires Do not smoke or permit flames or
personnel and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in comp1iance with pump or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council ABYC stondards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel filters
PREVENT ELECTRIC SHOCK Do not operate with a Coast Guard Approved flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do nut touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will burn
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions from fuel vapOIS can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a double throw after fueling Check below for fumesvapor before
transfer switch Damage to vessels AC generator may running the blower Run the blower for four minutes
result if this procedure is not followed before starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a well
ventilated area away from equipment
PREVENT BURNS HOT ENGINE and out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING Do not touch hot engine parts or Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
exhaust system components Arunning engine gets spill DO NOT allow any smoking open flames or other
reryhot sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
Always check the engine coolant level at the coolant fuel system
recovery tank
Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
A WARNING Steam can cause injury or death Be certain fuel line fittings are adequately tightened and
free of leaks
In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas
Dr death
Disconnect the battery cables before servicing the engine Ensure that the exhaust system is adequate to expel gases
generator Remove the negative lead first and reconnect discharged from the engine Check the exhaust system
it last regularly for leaks and make sure the exhaust
elbow is securely attached
Make certain all personnel are clear of the engine before
starting Be sure the unit and its surroundings are well ventilated
Run blowers when running the generator set or engine
Make certain all covers guards and hatches are
reinstalled before starting the engine Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA24 Consult your
BATTERY EXPLOSION boat builder or dealer for installation of approved
detectors
A WARNING Battery explosion can cause injury For additional information refer to ABYC T22
ordeath educational information on Carbon Monoxide
Do not smoke or allow an open flame near the battery
being serviced Lead acid batteries emit hydrogen a A WARNING Carbon monoxide CO is an invisible
highly explosive gas which can be ignited by electrical odorless gas Inhalation produces ulike symptoms
arcing or by lit tobacco products Shut off all electrical nausea or death
equipment in the vicinity to prevent electrical arcing
during servicing Do not use copper tubing in diesel exhaust systems Diesel
Never connect the negative battery cable to the fumes can rapidly destroy copper tubing in exhaust
positive connection terminal of the starter solenoid systems Exhaust sulfur causes rapid deterioration of
Do not test the battery condition by shorting the terminals copper tubing resulting in exhaustwater leakage
together Sparks could ignite battery gases or fuel vapors Do not install exhaust outlet where exhaust can be drawn
Ventilate any compartment containing batteries to prevent through portholes vents or air conditioners If the engine
accumulation of explosive gases To avoid sparks do not exhaust discharge outlet is near the waterline water could
disturb the battery charger connections while the battery enter the exhaust discharge outlet and close or restrict the
is being charged flow of exhaust Avoid overloading the craft
Avoid contacting the terminals with tools etc to prevent Although diesel engine exhaust gases are not as toxic as
bums or sparks that could cause an explosion Remove exhaust fumes from gasoline engines carbon monoxide
wristwatch rings and any other jewelry before handling gas is present in diesel exhaust fumes Some of the
the battery symptoms or sigus of carbon monoxide inhalation or
Always tum the battery charger off before disconnecting poisoning are
the battery connections Remove the negative lead first Vomiting Inability to think coherently
and reconnect it last when disconnecting the battery
Dizziness Throbbing in ACID Headache Muscular twitching
Nausea Weakness and sleepiness
A WARNING Sulfuric acid in batteries can cause AVOID MOVING PARTS
severe injury Dr death
When servicing the battery or checking the electrolyte A WARNING Rotating parts can cause injury
level wear rubber gloves a rubber apron and eye or death
protection Batteries contain sulfuric acid which is
destructive If it comes in contact with your skin wash it Do not service the engine while it is running If a
off at once with water Acid may splash on the skin or situation arises in which it is absolutely necessary to
into the eyes inadvertently when removing electrolyte make operating adjustments use extreme care to avoid
caps touching moving parts and hot exhaust system
Engines Generators
SAFETY INSTRUCTIONS
Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NfPA and USCG publications
for safety codes and standards Follow their
Make sure all attaching hardware is properly tightened
Keep protective shields and guards in their respective when installing your engine
places at all times ABYC American Boat and Yacht Council
Do not check fluid levels or the drive belts tension while Safety Standards for S1IaU Craft
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is runuing hair and clothing can easily 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection Association
HAZARDOUS NOISE Fire Protection Standard for Motor Craft
IWARNING High noise levels can C81S8 hearing
Order from
NfPA
II Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United Slates Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARNING Do not nt lin macIJinlll1 when ytlU are
fIT pJysItal by fatigue
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your peratOIs Manual along with other cautions and
notes to highlight critical information Read your manual
carefully maintain your equipment and follow all safety
procedures
GASOUNE ENGINE AND GENERATOR Preparations to instaII an engine should begin with a
thorough examination of the American Boat and Yacht
Councils ABYC standards These standards are a
combination of sources including the USCG and the NfPA
Sections of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust Systems
P4 InboanI Engines
E9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust 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 exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failare to use a siphonbreok 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 ofthe boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure
Failure to properly maintain a siphonbreak can result in catastrophic AVAILABLE FROM
YOUR damage Consult the siphonbreak manufacturer for proper maintenance 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
Adetailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
I Engines Generators
TABLE OF 4
Testing for Overhaul Alternator Inspection 10
Engine Measurements 11
Prior to 11
Injection Pump 11
Engine Disassembly Exploded View 12
Engine Inspection and Repair 15
Engine Assembly Sealants and Lubricants 25
Bolts and Fasteners 25
Engine Assembly Exploded View Assembly External Parts 34
Engine Assembly Engine Tuning Diagram System System Governor Drawing 46
Engine Testing Compression 50
Oil Pressure 50
Valve Clearance 51
Injection TIming 52
Warning Lights Alarms Circuit Breakers Motor Output Alternators Schematic Diagram Testing Data and Bolt Tightening Method Torque Standard
Metric Conversion Formulas WESTERBEKE
Engines Generators
PARTS INTAKEAIR AlTER
OIL UUI PRESSURE CAP
THERMOSTAT
ASSEMBLY
1c
ElBOW
10 PLATE
EXCHANGER
CONNECTION REAR
ANODE
RAW WATER DD
COOlER
FRONT
LEFT SIDE
WATER INJECTED
EXHAUST
PREHEAT uNUU
AIR INTAKEAIR rlLltH All
THERMOSTAT
FUEL UFT PUIRP
2DACIRCUIT
REAR BREAKER
Fua AlTER
fRONT
SHIFT lEVER PUllEY
Oll T1
OIL All
OIL COOLER
OllSSURE
SENOOR
MOUNT
RIGHT SIDE
Engines Generators
INTRODUCTION
PRODUCT SOFTWARE RAW WATER CODLING SYSTEM
Product software technical data parts lists manuals SiphonBreak
brochures and catalogs provided from sources other than For installations where the water injected exhaust elbow is
WESTERBEKE are not within WESTERBEKES control close to or will be below the vessels waterline provisions
WESTERBEKE CANNOT BE RESPONSIBLE FOR mE must be made to install a siphonbreak in the raw water
CONTENT OF SUCH SOF1WARE MAKES NO WAR supply hose to the water injected exhaust elbow The siphon
RANl1ES OR WITH RESPECT break provides an air vent in the raw water cooling system to
THERETO INCLUDING ACCURACY TIMEliNESS OR prevent raw water from filling the exhaust system and the
COMPLETENESS mEREOF AND WIUIN NO EVENT engines cylinders when the engine is shutdown
BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WIm OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOF1WARE A CAUTION Failure to use a siphonbreak when
WESTERBEKE customers should keep in mind the time the exhaust manifold injection port is at or below the
span between printings of WESTERBEKE product software load waterline will result in raw water damage to the
and the unavoidable existence of earlier WESTERBEKE engine and possible flooding of the boat
product software The product software provided with
WESTERBEKE products whether from WESTERBEKE or
other suppliers must not and cannot be relied upon exclu If you have any doubt about the position of the water
sively as the definitive authority on the respective product It injected exhaust elbow relative to the vessels waterline under
not only makes good sense but is imperative that appropriate the vessels various operating conditions install a siphon
ofWESTERBEKE or the supplier in question break This precaution is necessary to protect your engine
be consulted to determine the accuracy and currentness of the The siphonbreak must be installed in the highest point of a
product software being consulted by the customer hose that is looped a minimum of 20 inches 51cm above
the vessels waterline This siphonbreak must always be
SERIAL NUMBER LOCATION above the waterline during all angles of vessel operation to
prevent siphoning
The engines model number and serial number are located on
a nameplate mounted on the side of the engines manifold
NOTE A siphonbreak requires periodic inspection and
cleaning to ensure proper operation Failure to properly
The engines serial number can also be found stamped into
maintain a siphonbreak can result in catastrophic engine
I the engine blOck on the flat surface of the block just forward
damage Consult the siphonbreak manufacturer for proper
of the number one cylinders injection pump Take the time to
maintenance
enter this information on the illustration of the nameplate
shown below as this will providea quick reference when SIPHONBREAK
seeking technical information andor ordering repair parts PART NO 033327
SIPHONBREAK WITH STAINLESS
LOOP FOR 34 HOSE
PART ORDERING PARTS
Whenever replacement parts are needed always provide the
engine modelnumber 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 as original flY WESTERBEKE
Engines Generators
558 ENGINE
Type Diesel water cooled four cycle four cylinder
inline overhead valve type
Fuel Diesel fuel I catane rating of 45 or 133 cubic inches 2179 liter
Fuel Injection Pump BOSCH PFR Type Indirect injection
Injectors Throttle System Swirl chamber
Fuel Rner Primary full flow spinon element
Bore Stroke 335 x 378 incheS85 x 96 mm
Air cleaner Replaceable paper Angle of Installaon Notto exceed 14
Fuel Uft Pump Solid atate with extemal fitter
Max Angle of Rotaon Not to exceed 30 for 30 minutes
Rring Order 1342 COOLING of Roon when viewed
from flywheel General Fresh watercooled with tube and shell type
heat Shaft Right hand direction of rotation
Operating Temperature 170 190 F77 88 Rao 2151
Fresh Water Pump Centrifugal matal impeller type Naturally Aspirated
Raw Water Pump Positive displacemen rubber Speed Idle speed 8501000 RPM
bendriven
CruiSing Speed 20002500 RPM
No load speed 3200 RPM neutral System Capaclly 725 US qts Consumpon 15 US gph running at 2500 RPM
approx Sea Water Row 80 85 gpm 302 321Ipm
when the propeller used allows the engine to at 3000 rpm measured before discharging into water
tum at 3000 RPM at full open throttle underway injected exhaust elbow
in inches mm Hght 233 inches 592 mm LUBRICATION SYSTEM
Engine Only Width 186 inches 472 mm General Forced lubrion bY Trochoid type pump
Length 270 inches 687 mm
Oil Rtter Full flow 448 Ibs 2032 kgs
Sump Capeclly 8 US qts Row Engine Combuon 116 cfm 33 cmn not including fitter
Engine Cooling 200 cfm 56cmm
Opemting Oil Pressu re 43 85 psi 290 590 KPa
engine hot
TUNEUP Oil Grade API Specifion CF or CG4 SAE
30 Pressure 441 psi 304 MPa
Oil Cooler Fresh water cooled
Valve Timing
Intake Opens Open at 15 BTDC Close 29 ABDC Closes Open at 40 BTDC
Close 16 ATDC
General ZF Marine Transmission case hamened Timing 16 BTDC
gears with a multiple disc
Nozzle Injector Pressure 1920 psi 132 MPa clutch
Valve Clearance 00157 inches 04 mm Gear Ratio atandam 1881 cold
Propeller 18 x13P2blade RH or 18 x l1P 3 blade RH
Propeller used should allow the engine to
ELECTRICAL SYSTEM reach its full rated RPM 3000 000 100 at
full open throttle while underway in Battery 12 Vott negative ground gear
Battery Capacily 400 600 CCA min Lubring Ruid Automatic transmission fluid type Dexron
DC Charging Altemator 50 Amp rated bettdriven 12V or III
Glow plugs 12V sheathed Transmission Sump
Starting Aid Capacity 075 US qts 079
12 von 18 KW wh solenoid
Cold Cranking Amps 175 200 Regulator Intema regulator buitt into altemator
EXHAUST Elbow 45 elbow
Exhaust Hose Size 30 10 hose
Exhaust Gas Flow 265 cfm at 3000 RPM
Muffler Size min 14 x 14
WESTERBEKE
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL CONDITIONS
Cause of Low Compression Compression pressure tends to increase a little in a new
Genenilly the time at which an engine should be overhauled engine until piston rings and valve seats have been broken in
is determined by various conditions such as lowered engine Thereafter it decreases gradually with the progress of wear
power output decreased compression pressure and increased of these parts
fuel and oil consumption The lowered engine power output When decrease of compression pressure reaches the repair
is not neoessarily due to trouble with the engine itself but is limit the engine must be overhauled
sometimes caused by injector nozzle wear or injection pump The engine requires overhaul when oil consumption is high
wear The decrease in compression pressure is caused by blowby evident and compression values are at minimum or
many factors It is therefore necessary to determine a cause below 558 FOUR COMPRESSION PRESSURE
