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Westerbeke Diesel 82b Four Parts Manual




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SERVICE MANUAL
FOR THE
82B FOUR MARINE DIESEL ENGINE
AND THE
25KW60Hz BED 20KW50Hz BED
MARINE DIESEL GENERATORS
SINGLE PHASE THREE PHASE
PUBLICATION NO 040485
EDITION ONE
NOVEMBER 1998
r WESTERBEKE
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319
NA Member NmioMl Marine Manufacture Associatwn
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can include
Dizziness 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 repaired
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are
caused byfailure to follow fundamental rules and Know when dangerous conditions exist and take the
A WARNING Fire can cause injury or precautions to protect yourself your personne Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with the pump or other potential sources of spilled fuel or fuel
American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard Approved
flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do not 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 bum
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 vapors 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 shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed 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 wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE 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 A running engine gets spill DO NOT allow any smoking open flames or other
very hot 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
or death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine
discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect
regularly for leaks and make sure the exhaust manifolds
it last
are