or causes on the basis of data produced by periodic 441 PSI 304 MPa NORMAL AT CRANKING
inspection and maintenance Oil analysis on a seasonal basis SPEED OF 250 RPM
is a good means of monitoring engine internal wear When 441 PSI BETWEEN CYLINDERS
caused by worn cylinders or piston rings the following DISASSEMBLY
symptoms will occur 1 Before disassembly and cleaning carefully check for
1 Low engine power output defects which cannot be found after disassembly and
2 Increased fuel consumption cleaning
3 Increased oil consumption 2 Drain water fuel and oil before disassembly
4 Hard engine starting 3 Clean or wash the engine exterior
5 Noisy engine operation 4 Do not remove or disassemble the parts that require no
These symptoms often appear together Symptoms 2 and 4 disassembly
can result also from excessive fuel injection improper injec 5 Perform disassembly in a proper order using proper tools
tion timing and wear of the injectors They are caused also Keep disassembled parts in order Apply oil when neces
by defective electrical devices such as the battery alternator sary Take special care to keep the fuel systern parts from
starter and glow plugs Therefore it is desirable to judge the intrusion of dust and dirt
optimum engine overhaul time by the lowered compression 6 Parts must be restored to their from
pressure caused by worn cylinders and pistons plus increased which they were removed at disassembly This means that all
oil consumption Satisfactory combustion is obtained only parts must be set aside separately in groups each marled for
under sufficient compression pressure If an engine lacks its component so that the same combination or set can be
compression pressure incomplete combustion of fuel will reproduced at assembly
take place even if other parts of the engine are operating
properly 1b detennine the period of engine overhaul it is 7 Pay attention to marks on assemblies components and
important to measure the engine compression pressure regu parts for their positions or directions Put on marks if
larly At the same time the engine speed at which the mea necessary to aid assembly
surement of compression pressure is made should be checked S Carefully check each part or component fore any sign of
because the compression pressure varies with engine rpm faulty condition during removal or cleaning The part will
The engine rpm can be measured at the front end of the tell you how it acted or what was abnormal about it more
crankshaft accurately during removal or cleaning
NDlE To test engine compression see the ENGINE ALTERNATOR INSPECTION
ADJUSTMENT section of this manual
When rebuilding the engine the alternator should be cleaned
ASSEMBLY and inspected The housing can be wiped off with a solvent
and the alternator terminal studs should be cleaned with a
1 Wash all parts except for oil seals Orings rubber sheets wire brush Make certain the studs are tight and clean the
etc with cleaning solvent and dry them with pressure air wiring connections that connect to the wiring harness
2 Always use tools that are in good condition and be sure
Thm the rotor pulley by hand It should tum smoothly
you understand how to use them before perfonning any
job Depending on when the alternator was last serviced the
brushes may need replacing If the alternator is at all suspect
3 Use only good quality lubricants Be sure to apply a coat
send it to a service shop for testing and overhaul
of oil grease or sealant to parts as specified
For additional information on alternators refer to the
4 Be sure to use a torque wrench to tighten parts for which
ALTERNATOR and MANDO
torques are specified SERVICE in this manual
5 Ant time the engine is assembled new gaskets and
Orings must be WESTERBEKE
Engines Generators
ENGINE following chart describes relating to engine service the probable causes of
these problems and the to overcome NOTE The engines electricol system is protected by a 20
these problemsThis chart may be of assistance in determining ampere 1IIl11IJJo1 reset circuit breaker The preheat solenoid is
the need for an engine oveIhaui mounted on the same bracket
PROBLEM PROBABLE CAUSE lIARD STARTING lOW CRANKING SPEED
1 Engine oil viscosity too high 1 Replace engine oil wh less viscous oil
2 Rundown battery 2 Recharge battery
3 Worn battery 3 Replace battery
4 Battery terminals loosely connected 4 Clean terminals and correct cables
5 Defective slarter 5 Repair or replace slarter
DEFECTIVE INJECTION SYSTEM
1 Airtrapped in fuel passage 1 Bleed air from fuel system
2 Clogged fuel fmer 2 Clean or replace filler
3 low injection pressure 3 Adjust injection pressure
4 Inadequate spray 4 Clean or replace nozzle
5 Injection pump delivering insufficient fuel 5 Repair or replace injection pump
6 Injection too earty 6 Adjust injection timing
MAIN ENGINE TROUBLES
1 low compression
a Incorrect valve clearance a Adjust valve clearance
b Inadequate conlact of valve seat b lap valve
c Valve stem seized c Replace valve and valve guide
d Broken valve spring d Replace valve spring
e Compression leaks through cylinder head gasket e Replce gasket
I Piston ring seized I Replace piston and piston ring
g Worn piston ring and cylinder g Overhaul engine
2 Burnt glow plug 2 Replace glow plug
3 Faulty glow plug operation 3 Correct lead wire connection
4 Incorrect governor lever position 4 Set lever to slarting position
LOW OUTPUT LOW COMPRESSION See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1 Incorrect injection timing 1 Adjust injection timing
2 Insufficient injection 2 Repair or replace injection pump
3 low injection pressure 3 Check injection nozzle and adjusl pressure
INSUffiCIENT FUEL
1 Airtrapped in fuel system 1 Check and retighten connector
2 Clogged fitter 2 Clean or replace filter
3 Contaminated fuel tank 3 Clean lank
INSUffiCIENT INTAKE AIR
1 Clogged air cleaner 1 Clean or replace air cleaner
WESTERBEKE
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT ooM OVERHEATING
1 Low coolantlevel 1 Add coolant
2 Loose Vbe 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low 6 Add engine OIL OIL 1 Defective oil seals 1 Replace oil seals
2 Broken gear case gasket 2 Replace gasket
3 Loose gear case attaching bolts 3 Retighten bolts
4 Loose drain hose 4 Retighten hose
5 Loose oil pipe connector 5 Retighten oil connections
6 Broken rocker cover gasket 6 Replace gasket
7 Loose rocker cover attaching bolts 7 Retighten attaching bolts
OIL LEVEL RISING
1 Incorrectly positioned piston ring gaps 1 Correct ring gap positions
2 Displaced or twisted connecting rod 2 Replace connecting rod
3 Worn piston ring 3 Replace ring
4 Worn piston or cylinder 4 Replace piston and rebore cylinder
OIL LEVEL FALLING
1 Defective stem seal 1 Replace stem seal
2 Worn valve and valve guide 4 Replace a valve and valve FUEL ENGINE BODY 1 Noisy knocking
1 See KNOCKING
2 SmokY exhaust 2 See SMOKY EXHAUST
3 Moving parts nearly seized or excessively worn 3 Repair or replace
4 Poor compression 4 See LOW COMPRESSION HARD STARTING
5 Improper valve timing 5 Adjust
6 Improper valve clearance 6 Adjust
INSUFFICIENT INTAKE AIR
1 Air intake obstructed 1 Remove NOZZLE mOUBLES
1 Seized nozzle 1 Replace
2 Worn nozzle 2 Replace
IMPROPER FUEL Replace with proper fuel
FUEL LEAKS Find fuel leaks
SMOKY EXHAUST WHmSH OR PURPLISH
1 Excessive engine oil 1 Correct oil level
2 Excessive rise of oil into combustion chamber
a Poor piston contact a Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
WESTERBEKE
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE 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 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 OPERATION INJECTION PUMP SYSTEM
1 Uneven injection 1 Adjust injection or replace paris
2 Control rack 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 1 Check governor shaft and correct operation
2 Fatigued governor spring 2 Replace
v WESTERBEKE
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE

KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE
1 Main engine troubles
a Overheated cylinder a See OVERHEATING LOW OUTPUT
b Carbon deposits in cylinder b Clean
2 Too early injection timing 2 Correct
3 Too high injection pressure 3 Correct
4 Improper fuel 4 Replace wnh proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See LOW COMPRESSION HARD STARTING
2 Injection pump 2 3 Improper nozzle
a Poor spray a Clean or replace nozzle
b Poor chattering b Repair or replace nozzle
c drip c Repair or replace nozzle
d Nozzle needle valve seized d 1 Fuel fier clogged 1 Clean or SOUND 2
Water mixed in fuel 2 Replace 1 Vbelt slackening or slippery wnh oil 1 Adjust replace or
clean
2 Damaged water pump 2 Replace
3 Lack of coolant 3 Add
4 Low oil level or poor oil quality 4 Add or change
5 KnOCking 5 See KNOCKING
6 Moving parts seized or damaged 6 Replace
7 Defective thermostat 7 Replace
LOW OIL PRESSURE 1 Wom Bearings 1 Engine overhaul replace bearings
2 Relief valve malfunction 2 Overhaul oil pump
3 Clogged oil cooler 3 Repair
4 Diesel dilution of the oil 4 Injection pump repair
I engines Generators
ENGINE ENGINE ENGINE off the batteries and disconnect the battery cables Take the
following the engine and tape over the tenninals Clean the exterior of the engine of any deposits of
Drain or pump out all the engine oil and drain the coolant dirt and oil
from the engine and engine hoses Be careful not to damage the disassembled parts
Unplug the instnnnent panel wiring harness Drain the Arrange parts in the order of disassembly Mark fluid and the ttansmission oil
cooler hoses label parts as needed to insure proper mating and
Detach the oil cooler hoses and unbolt the ttansmission from reassembly Keep parts clean
the engine
Mount the engine on a suitable engine stand for
NOTE Lobel any lines hoses or cables as you separate them disassembly
With the ttansmission separated from the engine begin following step by step procedure to
disassemble the engine
If the ttansmission is not being rebuilt it should be visually IRemove the transmission damper plate from the
inspected Flusb out and pressure test the oil cooler and engine the coolant hoses Inspect and lubricate the gear shift 2
Remove the engine oil cooler and oil hoses Note oil
linkage and the propeller shaft coupling Clean and repaint hose connections from the oil cooler to the engine
the IIlInsmission and cbange the IIlInsmission fluid
3 Remove the engine heat exchanger If possible leave
For transmissi9n service and maintenance refer to your one end of each hose connected to the part being manual To rebuild a
transmission contact
4 Remove the bell housing and the circuit breaker
your WES1ERBEKE dealer or an authorized
preheat solenoid mounting service center
5 Remove the engine back plate
6 Remove the start motor drive belt and the alternator
OAMPER PLATE Label the wires and cables
BOLTS
7 Remove the engine mounted raw water pump
complete with its adapter mounting plate See RAW
WArnR PUMP for parts breakdown
DAMPER INSPECT THE DAMPER 8 With the hoses disconnected remove the thermostat
PlATE PLATE FOR WEAR AND
housing and housing gasket leaving the temperature
BROKEN SPRINGS
sender in place
9 Remove the coolant circulating pump Refer to
COOLANT CIRCULATING PUMP ASSEMBLY
10Remove the air intake silencer and the intake manifold
1lRemove the oil filter and the mounting bracket from the
engine block
12Unbolt the elbows and remove the exhaust manifold in
its entirety
13 Remove the fuel injection pumps Disconnect the fuel
injection pipes and fuelleakoff pipe from the fuel
injection pumps and nozzles
14 Fuel pipe injection pipe and leak off pipe
a Loosen the sleeve nuts on the nozzle holder side and
on the injection pump side and then disconnect the
injection pipes
b Disconnect the leak off pipe together with gaskets
COOLANT DRAIN
c Remove the eye bolt and then disconnect the fuel
pipe
Injection pipe
Leak off pipe
J 0
O Fuel pipe
Nozzle holder
Engines Generators Injection pump
ENGINE DISASSEMBLY
Injection pump
1 Align the hole of the fuel cut lever with the hole of
the governor cover and then insert a pin 6 into PRIOR TO MAIN ENGINE DISASSEMBLY
tliis hole to hold the fuel cut lever
2 Check to see if the pin groove of the control link is at Backlash oftiming gear
mm in
the center of the injection pump
3 Remove the injection pump and then take out the STANDARD LIMIT
shim CRANK GEAR 004 02
Fuel cut lever IDLER GEAR 00017 00079
Pin6 CAM GEAR 003 02
IDLER GEAR 00012 00079
IDLER GEAR END PLAY
mm in
STANDARD LIMIT
0058 0115 00023 00045 02 00079
Governor cover
CRANKSHAFT END PLAY
Control link 1
Injection pump
center position STANDARD LIMIT
mm in
0058 0208 00023 00082 03 00118
nection pump rack
NOTE
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
WESTERBEKE
Enginds Generators
ENGINE DISASSEMBLY
INTERNAL PARTS
DiSassembly Steps
11 Rocker Bracket Assembly
21 Push Rods
31 Rear Hanger 111
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 Gear Case
15 Oil Pump Assembly
16 Idler Gear and Shaft
171 Cam Gear
181 Camshaft
19 Rear Seal Retainer
20 Piston Crankshaft
00 nat pull out
this bolt
Rocker bracket
Push rod
t 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
E19ines Generators
ENGINE DISASSEMBLY
5 4 3 2 1 Timing gear
1 Remove the idle gear and the idle gear shaft
2 Pull out the sleeve from the tip end of the cam shaft
3 Remove the lock nut of the cam shaft gear and then
remove the flyweight assembly and the cam gear
Rear hanger
Head bolt
Cylinder head M12
ASM
Valve mechanism
1 Before disassembling the valve mechanism remove
the connector glow plug and nozzle holder as
sembly
2 Compressing the valve spring remove the split col
lar spring seat valve spring and valve
connector r
Glo w
udsare appHed wfih
sealing agent
Do not pull them out
Nozzle holder 3 5 locations
Camshaft
1 Remove the snap ring which holds down the front
bearing of the cam shaft from the ring groove of the
cylinder block
2 Pull out the cam shaft from the cylinder block
e F1I Split collar 4
together with the bearing
t 11
Spring seat 151
Snap ring
Hot plug
lveSprlng lSI
Seat valve insert
Engines GelJerstors
ENGINE DISASSEMBLY
Piston and Connecting Rod Piston ring
Remove the piston ring with a ring pliers
Brass bar
Connecting rod
Piston pin
Piston and connecting rod 1 Remove the snap rings with a commercially avail
1 Turning the crankshaft position the piston to be able tool
removed at the bottom dead center 2 With a brass bar attached to the piston pin push it
2 Loosen the cap nut of the connecting rod and then out by hammering it lightly
remove it Note
3 Give another rotation to the crankshaft to position Keep the pistons piston pins and connecting rods in
the piston at the top dead center order for each cylinder
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
r 1
Piston ring 4
Snap rn9 5
Piston bolt
The drawingout ofthe conrod bolt
must be limited to only when Connecting rod 7 Bearing 3
Engines Generators
ENGINE INSPECTION AND REPAIR
Cylinder block Cylinder Body Upper Face Warpage
Check the cylinder block for wear damage or any other
Use a straight edge D and a feeler gauge to measure
defects the four sides and the two diagonals of the cylinder
Use the hydraulic gauge to check the water jacket water body upper face
Regrind the cylinder body upper face if the measured
values are greater than the specified limit but less than
the maximum grinding Cylinder bore
Measurement position 13mm below the top
Measure in XX and
yy directions If the measured values exceed the maximum grinding
Near the No1 allowance the cylinder body must be replaced
compression ring Cylinder Body Upper Face Warpage mm in
y Maximum Grinding
Standard Limit
X X Allowance
0075 00029 015 00059 03 00118
If the measured value is less than the limit the cylinder
body may be reground
mm in
Engine Limit Repair method
Perform boring and
02 00079 honing of the inner EI IF
diameter
Cylinder bore diameter and grade mark
The grade mark is stamped on the top surface of the
cylinder block on the mating face with the cylinder
head
Bore grade mark
Stamp mm in
Engine Bore Diameter Grade
85000 85010
Cylinder Body Height Reference mm in
33464 33468 Engine Standard
85011 85020 30794 30806
33468 33472 12123 12128
85021 85030
33472 33476
WESTERBEKE
Engines Generators
ENGINE INSPECTION AND head inspection HOT PLUG
Remove carbon deposit on the bottom surface of the Hot Plug with care not to damage the valve seat
1 Clean the cylinder head lower face taking care nO
Leakage Water pressure test 5kgcm for 3 minutes to damage the hot plug surfaces
2 Use a straight edge and a feeler gauge to measure
the hot plug depression in a straight line from the
No1 hot plug to the No3 hot plug
If the measured value exceeds the specified limit
the hot plugs must be replaced
rot PI ug Depression mm in
Limit
005 Head Lower Face Warpage
1 Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
head lower face
2 Regrind the cylinder head lower face if the mea
sured values are greater than the specified limit but
less than the maximum grinding allowance
Combustion Chamber Inspection
1 Remove the carbon adhering to the inside of the
combustion chamber Take care not to damage the
hot plug fitting positions
2 Inspect the combustion chamber the hot plug hole
and the hot plug machined faces for cracking and
other damage
If cracking or damage is present the cylinder head
must be replaced
Note
I A 1
Be absolutely certain that there are no scratches or
on the combustion chamber surfaces
which will be in contact with the hot plug after it is in
EI IF
L stalled These flaws will prevent the hot plug from
seating correctly
B
If the measured values exceed the maximum the cylinder head must be Head Lower Face Warpage mmin
Maximum Grinding
standard Limit
Allwance
0075 00029 015 00059 03 00118
Hot Plug Head Height Reference mm in
Hot Plug Removal
Engine Standard
1 Insert a 30 50 mm 012 020 in diameter brass
6390 6410 bar into the nozzle holder fitting hole until it makes
2515 2523 contact with the hot plug
2 Lightly tap the bar with a hammer to drive the hot
If the cylinder head lower face is reground valve plug must be checked
y WESTERBEKE
Engines Generators
ENGINE INSPECTION AND REPAIR
Hot Plug Inspection Heat Shield the hot plugs for excessive wear and other dam
Heat Shield Removal
e Replace the hot plugs if either of these conditions
e discovered A After removing the hot plugs use a hammer CD and a
brass bar to lightly tap the lower side of the heat
shield and drive it free
Hot Plug Align the hot plug knock ball CD with the cylinder
head groove and tap it temporarily into position
with a plastic hammer
Heat Shield Installation
Install the heat shield to the cylinder head from the noz
zle holder installation hole side Ughtly tap the heat
shield flange into place with a hammer and a brass bar
The heat shield flange side must be facing up
Note
Always install a new heat shield Never reuse the old
heat shield
2 Place a metal plate approximately 25 mm 1 in
thick over the hot plug upper surface
3 Use a bench press to exert a pressure of 4000
5000 kg 8819 11023 Ib39227 49033 N on the
metal plate covering the hot plug upper surface
This will drive the hot plug into position
4 Lightly tap the hot plug head to make sure that it is
firmly seated
5 Repeat the procedure Steps 1 4 for the remaining VALVE VALVE SEAT INSERT AND VALVE SEAL
hot plugs
Inspection of valve seat
A Contact width
2 B Valve er r f
Do not apply pressure greater than that specIfIed
Damage to the cylinder head will result
6 Use a surface grinder to grind off any hot piug sur
face The hot plug surfaces must be perfectly flush with
the cylinder head lower face
mmin
7 After grinding make sure that the hot plug surfaces Standard Limit
are completely free of Contact width 20 00787 25 00984
The hot plug surfaces must also be free of depres
sions Valve depression 07 00276 12 00427
Once again lightly tap the hot plug heads to make
sure that they are firmly seated
Engines Generators
ENGINE INSPECTION AND REPAIR
Valve thickness Valve Seat Insert Installation
Nominal Limit Repair method 1 Carefully place the attachment j having a small
outside diameter than the valve seat insert on t
10 07 valve seat insert
Replace
003937 00276
Note
The smooth side of the attachment must contact the
valve seat insert
2 Use a bench press to gradually apply pressure to
t the attachment and press the valve seat insert into
place 4000 kg 8819 Ibs
I J Note
Do not apply an excessive amount of pressure with the
Valve Stem OutsIde DIameter t bench press Damage to the valve seat insert will
Measure the valve stem diameter at three points result
If the measured value is less than the specified limit the
valve must e Stem Outside Diameter mm in
Standard Limit
70 685
Intake Valve
02756 02697
70 680
Exhaust Valve
02756 02677
Valve Seat Insert Conection
Remove the carbon from the valve seat insert sur
face
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 Seat Insert Seat Insert Removal
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 Valve Seat Angle degree
free 45
Take care not to damage the cylinder head
4 Carefully remove carbon and other foreign material Note
from the cylinder head insert bore 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
ENGINE INSPECTION AND REPAIR
VALVE 5 Apply light pressure to the valve while turning it to
fit the valve seat insert
6 Check that the valve contact width is correct Valve Spring Free Length
7 Check that the valve seat insert surface is in contact
Use a vernier caliper to measure the valve sprng free
with the entire circumference of the valve
length
8 Clean the head and valves to remove the abrasive
If the measured value is less than the specified limit the
compound and metal particles
valve spring must be replaced
mm in
VALVE SPRING
Exhaust and Intake
Standard
Limit
Valve Spring Inclination Valve Spring Free
16575 15748
Use a surface plate and a square to measure the valve Length
spring inclination
If the measured value exceeds the specified limit the
valve spring must be replaced TAPPET Cam Follower or Valve Lifter
mm in AND PUSH ROD
Standard Limit TAPPET
Valve Spring 18 25 Inspect the tappets for excessive wear damage and any
Inclination 00709 00984 Use a micrometer to
measure the tappet diameter
mm in
Standard
20967 20980
Tappet Diameter
082547 082598
Valve Spring Tension
Use a spring tester to measure the valve spring tension
If the measured value is less than the specified limit the
valve spring must be replaced
mmin1
Standard Limit Use a dial indicator to measure the clearance between
Valve Spring the tappet and cylinder body tappet travelling bore
Tension at 299 mm
Set Length I
37479
f
33069
Tappet and Tappet
Travelling Bore
Standard
0020 0054
mm in
000079 000213
Limit
000315
Clearance
WESTERBEKE
Engines Generators
VALVE SPRING TESTER 19
ENGINE INSPECTION AND REPAIR
PUSH ROD
Use a filler gauge to measure the valve push rod runout
Roll the push rod along a smooth flat surface PUSHROD
3 Uneven wear of journal mm in
Nominal Limit Repair method
52 III 005 0002 Replace
mm in 20472
Limit
4 Runout of cam shaft mm in
Push Rod Runut 03 00118
Nominal Limit Repair 002
01 0004 Replace
of cam shaft
Check the joumal and the cam for evidence of wear
damage or any other defect ROCKER ARM SHAFT AND ROCKER ARM
Note Inspect all disassembled parts for wear damage and any
With the front and rear parts of camshaft pressed in ball bearings andwith the cylinder block pressed
in with roller bearings as the center bearing check to
see if the camshaft rotates smoothly with no play at
each bearing
8
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm outside
of journal and cam If the measured value is less than the specified limit the
shaft must be replaced
1 Cam height A B mm in
mm in
Standard Limit Repai r method
Standard
613 583
Intake Replace Rocker Arm Shaft 11935 11955
02413 02295 04699 04707
Diameter
643 613
Exhaust Replace
02531 02413
2 Center journal diameter mm in
Nominal Limit Repair method
52 III 5192 III
Replace
20472 20441
Engines Generators
ENGINE INSPECTION AND REPAIR
Rocker Arm Shaft and Rocker Arm Clearance PISTON PISTON
PIN AND PISTON RING
I 1 Use a vernier caliper to measure the rocker arm
bushing inside diameter Clearance between piston
and cylinder bore
1 Measure the outside diameter of the piston at about
mm in
60 mm from the top in a right angle to the piston pin
Standard in the unit of 1000 mm
Rocker Arm Bushing 11960 11980 2 Calculate the
clearance based on the measurements
Inside Diameter 04709 04717 of the cylinder bore
and the outside diameter of the
piston
2 Measure the rocker arm shaft outside diameter
mm in
Replace either the rocker arm or the rocker arm shaft Clearance
0015 0035 00006 00014
if the clearance exceeds the specified limit
ROCKER ARM
mm in
Standard Umit
oUl 60
Rocker Arm Bushing
0005 0045 02
and Rocker Arm
00002 00018 00079 Outside diameter of piston and grade mark
Shaft Clearance
The grade mark is stamped on the top surface of the
3 Check that the rocker arm oil port is free of obstruc piston
tions
mm in
If necessary use compressed air to clean the rocker
arm oil POl Model
Outside diameter of piston Grade
84975 84985
00 33454 33458
84986 84995
ROCKER ARM SHAFT 1 33459 33462
85005
Rocker Arm Correction
C
33466
Inspect the rocker arm valve stem contact surfaces for
oe mark Stamped
ridges and scoring
If the surfaces have light ridge or scoring they may be
honed with an oil stone
If the ridge or scoring is severe the rocker arm must be
SCORING
mm in
Model Nominal Limit Remarks
250 2497 Replace if worn
09843 09831 beyond limit
WESTERBEKE
Engines Generators
ENGINE INSPECTION AND between piston pin and piston pin hole CONNECTING ROD AND CONNECTING
mm in ROD BEARING
Standard
0002 0012
000008 ring gap
With the ring inserted into the cylinder bore push it in
with the piston head so that it becomes a right angle to
the cylinder and then measure the gap of the worn beyond the limit replace the rings
Torsion and parallelism of connecting rod
If worn beyond the limitrepair or replace
mmin
Per 100 mm 394 Standard Limit
005 02
Torsion
0002 00079
compression ring
Standard
02035
00079 00138
mmin
Limit
00590
Parallelism
0002
00059
Clearance between small end pin hole of connecting rod
and piston pin inside diameter of bushing
mm in
compression Standard Limit
ring 03505
00138 00197 0008 0020 005
Clearance
00003 00008 00020
0204 10
Oil ring
00079 00157 003937
Inside between piston ring groove and ring 25 clearance at several places on the worn beyond
the limit replace the rings or piston
compression ring
compression ring
Standard
0085 0105
00033 00041
0050 0085
00020 00033
mmin
Limit
00078
MEASURING CONNECTING ROD
BUSHING INNER DlAMmR
0030 0070 00059
Oil ring
00011 00027
PISTON PIN
Engines Generators
ENGINE INSPECTION AND REPAIR
Connecting Rod Bearing Inspection CRANKSHAFT AND CRANKSHAFT BEARING
1 Fit the connecting rod bearing lower half into the
connecting rod bearing cap Outside diameters of journal and pin
2 Check the connecting rod bearing lower half tension If worn beyond the If the tension is insufficient the bearing must
be Crank journal mm in
replaced Standard Limit
3 Tighten the connecting rod and the bearing cap to
600 23622 5986 23567
the specified torque
Fm1NG THE LOWER
BEARIIIG
kgm ft Ibs
Tightening 7585
torque 5461
Crank pin mmin
Clearance between bearing and crank pin inside di
ameter with bearing installed and without
Standard Limit
490 19291 4887 19240
mm in
Standard Limit
0035 0073 010
Clearance
00014 00029 When there occurs an uneven wear to the crankShaft
replace it with a new one without grinding it for reuse
Clearance between journal and bearing inside diameter
with bearing installed and without
mm in
Standard Limit
0029 0072 011
Clearance
00011 00028 00043
Engines Generators
ENGINE INSPECTION AND REPAIR
REMOVING THE
RING GEAR
Ring Gear Installation
1 Heat the ring gear evenly with a gas burner to invite
thermal of crankshaft
Do not allow the temperature of the gas burner to
Replace if beyond limit exceed 200C 390F
mm in 2 Use a hammer to install the ring gear when it is suf
Standard Limit ficiently heated
0025 0001 005 gear
Check the crankshaft gear visually for damage and any
other defects
TIMING GEAR
Uneven wear of idle gear shaft
Oil seal mm in
When the lip of an oil seal is found defective replace it Nominal Limit
with a new one 450 17717 01 the crankshaft front oil seal installer to
install front oil seal
Clearance between idle gear bushing and shaft
mm in
Standard Limit
0025 0085 0001 00033 02 AND RING GEAR
Ring Gear Gear
Inspect the ring gear
Ifthe ring gear teeth are broken orexcessively worn the
ring gear must be Gear around the edges of the ring gear with a hammer
and chisel to remove it
Engines Generators
ENGINE INFORMATION Bolts and Fasteners
Be careful not to mix bolts and nuts Metric and SAB Lightly oil head bolts and other fasteners as you assemble
bolts are used on various engine assemblies them Bolts and other plugs that penetrate the water jacket
During assembly recheck clearances and insure that parts should be sealed with PERMATEX 2 or mGH TACK
are being assembled in their proper order and faCing in the
correct direction in relation to the engine block such as When assembling the flywheel coat the bolt threads with
pistons piston rings bearings and bearing caps LOCTITE blue
Apply lubricating oil to moving parts during assembly LITInUM based grease is waterproof ideal for water pump
Insure that moving parts when assembled on the engine bearings and stuffing boxes
rotate or slide and are not subject to binding or
excessive tension Antiseize compounds and thread locking adhesives such as
LOCTITE protect threaded components yet allow them to
If there are mating marks scribed during disassembly come apart when necessary LOCTITE offers levels of
reference them correctly for assembly lOCking according to the job
Use new gaskets lockwashers Orings packings and seals Heavily oil all sliding and reciprocating components always
Tighten the bolts and nuts on important parts of the engine use clean engine oil
to specified torques using a reliable torque wrench
When required use liquid sealants when required on nuts PISTON AND CONNECTING ROD
bolts and gaskets Refrain from using tape sealants
Most gaskets and many bolt washers are asymmetrical Piston Pin Snap Ring
make certain they are positioned properly 1 Use a pair of snap ring pliers to install the piston pin
snap Hardware 2 Check that the piston moves smoothly on the mechanical damage by running
fasteners down in pin
three stepsII2 213 and III torque Exceptions are torqueto SNAP RING
yield bolts and rocker arm shaft fasteners The former are as indicated The latterrocker shaft be
brought down in very small increments working from the
center bolts out Gaskets especially head gaskets might be
damaged during assembly they should be positioned with great
care See TORQUE thru out this and Lubricants
Piston Ring
Oil based PERMATEX 2 and its mGH TACK equivalent are
excellent all purpose sealers They are effective in just about 1 Use a piston ring installer to install the three piston
any joint in contact with coolant raw water oil or fuel A light of oil or LIQUID TEFLON can be used on rubber Install
the piston rings in the following and orings 1 Oil ring
LOCTITE hydraulic red sealant should be used on oil adapter 2 2nd compression ring
hoses and the oil filter assembly 3 1st compression ring
Coat both surfaces of the oil pan gasket with high temp RED The marked side of the two compression SEALER
be facing up
The undercut side of the second compression ring
When installing gaskets that seal around water coolant
will be facing coat both sides with WHITE SILICONE GREASE
As the oil ring has no any facing mark it may face in
Do not use sealant when installing a new gasket either ADHESIVE SPRAYS are useful for hold 2
Lubricate the piston ring surfaces with engine oil
ing a gasket in position during assembly 3 Check that the piston rings rotate smoothly in gasket sealers such as
HYLOMAR work well in piston ring requiring nonhardening properties HYLOMAR I st
is particularly effective on copper cylinderhead gaskets and
resists fuel oil and water
2 st
NOTE TAPE SEALANTS should be used on pipe plugs and
fitting that connect water cookmt passages
Engines Generators
BOil
ENGINE ASSEMBLY
CYUNDER HEAD ASSEMBLY Valve Stem Oil Seal
Ii Glow plug 7
1 Lul1ricate the oil seals and valve stem sealing are
with engine oil
2 Use a valve stem oil seal installer to install the oil
seal
INSTAlLER
Nozzle holder 6
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 to the intake or exhaust guides
Install the valves to their original lapped valve seats
Seat Valve insert
t Split collar 5
e Spring seat 4
I Valve spring 3
Intake and Exhaust Valve Springs
Install the valve springs with their painted end the close
pitched end facing down
PORTION
Engines Generators
ENGINE ASSEMBLY
Spring Seat Split Collar Piston ring 5
1 Use a spring compressor to push the valve spring
snap ring 4
into position
2 Install the spring seat split collar Piston 1 IJ
3 Set the spring seat split collar by tapping lightly
around the head of the collar with a rubber hammer
Spring Compressor Piston pin 31
Rod bolt removed
for clarity
Bearing 6
CapnutB
Nozzle holder assembly
Before assembling the nozzle holder assembly check to
see if the spray condition and the spray pressure of the PISTON AND CONNECTING ROD
injection nozzle are appropriate Refer to INSPECTION Piston
AND SERVICE
Use a piston heater to heat the pistons to Assemble to the cylinder head the gasket heat shield 100C 212F
heat shield corrugated washer and gasket nozzle
holder in this order
Install the nozzle holder assembly and then tighten it to
the specified torque
kgm ft Ibs
TIghtening torque 40 50 290 360 I
USING A PISTON
HEATER
Nozzle holder ASM Connecting Rod
1 Install the connecting rod to the piston with setting
Gasket
the marks as illustrated
Corrugated washer 2 Install the piston pin into the piston and the connect
Heat shield ing rod bushing
Glow plug
GaSket
Hot plug side
mark
Front malK
Connector
Engine
Glow plug and connector front
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
kgm ft Ibs Cylinder nl
Parts TIghtening torque stamped side
Glow plug 15 20 110 140
WESTERBEKE
EngInes Generators
ENGINE Steps INTERNAL PARTS
1 Crankshaft
2 Piston Assembly
3 Rear Seal Retainer
4 Camshaft 121
5 Cam Gear
6 Idler gear and Shaft
7J 011 Pump Assembly
8 TIming Gear Case
9 Flywheel Housing
10 Flywheel
11 Crank Pulley
12 Oil Pipe
13 Oil Pan
15 Tappets
16 Cylindar Head Gasket
17 Cylinder Head Assembly
18 Push Rods
19 Rocker Bracket Assembly
20 Engine Hangers
Engines Generators
ENGINE ASSEMBLY
Reassembly Steps INTERNAL PARTS
111 Crankshaft
121 Piston Assembly
31 Rear Seal Retainer
41 Camshaft
151 Cam Gear
61 Idler gear and Shaft
7J Oil Pump Assembly
81 TIming Gear Case
91 Flywheel Housing
101 Flywheel
111 Crank Pulley
121 011 Pipe
131 Oil Strainer
141 Oil Pan
151 Tappets
161 Cylinder Head Gasket
171 Cy6nder Head Assembly
1181 Push Rods
191 Rocker Bracket Assembly
201 Eiglne Engines Generators
ENGINE ASSEMBLY
Installation of retainer
3 Apply engine oil to the shaft of the sleeve and the
After applying engine oil to the lip of the oil seal install slide of the flyweight
the retainer Apply sealant
4 With the lip of the sleeve placed in the cavity of t
Tighten bolts on the retainer to the specified torque in flyweight insert the shaft of the sleeve into the til
the order as shown in the figure left end of the camshaft
kgm ft Ibs
Note
Tightening torque 08 12 60 90 I Check to see if the sleeve moves assembly
1 Apply engine oil to the inside of the bearing of
the cylinder block and then install the camshaft Idle Gear
assembly Install the idler gear shaft with the oil hole facing up
Note ward
When installing the assembly care should be taken not Lubricate the shaft with oil
to damage the bearing Install the idler gear
2 After installation of the snap ring to the outside of Align the timing marks as shown in the the front bearing check to see if
the camshaft
rotates smoothly Install the thrust collar and tighten the bolts to the
specified torque
kgm ft lb
Tightening torque 21 31 152 224
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 Idle gear
2 With the flyweight installed tighten the cam gear
with a lock nut
kgm ft Ibs
Tightening torque I
Cam gear l
Timing pOlnt
Sleeve
Flyweight
Engines Generators
ENGINE ASSEMBLY
Crankshaft bearing 151
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 2st
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
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
0 N O OIL GROOVE AND HOLE Position the piston front mark towards the front of the
LOWER engine
Crankshaft and bearing Use the piston ring compressor to compress the piston
Lubricate the bearings with engine oil install the crank rings
shaft install the thrust bearings with the groove facing Use a hammer grip to push the piston in until it makes
the crankshaft contact with the crank pin
Thrust bearing At the same time rotate the crankshaft until the crankpin
reaches its highest point
V Crankshaft
p V 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
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
kgm ft lbs
Crankshaft Bearing Cap
85 95 610 690 Cylinder
Bolt Torque No
4 Check that the crankshaft turns smoothly by manu
ally rotating WITH ENGINE OIL Arrow mark kgm ft lbs
10 6 Tightening
4LEl 7585
5461
torque
Note
q After installation confirm that the crankshaft rotates
Front Engines Generators
ENGINE ASSEMBLY
Oil pump assembly Governor cover
Install the oil pump
assembly to the cylinder block
PrO not provided kgm ft Ibs
TIghtening torque I
Cylinder block 4 Assemble the gasket and the governor cover to the
top of the gear case and then tighten them to the
Front oil seal specified the front oil seal to the timing gear case
kgm ft is made according to the L n dimension Cover tightening torque 08
12 60 90
shown in the figure
mm in
L dimension
602 608 2370 2384
I Flywheel housing
Install the flywheel housing to the cylinder body
kgm ft Ibs
Tightening torque 42 56 300 400 I
Front oil gear case with governor Flywheel
Install the timing gear Lubricate bolts with engine oil
case to the cylinder block
Tighten a little at a time in the sequence shown in the
Put the link plate of the governor incorporated in
the gear case through the connecting hole of the kgm ft Ibs
injection pump in advance Tightening torque 90 110 650 800
2 Apply engine oil to the bushes provided on both
ends of the main spring lever of the governor
3 Apply sealant to the gear case and then install it to
the cylinder block or the front plate
kgm ft Ibs
Case tightening torque 19 29 140 210 I
Apply
engine oil
WESTERBEKE
Engines Generators
ENGINE pulley Tappet and head the lip of the front seal with qil
1 Install the tappet to the cylinder the crank pulley lock the crankshaft and tighten 2 When installing the head
gasket turn up the stamp
the front bolt mark of the parts number last 4 digits which is
kgm ftlbs between the No2 and No3 cylinders of the gasket
Tightening torque 170 190 1230 1370 I
Parts number Last 4 digits
Stamp mark position
Cylinder head assembly
Lubricate the bolts with oil
Tighten the bolts in the sequence shown in the iIIustra
tion to the specified torque
kgm ft Ibs
Oil pipe and oil strainer Bolt size Tightening torque
1 Install the oil pipe from the oil pump assembly to M12xl5 8595
6090
the cylinder block and tighten the sleeve nuts 8 each 61 69
2 Install the oil strainer to the oil pump and then M8x 125 2535
tighten the bracket of the strainer to the No2 bear 4 each 18 25
ing cap
kgm ft Ibs 11
Tightening torque 1929 140210 I
To 2nd bearing cap
Push rod
Install the push rods
Rocker arm bracket assembly
Oil pan Apply liquid gasket to the the bottom of the rocker arm
bracket assembly being careful not to get any in the
1 Apply sealant to the oil pan
groove around the oil galley as shown in the Install the oil pan to the cylinder block and tighten
Install the rocker arm bracket assembly making sure the
fixing bolts evenly
push rods align with the rocker arms and tighten to the
kgm ft Ibs
specified torque
Tightening torque 08 12 60 90 I kgm ft Ibs
Tightening torque 08 12 60 90 I
Apply stem of sealant Rocker arm
rAvoid the application
1l1 of seQlant to this
grocle
Oil gallery
Rocker bmcket bottom srace
WESTERBEKE
Engines Generators
ENGINE ASSEMBLY
ADJUST THE VALVE CLEARANCE
Refer to the ENGINE ADJUSTMENTS section in this
PARTS Righthand Side EXTERNAL PARTS Lefthand 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
14 113
hanger and rear hanger
Oil filter them to the specified torque shown below
1 Insert the dipstick
kgm ft Ibs
Tightening torque 1929 140210 I
Rear hanger
IOFront
hanger
v WESTERBEKE
Engines Generators
ENGINE ASSEMBLY
Injection pump
Align the two 2 holes in the fuel cut lever and the gov
ernor and lock into place with a pin
This will center and hold the control link for the installa
tion of the injection pumps
Injection pump
center position Fuel cut lever Housing cover
Apply portion of sealant
Y J4 About2mm
About 4mm in width
around the bolt hole
from the cover edge
Install a new shim with the same thickness as the one Injection pump housing cover
that was removed Refer to the maintenance section on
After applying sealant TB1207C to the housing cover
shim selection
install it to the cylinder block by the side of the injection
pump
Injection pump ASM kgm ft Ibs
Tightening torque 08 12 60 90 I
Shim The areas of the housing cover to which liquid gasket is
applied are about 4 mm In width from the cover edge
and about 2 mm around the bolts
Cylinder block Solenoid ASM
Install the injection pump making sure the rack pin is in
the groove of the control rack before tightening the
injection pump to the specified torque
kgm ft Ibs
Tightening torque 1929 140 21 0
Solenoid assembly
Remove the rack pin 6 which is inserted into the fuel 1 Apply sealant TB1207C to the surface bite groove
cut lever and then confirm that the fuel cut lever moves in which the solenoid is installed
smoothly Note
IInjection pump Avoid the application of sealant to the screw thread
I center position
RackPin
2 Screw in the solenoid from the rear of the cylinder
block the rear of the No 3 injection pump rack and
Control link then tighten it to the specified torque
kgm ft Ibs
Tightening torque 152511 0180 I
SolenOid ASM lnsmlled surface
Apply SUrface
ofsealilnt
Screw thread
Avoid the apPlication
of sealant
Engines Generators not adjustable pull to run
ENGINE ASSEMBLY
Leak off pipe
pipe Fuel hose
Leak off pipe
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
kgm ft Ibs
Tightening torque
Fuel pipe 20 25 140 180
Leak off pipe 2535 180250 Thermostat
Water outlet pipe
When tightening it hold the pipe securely by hand so
Assemble the thermostat install the gasket and the
that it will not rotate
water outlet pipe and then tighten it to the specified
3 Connect the fuel pipe and the leak off pipe with the torque
fuel hose and fix them with clips
kgm ft pipe
Install the injection pipe to the injection pump and the
Tightening torque 1929 140210 I
nozzle holder and tighten them up with sleeve nuts
kgm ft Ibs
Adjust the Valve Clearance
Tightening torque I Refer to the ENGINE ADJUSTMENTS section in this
manual
Cylinder head cover
1 Install the gasket to the cylinder head cover
Notes
Nozzle holder 1 Much care should be taken for the gasket not to get
Injection pu dislocated or twisted when installing the head
cover
2 Avoid the application of sealant to the rubber gas
Set the thread of the sleeve nut securely before tighten ket
ing it up 2 Install the cylinder head cover to the rocker arm
Water pump assembly bracket and tighten it to the specified torque
kgm ft Ibs
1 Put sealant on the water pump where it contacts the
block and head Tightening torque 02 04 14 29 I
2 Tighten to the specified torque
Cylinder cover
kgm ft Ibs
Tightening torque 1929 140210 I Gasket
Rocker arm
bracket
WESTERBEKE
Engines Generators
ENGINE ASSEMBLY
Air inlet pipe
1 Apply sealant TB1207C to the surface in which the
Alternator
air inlet pipe is installed 1 Tighten the adjustment plate together with the water
pump and then install them Install the air inlet pipe to the cylinder head cover 2 Install the bottom of the alternator to the timing gear
and tighten it to the specified torque case and then tighten it temporarily with bolts and
kgm ft Ibs nuts
Tightening torque 0812 6090 I 3 Install the fixing bolts onto the top of the alternator
through the adjusting plate temporary tightening
Cylinder head
cover
Water pump
Air inlet pipe
Drive pulley and belt
Exhaust manifold 1 Install the drive pulley to the water pump and then
Assemble the gasket to the cylinder head install the tighten it up 2 manifold along the stud bolts and tighten it to
kgm ft Ibs
the specified torque
kgm ft Ibs
Tightening torque 08 12 60 90 I
Tightening torque I 2 Set the drive belt to each pulley
Gasket
the starter to the flywheel housing and tighten it
to the specified torque
kgm ft Ibs
Tightening torque I
For starter motor disassembly and repair refer to the
starter motor section in this manual
Drive belt tension should be very tight about 12
deflection at midpoint
For alternator disassembly and repair refer to the
MANDO ALTERNATOR SECTION in this manual
Engines Generators
ENGINE exhaust manifold which was disassembled ENGINE TUNING the cylinder head should be inspected
After reassembly the engine must be tuned This will
ensure that the engine operates at its maximum
a Remove the exhaust elbows from the lower surface efficiency Fill the engine cooling system with antifreeze
of the manifold Clean and inspect for cracks and mixture and the engine oil sump with lube oil
defects Replace as needed API spec CF or CG4
b Remove the exhaust nipples elbows and plugs from 1 Mount the engine on a test bench and connect
the manifold and heat exchanger the fuel lines
c Remove water connectors from the ends of the 2 Connect the electrical wiring Refer to the WIRING
manifold Be sure to note the proper location and DIAGRAM
arrangement of each for proper alignment
3 Connect the air intake line to the air cleaner
d Examine all parts for defects corrosion and wear
and replace as needed 4 Connect the exhaust pipe
f Flush out the coolant recovery tank and clear its 5 Manually operate the fuel feed pump to feed fuel
hose passage Set aside to reinstall on the boat to the engine
6 Bleed the fuel lines of air
HEAT EXCHANGER 7 Crank the engine with the starter
operation for about twenty seconds This will
Install the heat exchanger replace the heat exchanger prelubricate the engine internal and aUach new hoses with new clamps to the
cooling system Refer to the COOLING SECTION in this B Start the engine and allow it to run at 750 to BOO
manuall for HEAT EXCHANGER SERVICE rpm for five minutes
9 Remove the cylinder head cover while the engine
MARINE TRANSMISSION is running
1 Assemble the damper plate to the flywheel 10Check that the engine oil is continuously
circulating from the oil pump to the valve rockers
2 Reinstall the marine transmission and fill with through the cylinder head
ATF Dextran III If there is no oil circulation or if the oil circulation is
sluggish stop the engine and make the Some such as the Borg Warner Velvet repairs or require oil coolers Oil coolers should be cleaned
Reinstall the cylinder head tested and repainted at engine overhaul The
11 Increase the engine speed to 1500 rpm to do oil cooler hoses should also be inspected engine warmingup to the text on Heat Exchangers
12Check the engine for oil fuel coolant and air
intake leakage
13 Check for abnormal noise and odor
14Check for abnormal electrical charging
15 Check the engine fastening parts for looseness
16 When the engine coolant temperature reaches
75C 167F or more increase the engine speed
to 2000 rpm and allow it to run for twenty
seconds
This will give the engine the essential runin
operating time
17Adjust the engine operation speed to the
specified value
1BStop the engine to complete the tuning
procedure
Refer to the following pages for details of
These sections also include
Wiring Diagrams Engine Torque
Diagrams Starter Motor Alternator Raw Water Pump
and a detailed Section
Adjust the Valve Clearance
Refer to the ENGINE ADJUSTMENTS section in this
manual
Engines Generators
LUBRICATION SYSTEM
Valve opening pressure lkgtcm2 140 PSI
Oil filter Oil gallery
Valve
opening
pressure
45kgcrn
640 PSI
1 Govmo I
H jectiO pump h
LGJllton
Oil pan
Pressure feeding Non pressure feeding
LUBRICATING OIL CIRCULATION DIAGRAM
Body Oil pump
Inspection and replacement
When there is wear damages or any other defects
found repair or replace the rotor
Clearance between the outer rotor or inner rotor and
the pump cover
mm in
Standard Limit
0040 0085 00016 00033 015 00059
Clearance between the periphery of the outer rotor and
the pump body
mm in
Standard Limit
010 0185 00039 00073 04 00157
Clearance between the inner rotor and the outer rotor
OIL PUMP mm in
Standard Limit
017 00067 02 00079
WESTERBEKE
Engines Generators
COOLING SYSTEM
WATER PUMP REASSEMBLY
Seal unit
Cover
Bearing unit
Body With a hole in the bearing unit set in line with one in the
body lock the bearing unit with a setscrew
kgm ft Ibs
setscrew Set screw tightening torque 0812 60 90
Cover Cover
1 Loosen the set screw
2 Remove the cover is applied with sealant TB1207B When re
moving the cover much care should be taken not to
deform it by applying an excessive force to it
Impeller
Seal unit
Cover
Bearing unit
Impeller Seal unit
1 Apply BELCO bond No4 to the surface where the
seal unit comes into contact with the body and then
assemble the seal unit
2 Press in the impeller with a press until the clearance
center 4 Setscrew between the pump impeller and the body gets to the
specified value
Cover
1 Apply liquid gasket to the surface to which the cover
is installed and then install the cover
2 Apply Screwlock to the cover installation screws
and then tighten them
Clearance play and tightening allowance between parts
1 Clearance between the pump impeller and the body
Impeller mm in
Standard 053 217 00209 00854
Seal unit
2 Play in the water pump ball bearing mm in
Standard Limit
0008 0010 00003 00004 02 00079
3 Tightening allowance between center and
the bearing shaft mm
Standard 0026 0061 0001 00024
Engines Generators
COOLING SYSTEM
A CAUTION any Df the VIIJIBS hare IIml uff tire
Impeller hey IIIDSf be fDrmd fD pment IIIDCkageln tire
cooling 111 They DflBn can be fDtmd In tire heat
filter should be cleaned every 100 operating hours Tap
the cartridge on a flat surface to dislodge dirt or clean off
with compressed air If the cartridge is badly contaminated or
oily replace it
HAW WATER PUMP
PART NO 11361
RAW WATER PUMP
PART NO 11885
TO TRANSMISSION COOLER Exchanger Service
After approximately 1000 hocrs of operation remove clean
and pressure test the engines heat exchanger A radiator shop should be able to clean and test the
heat THERMOSTAT ASSEMBLY
WESTERBEKE
Engines Generators
RAW WATER PUMP
PN4612D
19 CIRCLIP 2QPLATE
INSPECT THE aRING
ANa IMPELLER REPLACE
IF THEY SHOW SIGNS
OF WEAR
LIGHTLY GREASE THE
PUMP CHAMBER ORING
AND IMPELLER WITH
GLYCERIN
Inspection
Inspect all parts and replace those showing wear or corrosion
Reassembly
1 Install a new shaft seal 5 in the pump body Apply some
PUMP OVERHAUL glycerin to the lip of the
2 Install the circlip 13 on the shaft Support the outer
The pump when removed from the engine will have the hese bearing 18 and push the shaft into the bearing until nipple threaded into the
inlet and outlet pons of bearing contacts circlip
the pump along with a drive pulley attached to the shoft of 3 Install spacer 17 against the circlip Support the inner
the pump Remove these attachments noting their positions bearing 16 and push the shaft into the bearing until it
before starting the pump disassembly contacts the spacer
4 Apply some glycerin onto the Oring 6 and install it on
1 Remove the four cover plate screws 12 cover plate 11 the shaft approximately 18 away from the inner bearing
and sealing Oring 10 S Support e pump body on an arbor press With a twisting
2 Remove the impeller 9 using a pair of pliers grasping mobon install the shaft and bearing assembly into the
the ub and pulling it out of the pump with a twisting shaft seal 5 until the inner bearing contacts the pump
mobon body Then with the push shaft and bearing assembly into
3 Remove the screw 4 and seaIing washer 3 that hold the the pump body so that the outer bearing just clears the
cam in place Remove the cam 2 and inner wear plate 8 boss for circlip 19
behind it 6 Install circlip 19 and push the shaft and bearing
4 Remove dust plate 20 and circlip 19 assembly so the outer bearing 18 contacts the circlip 19
S Support the pump body on an arbor press and with a drift 7 Install the dust plate 20
press the shaft and bearing assembly out the pulley end of 8 Install wear plate 8 cam 32 and secure it in place with
the pump washers and screw 4
6 Remove the Oring from the shaft 9 Apply some glycerin to the surface of the impeller
7 Support the outer bearing 18 and push the shaft out of housing impeller inner surface of the cover plate 11 and
the bearing Oring 10
8 Remove the spacer 17 and circlip 13 toWith a twisting motion install the impeller 9 into the
pump Install the Oring 10 and secure the cover plate
11 with the four screws 12
lltall the pulley on the shaft and the hose nipples back
mto the pump Mount the pump on the engine Check
pulley alignment Attach the raw water hoses
WESTERBEKE
EngInes Generators
FUEL SYSTEM
GOVERNOR
1 The adjustments of the 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 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 Governor cover
Main spring lever Guide lever
Timing gear esse
Tensioner lever
Angleich
Sleeve
Fulload stopper
Shifter
WESTERBEKE
Engines Generators
FUEL SYSTEM
Reassembly of shifter
1 Assemble the shifter to the guide lever put the shaft through it and then assemble the snap ring
2 After assembly confirm that the shaft moves smoothly
3 Also confirm that the shifter shakes smoothly
Reassembly of governor cover Guide lever
Assemble the related Pijrts such as the fuel cut lever and
the idle spring to the governor cover
1 When assembling the shaft apply engine oil to the
sliding portion with the governor cover
2 Set both ends of the retum spring securely to the
notched groove at the bottom of the cover and the
bentup arm of the lever Shifter
3 After reassembling the govemor cover confirm that
the governor moves smoothly
4 When assembling the timing gear case to the gover
nor cover tighten the A n dimension shown in the
illustration to 2 3 mm temporarily
The parts given in the square indicated by are assem
bled after performance test
mm in
When assembling
A dimension
2 3 00787 00118
Stop Operate
Governor cover
I
L L
Gasket
Idle screw
Governor lever
Notched groove Washer
Idle spring
Washer
Snap ring
view of the drawing above
v WESTERBEKE
Engines Generators
FUEL SYSTEM
REASSEMBLY OF CONTROL LEVER RELATED PARTS
Lever Main spring
Bush
Apply loctite NoSO
to the Put the lever main spring through the hole ofthe timing gear case hammering in the bushes put both shafts of the lever through the holes of
the timing gear case
lever respectively
2 Put the return spring ofthe control lever through the shaft of the Iever main spring
3 Assemble the bushes
Assemble the bush of the lever main spring first and then the control lever assembling the bushes apply Loctite 601 to the periphery of the bushes
4 Hook both ends of the return spring control lever securely to the protrusion and the pin of the lever
main spring Assemble the control lever
Assemble the Oring to the groove of the bushes control lever first and then assemble the washers
and the control lever before tightening up the control lever with a nut
kgm ft Ibs
I Control lever tightening torque 112 18 90 130
Control lever
aring
Bush Spring washer
Notes
1 TIghten the control lever after locking the control lever firmly
Do not tighten the control lever after locking the main spring lever
2 After assembly confirm that the control lever moves smoothly
i Ellfllnes Generators
FUEL SYSTEM
STRUCTURAL DRAWING OF GOVERNOR
Start spring
Snp pn
Control link
Set spring
Guide tever I
Floating fever
Link
WESTERBEKE
Engines Generators
FUEL of fullload the fullload stopper to the timing gear case and then tighten it with a nut
Lever shaft Main spring lever
Link plate
Mainspring
Eye start spring
Timing gear case
Full load stopper Guide piece
Set spring
Floating lever
Reassembly of governor lever related components
Assemble each lever and spring to the timing gear case
Notes when assembling governor related components
1 When assembling components apply engine oil to each slide such as the end face of the lever the
hole in the shaft and the periphery of the shaft
2 Install the set spring securely to the groove of the pin connecting the floating lever with much care to
its assembling direction
3 Confirm that each lever moves by its dead weight before installing the start spring
4 After assembly confirm that each lever moves smoothly
And also confirm that each spring operates WESTERBEKE
Engines Generators
FUEL SYSTEM
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
THE IJRING GASKET
ONlY NESJS ro BE
FIEPACED IF IT SHOWS
FROM
the Fuel Filter Element
Refer to the illIIstratWn above
L Shut off the fuel supply
2 Ibm the fuel filter bowl to remove
3 Pull the filter eIemeut SlIaight down and off
4 InsJecl both Orings and replace if worn
5 Wipe the Orings with clean fuel and snap the new filter NOZZLE ASSEMBLY
up into place over the small Oring
Inspection and Clean off the filter bowl and threads The bowl can be
profilled with fiicJ Screw the bowl inta place when the Place the removed nozzle in the clean light oil disas
Oring contacts the bousing TIghten the bowl fumly by semble it into the nozzle body and the needle valve and
clean them thoroughly Then check to see if the valve
hand moves smoothly in the body
7 TIle keyon preheat sequence will allow the lift pump to When it does not move smoothly repair or replace the
fill the fuel filter nozzle
8 Run the engmes and inspect for leaks
Injection pipe
Leak off PUMP
The fuel injeCtion pump is a very important component of
the diescJ engine requiring the utmost care in handling
The fuel injection pump bas been thoroughly benchtested the is cautioned
not to attempt to service
it If it requires servicing remove it and take it to an fuel injection pump service
facility Do not
attempt to disassemble and repair it
Injection pump
L
Hetsheld
Gasket fdP
tIY WESTERBEKE
EngInes Generators
FUEL TESTING
1 Using the nozzle tester check the spray pattern and injec
Shim
tion starting pressure of nozzle and if it exceeds the
limit adjust or replace the nozzle When using nozzle
tester take thefolowing precautions Nozzle spring
a If the diesel fuel of the nozzle tester is discolored Spring seat
replace it At the same time clean or replace the filter
Spacer
b Set the nozzle tester in a clean place where there is no
dust or dirt Body
Co Mount the nozzle and nozzle holder on the nozzle
NozzleASM
tester
d Use the fuel at the approximate temperature
of 68 F 20 C
RETAINING NUT
e Operate the hand lever of nozzle tester several times to
bleed the air in the nozzle line then move the hand
lever at intervals of one stroke per second while read
ing the injection starting pressure
Nozzle holder ASM
INJEtnON PRESSURE GLOW PLUGS
1920 PSI The glow plugs are wired through the preheat solenoid
When PREHEAT is pressed at the control panel this
solenoid should click on and the glow plug should
NOZZlE begin to get hot
TESTER Inspection
To inspect the plug remove the electrical terminal con
nections then unscrew or unclamp each plug from the
cylinder head Thoroughly clean each plugs tip and
threads with a soft brush and cleaning solution to
remove ali the carbon and oil deposits While cleaning
examine the tip for wear and burn erosion if it has
eroded too much replace the plug
Testing
An accurate way to test glow plugs is with an ohmmeter
A CAUTION The spray injected from the nDZZle is Touch one prod to the glow plugs wire connection and
the other to the body of the glow plug as shown A
of such velocity that It may penetrate deeply Into the good glow plug will have a 04 06 ohm resistance
skin of ffngers and hands destroying tissue If It This method can be used with the plug in or out of the
enters the bloodstream it may cause blood poisoning engine You can also use an ammeter to test the power
drain 5 6 amps per plug
good No good No good No good
10 JI
About 4
Check to see if the spray condition and the injection pressure
are normal Adjust them to the specified value respectively GLOW PLUG llGHTENING TORQUE
when they do not meet the standard value Use shims to 10 151oflG 7 11 FTLB
adjust the injection pressure
USIIIGA
TESTUGHT
Engines Generators
ENGINE ADJUSTMENTS
TESTING ENGINE COMPRESSION Low Compression
Make certain the oil level dipstick is at the correct level When low compression is found determine the cause by
and the air intake filter is clean The battery and starter motor applying a small amount of oil in the cylinder thru the glow
must also be in good condition plug hole Allow the oil to settle
1 Warm the engine to normal operating temperature Install the pressure gauge and repeat the above test If the
2 Disconnect the wire to the fuel shutdown solenoid compression reading rises dramatically the fault is with the
rings If the compression valve does not rise the problem is
3 Remove all the glow plugs from the engine and install
the compression gaugeadapter combination to the with the valves
cylinder On which the compression is to be measured A slight rise in compression would indicate a problem with
both the rings and the valves
DlL PRESSURE
Low Oil Pressure
The specified safe minimum oil pressure is 5 10 psi A
gradual loss of oil pressure usually indicates worn bearings
For additional information on low oil pressure readings see
Note
the ENGINE chart
Compression pressure may be measured starting at any
cylinder and in no particular cylinder order However it
is very important that the compression pressure be Testing Oil Pressure
measured in each cylinder To test oil pressure remove the oil pressure sender then
Therefore start at the No 1 cylinder and work back In install a mechanical oil pressure gauge in its place After
this way you will be sure to measure the compression warming up the engine set the engine speed at idle and read
pressure in each cylinder the oil pressure gauge
4 Oose the raw water seacock thruhull 558 FOUR OIL PRESSURE
5 Crank the engine and allow the gauge to reach a 43 TO 65 PSI 290 TO 590 KPa NORMAL
maximum reading then record that reading
6 Repeal this process for each cylinder
NOTE Ifthe readings are below the limit the engine needs
an overlraul
55B FOUR COMPRESSION PRESSURE
441 PSI 304 MPa NORMAL AT CRANKING
SPEED OF 250 RPM OIL PRESSURE
441 PSI BETWEEN CYLINDERS SWITCH
7 Reinstall the glow plugs use antiseize compound on MECHANICAL
the threads and reset the fuel shutoff to the run position OIL PRESSURE
GAUGE
S Open the raw water seacock Compression gaJge
Engines Generators
ENGINE ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT 3 In accordance with the conditions of cylinder No1 mea
sure and adjust if required the clearance of the valves
The valve clearance must be adjusted every 500 operating marked with eiiher or in the table below
hours or whenever the valve rocker is abnormally noisy
Valve adJustment should only be done when engine is cold
Cold engine valve clearance is OOI5in O4Omm Cylinder No 1 2 3 4
Valve arrangement I E I E I E I E
When No1 cylinder is at TOe
in the compression stroke
When Np 4 cylinder is at TOe
in the compression stroke
I Inlet E Exhaust
4 On completion of the valve clearance alignment make a
mark alignment as in 1 by giving a turn to the crankshaft
in the normal direction Then measure and adjust the
VALVE CLEARANCE clearance of the other valves
NOTE The cylinder head bolts have been tightened with the
A CAUTION The rocker ann is made of diecast
Angular 1ightening Method Thereore it is not necessary aluminum Therefore be careful not to tighten the
to retighten the cylinder head bolts before adjusting the valve adjusting screw to excess
elearanees
ADJUSTMENT PROCEDURE Adjusbnent of Injection Timing
f The injection timing may not be readjusted Take care not to
forget to insert a shim in the mounting surface when
CRANK PULLEY reassembling the injection pump after Q
Co V
1 Thm the crankshaft clockwise so that the marlc groove 0
the crank pulley is aligned with the TDC mark cast out
on the timing gear case cover
2 Remove the cylinder head cover and check to see if cylin
der No1 is at TDC in the compression stroke or at IDC
in the exhaust stroke When the intake and exhaust valves
are closed the cylinder is at TDC in the compression
stroke and when only the exhaust valve is open it is at
TDC in the exhaust i Engines Generators
ENGINE TIMING
Injection timing I BTDC 16
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made Note
The injection timing varies according to the specifica
1 Remove the injection pipe of the No1 cylinder tions of the machine
2 Remove the delivery valve holder of the injection
pump of the No 1 cylinder and then pull out the 6 Adjust the injection timing with a shim between the
delivery spring injection pump and the cylinder block
3 With the spring left removed install the delivery Shim is available in the following 9 types and iden
valve holder tification mark is stamped or imprinted on the top
face
oelivery valve
holder Injection pump mark of shim and its thickness mm
Mark Thickness Mark Thickness Mark Thickness
2 02 5 05 8 08
3 03 6 06 10 10
4 04 7 07 12 12
Note
For each of the injection pumps of three cylinders the
shim adjustment is made at the same time
4 Slowly tum the crankshaft pulley clockwise at the
same time continue to feed the fuel When a shim is missing while overhauling the engine
and the shim thickness is unknown assemble the
When the fuel stop flowing out from the No1 deliv engine with provisional shim inserted After assembling
ery valve holder stop turning the crankshaft the engine check the injection timing and adjust the
This crank angle position is the starting point of shim until the normal injection timing is obtained
injection Reference
5 In the condition at Step 4 above confirm what To add the 01 mm shim thickness corresponds to the 1
degree the groove mark of the crank pulley is at degree of crankshaft angle advance
when seen by the timing mark provided in the
timing gear case
When the value is out of the range of the normal Injection pump
injection timhg adjust it accordingly
Cylinder block
Engines Generators
WARNING LIGHTS ALARMS CIRUlT BREAKER
ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low dischaIge A low oil pressure alarm switch is located on the engine
I with a red warning light block This switchs sensor monitors the engines oil
The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 psi
perfonnance of the alternator 04 07 kgfcm this switch will activate a pulsating
alarm
COOlANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing This switch will activate a continuous alarm if
the coolants operating temperature reaches 2100 P 99C
OIL PRESSURE AlARM
SWITCH
BUZZE5 ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by an engine
mounted manual reset circuit breaker 20 arnps DC
Excessive current draw or electrical overload anywhere in
the instrument panel wiring or engine wiring will cause the
breaker to trip In this event most engines will shut down
because the opened breaker disconnects the fuel supply If
this should occur check and repair the source of the problem
After repairing the fault reset the breaker and restart the
engine
BREAKER
WIRES
WESTERBEKE
Engines Generators
STARTER NoLoad Test
The sttuter can be roughly divided into the following sections 1 Connect the ammeter voltmeter and battery to the starter
A motor section which generates a drive power as An ovemmning clutch section whicb transmits an arma 2 When the
switch is closed the pinion must protrude and
lUre tmque preventing motor overrun after starting the starter must run smoothly at 3000 rpm or more If
A switch section solenoid whicb is operated wben actu the current or starter speed is out of disas
ating the overrunning clutch through a lever and whicb semble the starter and repair it
supplies load current to the motor
The starter is a new type small lightweight and is called a
highspeed starter The pinion shaft is sep
3I8Ie ftom the motor shaft the pinion slides only on the pin
ion sIIoI4 A reduction gear is installed between the motor
shaft and a pinion shaft The pinion sliding part is not
exposed outside the starter so that the pinion may without becoming fouled with dust and grease The
motor shaft is supported at both ends on ball bearings The
lever mech8ism switch and overrunning clutch inner circuit
r I SAnERY 1
are identical to conventional AND REPAIR A CAUTION Use thick wires as muth as possible and
tighten el8ry tetminal SllCursly This is a solBloid shift
If any almormaIity is found by the following tests the starter type starter whlth makes a rotating sound loudsr than
should be disassembled and repaired that of a dITBCtdri18 type stalter When dllfflcting
starter rotation at the pinion tip be careful not to come
Piaion Gap Inspection In contact wfth the pinion gsar whent protrudes
1 Connect a battery 12V between the starter terminaI S
and the starter body and the pinion drive should rotate out
and stop SOLENOID
Perform the following tests If any test result is not
satisfactory replace the solenoid assembly
A cAIJID IlI1rtI1t apply wtage tor over 10
I 1 lnspect the solenoid for continuity between terminals
battery
and and between terminals S and the body and
M and the body There should be no continuity found
2 tightly push the pinion bsck and measure the return between terminals S and M Continuity will be found
stroke called pinion gap between terminals S and the body and terminaI M and
the body
3 If the pinion gap is not within the standmd range 05 to
20 mm adjust it by increasing or decreasing the number
of shims on the solenoid The gap is decreased as the
number of shims GENTLYPUSH
BACK MUlTIMETER
NOTE Disconnect the wire from terminal M
2 Connect a battery to the solenoids terminal S for
and M for Have a switch in the lead and close it
The pinion drive should extend fully out
152D
A CAUTION Do not apply battery current for mote
than 10 seconds when testing the solenOid
PlalOaGAP
i Engines Generators
STARTER MOTOR
4 Return test With a battery connected to the solenoid ter
minal M and to the starter body manually pull out the
COIINECTDR OFF pinion fully The pinion must return to its original position
AT11IACTION lEST when released from holding by hand
3 Holding test With a b8ttery connected to the solenoid ter
minal S and to the starter body manually pull out the
pinion fully The pinion must remain at that position even
jlYben released from holding with your hand
RETURN TEST
CINNECTOR OFF
STARIER DISASSEMBLY 7 Pull out the reduction gear lever and lever spring from the
front bracket
L Discon the wire from the solenoid terminal M
8 On the pinion side pry the snap ring out and pull out the
2 Loosen the two screws fastening the solenoid Remove the solenoid assembly
9 At each end of the armature remove the ball bearing with
3 Remove the two long through bolts and two screws
fas1rning the brush holder Remove the rear bracket
a bearing puller It is impossible to replace the ball bearing
pressfitted in the front bracket Ii that bearing has worn
4 WlIh the brushes pulled away from the armature off replace the front bracket assembly
remove the yoke and brush holder assembly Then pull
the armature out TERMINALM
5 Remove the cover pry the snap ring out and remove the
washer
6 Unscrew the bolts and remove the center bracket At the
same time the washers f the pinion shaft end play
adjustmeDt will come off
WEAR CfflPING
STARTBI
II011IR
LEVER SPRING
NOTE Jnspect ceOJl and replace
if necessary brush COTTU1UJer
solenoid Ql77U2ture elc See the
Jollawing pages
PINION
Engines Generators
STARTER MOTOR
STARlER INSPECTION CRIICUS the solenoid for continuity
between terminals S and
M and between tenninals S and body No continuity should
be found between S and M Continuity should be found
between S and the body and M and the body
Brush and Brush Holder Inspection
1 Check the brushes If worn out beyond the service limit
replace the brushes
Brush Height
StlJlUiard 17 nun 0669 in
limit 6 nun 0236 in
Tbe Annature
L Checkthe aonature with a growler tester If its short
circuited repIace the 8IlllllIDre Also check for insulation 2 Check the brush spring tension A weak or defective
between the and its shaft If poorly spring will cause excessive brush wear replace the springs
insulated repIace the armaIlIre if suspect
ARMATURE BRUSH HOLOER
CHECK ASSEMBLY
3 Check for insulation between the positive brush holder
2 Measure the commutator OD and the depth of undercut and holder base If poorly insulated replace the holder
Repair or repIace4t if the service limit is exceeded Also assembly Also check the brush holders for proper staking
check the comm1i1ator outside surlace for dirtiness and
rouglmess If rough polish the commutator with fine
aocus cloth
CoIlUlUllDr OD StJuulJzrd
StiuuIIlrd 387 nun 1523 in
D lce limit 10 nun 0039 in
Engines Generators
STARTER MOTOR
Field Coil Inspection 2 Greasing Whenever the starter has been overhauled
apply grease to the following parts
1 Check for insulation between one end brush of the
coil and yoke a Armature shaft gear and reduction gear
2 Check for continuity between both ends brushes b All bearings
of the coil c Bearing shaft washers and snap rings
3 Check the poles and coil for tightness d Bearing sleeves
e Pinion
f Sliding portion of lever
A CAUTION Never Slllear the starter fitting rface
terminals bnIshes I1r with grease
3 After reassembly check by conducting a noload test
again
GEAR
FIELD COIL TEST
STARTER ADJUSTMm AND REASSEMBLY
WASHER
SNAP RING
A CAUTION IJeforB installing thl1lDUghly clean the IO5 mm MAX
stalter flange and mollJltfng SIIrfates reml1w alillil
old paint aad IUI Starter perflJrmanCB largely
depends I1n the quality 111 the wiring Use wire 111 suffi PINION SHAFT END PLAY
cient size aIJd grade between the battery and starter
and fully tigttBn to the rellllnal
Reassemble the starter assembly in the reverse order of
disassembly making sure of the following
1 Pinion shaft end play adjustment Set the end play thrust
gap to between 05 to 2 mm by inserting an adjusting
washer between the center bracket and the reduction gear
a Fit the pinion shaft reduction gear washer and snap
ting to the center bracket
b Measure end play by moving the pinion shaft in the
axiaI direction If the end play exceeds 05 mm
increase the number of adjusting washers
I Engines Generators
DUAL OUTPUT ALTERNATORS
SPACER TO MOUNTING
outpw and high output alternators are available as
optional equipment on most WESTERBEKE engines can be installed during factory assembly or as CABLE
TO BATTERY equipment at anytime
Dual alternators can be configured to charge two banks of
balteries at the same time or using a battery selector each set of batteries separately TO
PULLEY
an optional dual alternator has already been factory installed
simply follow the WESTERBEKE wiring diagram and the
engine installation the new dual alternator is being added to an existing engine carefully follow the alternator below
L Disconnect the alternators negative cable from the
battery
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse
3 Install the new Attach a new heavy gauge output cables from the
alternators output terminal s Using the cable sizes
indicated
DUAL OUTPUT ALTERNATOR
CHARGING ONE BAnERY
ALWAYS USE FINE STRAND CABlEl
S Make certain that the batteries negative post ground
BATTERY 1
cable to the engine block is the same heavy gauge as
the positive cable
6 Mount the regulator to a flat surface in a cool dry
location
a Connect the black wire to the ground terminal on the
alternator TO
A CAUTION DIl nllt CIInnect any pllwer stJUTeB with
Ilut first fJ1Junding the b Plug the 2pin connector into the alternator make
certain it is firmly seated
c The red battery sense wire should be connected to
the batteries positive post or the positive cable
d The brown wire keyed ignition is the key circuit
which actuates the regulator this wire must connect fila ONNECTS TO PINK AND
to a switched 12 volt source Refer to the LEADS THE PINK
ZWIJE CONNECTS TO THE
WESTERBEKE WIRING DIAGRAM for the proper BUZZER THE BLUE
connection WIRE CONNECTS TO THE
OIL PRESSURE SWITCH
Dual Pulleys
A variety of accessory pulleys for high powered and dual DUAL OUTPUT alternators are available from
your CHARGING TWO Engines
Generators
DUAL OUTPUT Alternator Testing
NOTE Before mrzke certain that the drive The regulator is functioning properly and the are tight and the batteries are in good
condition are in good Testing 1 Test the voltage at the alternator plug with
the engine
offkey on The voltage at the alternator terminal F and
The red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the always read battery voltage If
battery voltage is not should read the same
presen trace the wire for a bad connection
2 Hold a screw driver close 112 to the alternator pulley
The orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field If
volts with the key on If the readings are no the problem may be the brushes worn or the trace the wire for a bad connection
open circuit
The blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output terminals will vary depending on
the battery charge or actual indicate 142 volts no load A reading of 126 The readings can vary from 4 to 12 volts with the
indicte the alternator is not performing properly
key on 0 volts with the key off
Apply a load such as an electric bilge pump the voltage
KEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or less
KEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER IgnJUon 011
IgnRion On Engine Running NOTES
I Brown 0 volts 2 12 valls 142 volls o When the engine is first started it takes a few moments
A Red 126 volls 12 vulls 142 valls for the altel71lllOr to ldck in and take the load There
S Orange ovalls ovalls 68 Valls is a noticeable change in the sound of the engine and the
F Blue Ovolls 10 11 valls 4 12volls RPM gauge will excite
AltOUlpUi 126 valls 12 valls 142 volls
o A slight whine is normlll when running with a full load
on the o When the alternator is producing high amperage it will
become very hot
o When replacing the altel71lllOr drive belts always
purchase and replace dual belts in matched pairs
I Engines Generators
WIRING SCHEMATIC
STAIIT
II vot
m S1ARTCA
PItHtAl
rSOl
J 1
ALttRNA10R
1 J TH IIK WIR AT LUG 2 IS InIUUD AIID SHOULD BE INSUUlD CAN ANtl ONLY
4 THE GRAY IRE AT lUG 2 IS UMusro UD SHOULD lit INSULAlD AOKIUL ANEL OIIU
Y n CB 1
LIH PUMP
TO ALT I
TeRM
P J gf I
Ii
InUl
fl I
L U 1
I lQBP 1 30B ONl
IIDU
I MIIV6i I 4 LT BLU
fl4 PINK
difcH XI
1 1
0 RO
14 BRN
n lACora
ADMIRAL pRESTOI ITE 72 AMP AI T
ft PANEL
4 8RN
VOLTMUtA
SUIT
14 GRA
GAUGE
1114 PINK
414 LT 8L
I t I YfjRSAl PROPUI S I Wr
i MR
PR STO ITF 51 AMP A
I CAPTAIN
lESf
PANEL
51 AMP AI TERNATOR
STNOARO AllERtiA10R ON TilE
f 04 02
638 01 63C Il i IB IT 826 IT
1086 D 10SC
i
r
1101101
SIlIrCti
WIRING SCHEMATIC 39144
sruuW lWITW 19
OPT IONAI AI IERNATORS
JA 101 IOA ltsT1I ALHRNAlORi
AVAIAnqM 1H no rv ue ty liB II UB ty nRD I
WESTERBEKE
Englnes Generators
WIRING DIAGRAM rI
Q II flQSURC
mID I
1 N ME
MODELS
HOH 2
rT PUlAI
An onoff swiIh
should be installed in this
circuft to disconnect the battel in
an emergency and when
leaving theboat Twelve
volt engine dtaw 200 to 300 ADM I RAL
amps when etanking A PANEL
switch with a of 175 amps at 12
vac will normally serve
this function but a swiJch WIRING DIAGRAM 39144
must never be used to 1
make the sIllrter circuit
CAPTAIN
PANEL
o 1
WESTERBEKE
Engines Generators
METER NOTE Cumn model tachometers use a coarse adjustmen
dial 10 set the tachometer 10 the crankshaft pulley rpms The
The meter used in propulsion engine instru
calibrating screw is then used for fine tuning
ment panels contains two separate electrical circuits with a
common ground One circuit operates the hour meter and the
other the tachometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the back of the tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage DC
The following are procedures to follow when
TERMiNAl
a fault in eithei of the two circuits in a meter for the proper DC voltage between and
TACHOMETER CHECK New Voltage present meter is defective repair or replace NOTE In a new installntion having new insrrumen panels
the tachometer may not always be comctly calibrated 10 the
2 VolIllge not present trace and electrical con engines rpm This calibration should be checked in all new
nections for fault Jump 12 volts DC to meter terminaJ to verify the operation
1 Warm up the engine to normal operating Inoperative Remove any specks on the crankshaft pulley
with a clean
Check for the proper AC voltage between tachometer input cloth and place a piece of suitable reflecting tape on the
terminal and terminal with the engine running pulley to facilitate use of a photoelectric type tachometer
L Voltage present attempt adjusting meter through calibra 2 Start and idle the engine
tion access hole No results repair or replace meter 3 Aim the light of the tachometer onto the refiecting tape to
2 AC voltage not present check for proper alternator DC confirm the engine speed Check the instrument panel
output voltage tachometer reading Adjust the tachometer in the panel by
using the instrument coarse adjustment to calibrate the
3 Check for AC voltage at tach terminal on alternator to instrument reading to the closest RPM that the photo tach
ground is showing Then use the fine calibration adjustment to
4 Check electrical connections from tachometer input ter bring the instrument to the exact reading as the photo tach
minaI to alternator Sticking
1 Check for proper AC voltage between tach inp
terminaJ and terminal
2 Check for good ground connection between meter
terminaJ and Check that alternator is well grounded to engine block at
alternator pivot With a handheld tach on the front of the crankshaft
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley pm at idle
b Adjust the tachometer with a SmaIl PbilIips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the pm
indicated by the strobe or hand tach Verify the pm at
idle and at high speed and adjust the tach as needed
WESTERBEKE
Engines Genellltors
WESTERBEKE 51A MANDO ALTERNATOR
DISASSEMBLY AND TESTING
A WARNING A failed alternator can become very
hot Do not touch until the alternator has cooled down
REAR HOUSING
A WARNING Before starting the engine make
certain that everyone is clear of moving parts Keep
away from sheaves and belts during test procedures
A WARNING Multimeters and DC Circuits
DC and AC Circuits are otter mixed together in marine
applications Always disconnect shore power cords
isolate DC and AC converters and shut down generators
HOUSING
before performing DC testing No AC tests should be
ASSEMBLY COVER
made without proper knowledge of AC EXCITER
TERMINAL
TERMINALP
I COVER
SENSING
TERMINAL
GROUND REFER TO THE
TERMINALE WIRING DIAGRAMS FOR THE ABOVE
WIRING HARNESS CONNECTIONS
TESTING THE EXCITATION CIRCUIT
TESTING THE OUTPUT CIRCUIT 1 Connect the positive voltmeter lead to the excitation
1 Connect the positive voltmeter lead to the output terminal R on the alternator and the negative lead to
terminal B and connect the negative lead to the ground the ground terminal E on the alternator
terminal E on the alternator 2 Tum the ignition switch to the on position and note the
2 Wiggle the engine wiring harness while observing the voltmeter reading The reading should be 13 to 25
voltmeter The meter should indicate the approximate volts see battery voltage and should not vary If no reading is 3 If the
reading is between 75 and 11 volts the
obtained or if the reading varies check the alternator rotor field circuit probably is shorted or grounded
output circuit for loose or dirty connections or Disassemble the alternator and test the rotor as
damaged wiring described under CLEAN AND TEST ALTERNATOR
COMPONENTS in this section
NOTE Prior to any alternator testing inspect the entire
alternator system wiring for defects Check all connections 4 If the reading is between 60 and 70 volts the rotor
for tightness and cleanliness panicuarly battery cable field circuit probably is open Remove the regulator
clamps and battery terminals Inspect the alternator drive and inspect it for worn brushes or dirty slip rings
belt for excessive wear and replace if necessary Also adjust Replace the brushes if they are less than l4in 6 mm
for proper belt tension long If the brushes and slip rings are in good condi
tion disassemble the alternator and test the rotor as
outlined under CLEAN AND TEST ALTERNATOR
COMPONENTS in this section
Engines Generators
MANDO ALTERNATOR SERVICE
e Remove the regulator THE EXCITER LEAD
f Temporarily reinstall Jumper A and all associated
nuts Leave Jumper B installed
g Remove the plastic plug from the side of the
regulator
b Connect a jumper between the top brush lead
and the ground
JUMPER A
5 H no reading is obtained an open exists in the
lead or in the excitation circuit of COVER
the regulator Disconnect the lead from exc terminal R
Connect the positive voltmeter lead to the excitation SENSING lead and the negative
voltmeter lead to ground terminal TERMINAL TERMINAL
E If the voltmeter now indicates an approximate battery
voltage the voltage regulator is defective and must be
GROUND
replaced If no voltage is indicated check the excitation
circuit for loose or dirty connections or damaged wiring B
TEST VOLTAGE REGULATOR I
Perfonn this test to determine if the voltage regulator is CONNECT
operating correctly using a 0 20 volt DC voltmeter JUMPER WIRE
NOTE The battery must be folly charged to obtain a proper
voltage reading in this test If necessary charge the battery
with a battery chargeror allow the engine to run a of time to fully charge the battery before taking a Connect the positive
voltmeter lead to the positive
battery terminal and the negative voltmeter lead to
the negative terminal
2 Start the engine and run it at fast idle until the engine
reaches its normal operating temperature Adjust the PLASTIC PLUG
LEAD
engine speed to 1500 2000 rpm and observe the FROM BRUSH
voltmeter for the highest reading The reading should
be between 137 and 147 volts
3 If the reading is high check for a loose or dirty i Repeat steps 1 and 2
alternator ground lead connection If the connection is NOTE Do not let the voltage exceed 16 volts
good the voltage regulator is faulty and must be
j If a voltmeter reading of 145 volts or above is
replaced Be sure to disconnect the battery cables before
now obtained the voltage regulator is faulty and
attempting to remove the alternator
must be replaced If the voltmeter reading is below
4 If the reading is low 145 volts inspect the brushes and slip rings for
a Stop the engine and remove the alternator wiring wear dirt or damage If the brushes and slip rings
connections are good the alternator is fault internally
b Remove the Phillips cover screw from the regulator Disassemble the alternator and test the components
cover see as outlined in this section
c Remove the nut from the output terminal and the
nut from the sensing tenninal and remove Jumper
d Remove another nut from the sensing terminal and
the nut from the excitation terminal
Engines Generators
MANDO ALTERNATOR SERVICE
REMOVE ALTERNATOR 10 Place an oversized Vbelt around the pulley and fasten
the pulley in a vise
1 Disconnect the negative battery ground cable
11 Use a 78 in box wrench to loosen and remove the
I 2 Disconnect the wiring leads pulley nut
3 Loosen the screws Holding the alternator rotate it 12 Remove the pulley nut lockwasher pulley fan and
toward the engine and lift the belt off the pulley spacer
4 Remove the screws and washers and remove the TERMINAL
SCREWS PUUEY AND FAN COMPONENTS
A CAUTION DO NOT insert screwdriver blades
more than 116 in 16 mmJ Damage to the stator
TERMINAL winding could result from deeper NOTE Score the
stator and the front and rear housings so
the unit may be reassembled correctly
13 Remove the four throughbolts and carefully pry the
DISASSEMBLE ALTERNATOR front housing away from the rear housing using two
1 Remove the tenninal nuts to remove the jumper see
11 nllln HOUSING
2 Remove the remaining tenninal nuts
3 Remove the capacitor
4 Remove the Phillips screw from the regulator cover kFRONT
SCREW DRIVER HOUSING
5 Remove the cover
6 Remove the nut from the terminal
7 Remove the jumper HOUSING AND STATOR REMOVAl
8 Remove the enninal insulators
9 Remove the two Phillips screws and remove the 14 Carefully push the rotor assembly out of the front
assembly housing and rear housing
VBELT
NOTE If the bearing is removed from the housing a new
bearing must be installed
15 After removing the three bearing locking screws care
PUllEY fully press the front bearing out of the housing Press
REMOVAl against the inner race of the bearing
Engines Generators
MANDO ALTERNATOR SERVICE
2 Inspect and test the diodetrio assembly
3 Using a commercial diode tester a 12volt DC test
lamp or an ohmmeter check the resistance between
BEARING LOCKING each of the three diode terminals and the indicator
SCREWS light stud
light stud
FRONT BEARING
DIODE TERMINAL
BEARING
DRIVER
DIODE TRIO ASSEMBLY
b Reverse the tester leads and repeat the resistance
HOUSING checks
c A very low resistance should be indicated in one
16 Remove the rectifier assembly by removing the Phillips direction and a very high resistance should be indi
screw and lifting out the assembly cated in the other direction if the diodes are nonnal
d If any diode appears to be defective replace the
complete assembly Do not attempt to replace an
individual diode
3 Test the bridge as ASSiMBLY 3 Using a commercial diode tester check for
continuity from each of three terminals to the
ouput OUTPUT
RECTIFIER REMOVAL RECTIFIER
TERMINAL DIDOES
CLEAN AND TEST ALTERNATOR COMPONENTS b Reverse the tester leads and repeat Step 3
1 Inspect and test the assembly The c Continuity should exist in only one direction and
brush set may be reused if the brushes are 14 in
all diodes should check alike
6 mm or longer The brushes must not be oil soaked d Perfonn the same continuity checks between the
cracked or gt9Oved three terminals and strap ground terminal This
Test for continuity between I and 2 and 3 and 4 using should show continuity in only one direction
3 test lamp or an ohmmeter These checks will indicate through the diodes and all diodes should check
a good assembly replace the complete alike
assembly if necessary e If any diode appears to be defective replace the
rectifier TESTING BRUSH ASSEMBLY
Engines 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 outof
round bore in the mounting foot If possible
correct slightly damaged threads using a tap b Check the resistance from each lead I 2 and 3 to
Replace the housing if necessary the laminations 4 There should be no continuity
e If the housings are to be reused clean them in if the insulation is good
solvent and dry with compressed air e Inspect the stator windings for signs of Clean and inspect the rotor shaft bearings
A discolored winding should be replaced
NOTE Do not use a solvent on the rear rotor bearing d If a winding shows a high resistance or an open
since it is serviced as a unil wilh Ihe rOIOr circuit between any two of the three winding
terminals or indicates poor insulation between the
a The bearings should be wiped clean with a lintfree windings and the laminations the stator must be
cloth containing a moderate amount of commercial replaced
solvent Do not inunerse a bearing in solvent or
use pressurized solvent or air 8 Check the rotor assembly as follows
b Check the bearings for obvious damage looseness NOTE If slip rings need 10 be replaced you must
or rough rotation Replace a bearing if any doubt replace the entire rotor
exists as to its condition a Visually inspect for physical defects such as dam
NOTE If the rear rolor bearing needs replacement aged shaft threads worn or damaged bearing areas
repoce the entire rolor burned or pitted slip rings or scuffed pole fingers
6 Inspect the belt pulley for rough or badly worn belt b Measure the winding resistance across the slip rings
grooves or keyway and for cracks or breaks Remove A Place the ohmmeter leads on the edges of the
minor burrs aild correct minor surface damage replace slip rings not on the brush contact surfaces The
a badly worn or damaged pulley 0
correct winding resistance at 70 80 F 21
27 C is 41 to 47 ohms
c Minor burning or pitting of the slip ring surfaces
FRONT can be removed using a croCus cloth Thoroughly
wipe the slip rings clean afrer polishing removing
FRONT all grit and dust
BEARING
dCheck 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
HOUSING be indicated in both cases for a good rotor
e If the windings are defective or physical damage
cannot be corrected replace the rotor assembly
9 Use a commrcial capacitor checker to test the
capacitor for capacity shorts leakage and series
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
INTERNAL CIRCUIT WIRING
Engines Generators
MANDO ALTERNATOR SERVICE
2 Place the rotor pulley end up on the bed of an arbor
press on two steel blocks
3 Press the front housing and bearing assembly down
onto the rotor shaft Press against the bearings inner
race only using a sleeve driver Take care to insure that
ANGERS the rotor leads clear the steel blocks
SLEEVE DRIVER
FRONT HOUSING AND
BEARING THE ROTOR ROTOR
INSTAlliNG THE FRONT HOUSING ON THE ROTOR ASSEMBLY
ASSEMBLE ALTERNATOR 4 Install the rectifier assembly into the rear housing
1 Carefully press the front bearing inta the front housing 5 Insert the Phillips screw and tighten it
pushing agajnst the bearings outer raoe using a hearing
driver Lock the bearing in place with screws
TORQUE 25 351lrin 28 40 Nm
RECTIAER
ASSEMBLY
BEARING
HOUSING
6 Assemble the front and rear housings as follows
a Put the siator winding in the front housing with the
FRONT BEARING ASSEMBLY stator leads away from the front housing and the
notches in the stator laminations aligned with the
four throughbolt holes in the housing
b Align the scribe marks you made in the stator and
front and rear housings during disassembly
BEARING LOCKING c Slip the rear housing into place over the rotor shaft
SCREWS Align the mounting holes and put the stator leads
through the holes at the top of the rear housing
d Install the four bolts and tighten them
TORQUE 35 651bft 40 73 Nm
NOTE If the front housing is new the throughbolt
FRONT BEARING will not be tapped
ASSEMBUNG THE BEARINGS
Engines Generators
MANDO ALTERNATOR SERVICE
7 Install the spacer and the fan Then push the pulley INSTALL ALTERNATOR
lockwasher and nut onto the shaft Tum the nut a few
1 Install the alternator screws and washers
turns
8 Place an oversized Vbelt around the pulley and fasten 2 Connect the wiring leads
the pulley in a vise 3 Put the belt on the alternator crankshaft and coolant
pump pUlleys
4 Adjust the alternator belts tension see DRIVE BELT
ADJUSTMENT under ENGINE OVERSIZEO
MANDO ALTERNATOR Battery Vollage 12 von
Maximum Speed 13500 RPM
Cutin Speed Max 2000 RPM at exc
Max 1500 RPM at l2
Reg Set Vollage 147Votts
Ambient Temp 2OC 10OC
Ground Negalive
INSTALLING THE PULLEY AND THE FAN NUT
9 Use a torque wrench to the tighten the nut
TORQUE 3550 Ilrtt 47 68 Nm
10 Carefully install the assembly on the
rear housing with the two mounting screws
11 install the small terminal Install the large terminal Install the jumper
14 Install the nut on the terminal
15 Install the assembly cover
16 Install the Phillips screw for the assembly cover
TORQUE 25 351btt 28 51 Nm
17 Install the Install the tenninal nuts
19 Install the jumper
20 Install the last terminal nut
Engines Generators
TORQUE DATA
Kgm IbH
CYUNDER BLOCK AND OTHER COMPONENTS
25 35
1BO 253
i 1525
108 1801
I 1929
137 2101
CYUNDER HEAD ANoCYUNDER HEAD COVER POSitiOning
0812
70 90 15884
506 650
WESTERBEKE
Engines Generators
TORQUE DATA
Kgm IbH
CYLINDER BLOCK AND OTHER Dont remove hiS bolt
from connecting rod
COOLING FAN AND WATER PUMP
To cylinder head
170 190
IApplV engine oilI
11230 1374
Apply Locktite No262 to set up side of stud
Engines Generators
TORQUE DATA
Kgm IbII
With PTO 5887
0812
rI
GASKET LOCATION
LOCATIONS WHERE GASKETS ARE USED
Gasket joint bolt
Corrugated washer
ieldiI
Gasket
water outlet pipe
Qring
control lever
Oil seal
crankshaft front
I plug Gasket
Oring
Oil pump exhaust silencer
Engines Generators
ANGULAR NUT AND BOLT TIGHTENING METHOD
1 Carefully waSh the nuts and bolts to remove all oil and 6 Draw another line FG on the face of each of the parts
grease to be clamped TItis line will be in the direction of the
2 Apply a coat of molybdenum disulfide grease to the specified angle Q across the center E of the nut or
threads and setting faces of the nuts and bolts bolt
3 Tighten the nuts and bolts to the specified torque snug 7 Use a socket wrench to tighten each nut or bolt to the
torque with a torque wrench point where the line AB is aligned with the line FG
CENTER LINE Example Specified Angle and Tightening Rotation
LINE A 30 1112 ofa tum
C l D
16 ofa tum
14 ofa tum
112 ofa tum
E 360 One full tum
4 Draw a line AB across the center of each bolt
5 Draw another line CD on the face of each of the parts
to be clamped TItis line should be an extension of the E
line AB
COINCIDING LINE
Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts
TOOLS AND TESTING GEAR
COMPRESSION GAUGE ADAPTER FRONT DlL SEAL SmlNG TOOL
REAR OIL SEAL SmlNG TOOL
WITH DRIVE HANDLE WITH DRIVE HANDLE
ptl 15 CONTACT THE WESTERBEKE CORPORATION FOR
U VALVE GUIDE SEAL SmlNG TOOL
INFORMATION ON THESE AND OTHER SPECIAL TOOLS
Engines Generators
STANDARD BOLTS I TIGHTENING TORQUE The torque values given in the following table should be applid where a particular torque is not specified
kg m
cation
Bolt
diameter X
pitch mm
0702
M 6 X 10 06 02
08 02
09 02
03
16 04 18 05 05
M 8X125 13 05 21 24 07
06 06 07
M10 X 125 28 07 33 08 38 09 43 09 51 13
09 10
M10 X 15 27 07 32 08 37 09 42 10 49 12
M12 X 125 62 13 67 14 77 16 88 18 97 19
12 13 15 17 20
M12 X 175 58 12 63 12 72 14 82 16 91 18
2 2
M14 X 15 97 104 119 136 145 29
19 21
M14 X 20 91 18 98 19 112 22 128 25 136 27
M16 X 15 133 27 151 31 173 35 197 40 204 41
M16 X 20 127 25 144 29 165 33 188 38 195 39
M18 X 5 192 38 217 249 50 284 57 293 59
M18 X 25 44
192 38 218 250 50 285 57 294
61 79
M20 X 15 263 53 300 344 69 392 78 404 81
M20 X 25 243 49 278 318 64 363
374 7S
M22 X 15 3201 404 81 463 i 528105 541 108
1 106
M22 X 25 278 56 376 75 431 86
i 491 98 503 101
M24 X 20 458 92 4791 54 9 176 626 201 706 141
110 126
M24 X 30 431 86 451 90 517 103 I 589 11 8 664 133
I 117
NOTE Bolts marked with an asterisk are used for female threaded parts made of soft materials such as
WESTERBEKE
Engines Generators
TIGHTENING TORQUE NOTE The torque values given in the following table should be applied where a particular torque is not specified
FLANGED HEAD BOLT kgm lb ftNm
f
marking
Nominal
XDitch
M6 x1
0509 0612
361a5046 85 1120 1429 1934
Me x 125
433 2339 3664 4372
M10x125
1735 28202353 3824 2338 3558 4168
10 x 15
5687 5684 79119 87130
M12 x 125
4050 5714 86077747 11669 3595 73109 81122
12 x 175
7649 5280 11964
85127 117176 126189
M14 x 15
9113 76115 111166 118177
14x2
118177 171265 180271
M16x15
8534 17357 25693 26576
112167 166249 172257
16x2
12440 25301
A bolt with an asterisk 1 is used for female screws of soft material such as cast iron
WESTERBEKE
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet It x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 EQUIVALENTS
1 Degree of Latitude 60 Nm 111120 km
1 Minute of Latitude 1 Nm 1852 km
VOLUME
Cubic Inches in x 16387 Cubic Centimeters x 061 in
Imperial Pints IMP pt x 568 lfters l x 176 IMP pt
Imperial Quarts IMP qt x 1137 lfters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Uters l x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Millilfters x 034 Ounces
US Pints US pt x 473 lftersl x 2113 Pints
US Quarts US qt x 946 lfters l x 1057 Quarts
US Gallons US gal x 3785 Liters l x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water Ho x 07355 Inches of Mercury x 13783 H20
Inches of Water fi0 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ItIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUa CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter Kml
Kilometers Per lfter KmIL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter Kml
Kilometers Per lfter KmIL x 2352 US Degree Fahrenheft oF OC X 18 32
Degree Celsius OC OF 32 x 56
UQUID WEIGHTS
Diesel Oil 1 US gallon 713 Ibs
Fresh Water 1 US gallon 833 Ibs
Gasoline 1 US gallon 61 Ibs
Salt Water 1 US gallon 856 Ibs
WESTERBEKE
Engines Generators
ENGLISH TO METRIC CONVERSION CHART
Multiply Temperature By To aet eauivalent number of
Dearee Fahrenheit 0 OF32 18 Dearee Celsius C
Multiply Acceleration By To get eouivalent number of
03048 00254 Metersecond Imfs
Multiely Toraue By To eel eauivalent number of
011298 Newtonmeters Nm
Poundfoot IIb1t 13558 Newtonmeters INm
Multiply Power By To eet eaulvalent number of
Horsepower hpl 0746 KilowaHs IkWI
MultiDlv Pressure or stress By To gt quivalent number of
Inches of water fin H 0 02491 Kilopascals IkPal
in liMn 6895 Kilopascals kPll
Mulliel Enerav or Work By To aet equivalent number of
British Thermal Unit IBtu 1055 Joules IJ
FoolJound ftlbl 13558 JoulesJJ
3600000 or
kilowatthour kWhr Joules J one Ws
36 x 10
MulliJly Ught By To aet eQuivalent number of
Foot candle fc 10764 Fuel Performance By To number of
Milesaal ImileoaJ 04251 kmlLl
Gallonsmile eaVmilel 23527 Ukml
Multiely Vetocltv By To oet eauivalent number of
Mlleshour mllelhrl 16093 kmlhr
MulIY LenAlh By To aet eaulvalent number of
Inch lin1 254 Millimeters Imm
Fool Iftl 03048 Meters 1m
Yard Iydl 09144 Meters Iml
Mile mile 1609 Kilometers Ikml
MulIY Area By To aet eauivalent number of
Inchlin 6452 Inchlinl 645 Centimetersl fcm 2
Footiftl 00929 Metersiml
YardCydl 08361 Meterstml
Multiply Volume fa To oet eouivalent number of
Inchlin 16387 Inchlin 16387 Inchlin 00164
LHers III
Quart lat 09464 LHers Ll
Gallon iaah 3785 LHers Ll
Yardlvd 07646 Melerslml
Mulliply Mass By To aet eauivalent number of
Pound Ob 04536 Kjoorams ko
Ton ton 90718 Kiloarams Ikol
Ton lion 0907 Tonne ttl
Multiply Force BY To aet equivalent number of
Kiloaram Ike 9807 Newtons INl
Ounce oz 02780 Newtons INl
Pound lib 4448 Newtons INl
Engines Generators
INDEX
A1airms Engine Compression Dual Output Engine Disassembly 10
Alternator Thsting and Repair Camshaft 13
Circuit Breaker 53 Crankshaft End Play Engine Idler Gear End Play 11
Cooling System Injection Pump 11
Dual Output Alternator 58 Internal Parts Drawing 12
Engine Adjustments Measurements 11
Engine Assembly Piston and Connecting Rod 14
Air Intake Filter 41 Piston Ring 37 Piston Pin 14
Camshaft 30 Timing Gear Bearing 31 Timing Gear Backlash 11
Cylinder Head Assembly Transmission 10
Cylinder Head 33 Valve 13
Diagram External Parts 34 Engine Inspection and Repair 15
Diagram Lubrication 39 Camshaft 16 Connecting Rod Pulley and Shaft Connecting Rod Bearing 15
Engine Adjustments Crankshaft and Crankshaft Bearing 23
Engine Tuning 38 Crankshaft Gear Parts Diagram 34 Cylinder Block 15
Filter Air Intake 41 Cylinder Head 15
Flywheel 32 Heat Shield 17
General Information 39 Hot Plug 1617
Idle Gear 17 Oil Seal 24
Injection Pump 35 Piston Piston Pin Piston Ring Parts Piston Ring Gap Diagram 39 Ring Gear Filter 34 Rocker
Arm Pan 33 Tappet and Push Rod 19
Oil Pipe and Strainer 33 Timing Gear Pump 32 Valve Valve Seal 17
Piston and Connecting Rod Valve Seat 18
Piston Rings Valve Spring 19
Pump Oil 33 Engine 4
Pump Water 40 Engine 6
Push Rod 33 Flywheel 30
Solenoid 35 Front Oil Seal 32
Starter 37 Fuel Filter 3641 FuelInjection Pump 48
Timing Gear Case 32 Fuel Lift Pump 38 Fuel System 43
Tuning the Engine 38 Gasket Location Pump 36 Glow Plugs 49
Engines Generators
Idler Gear 30
Injection Pump Fuel 48
Injection Testing 49
Injection Timing Conversion Chart and Bolt Tightening Pressure 50
Oil Seal Testing Raw Water 4142
Raw Water Pump Arm Bracket Assembly 33
Schematic Wiring 60
Siphon Break Engine Torque Motor and Head Gasket 33
Timing Injection 52
Tools and Test Gear Data 10
Valve Clearance Lights 53
Wiring Diagram 61
Wiring Schematic 60
WESTERBEKE
Engines Generators

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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.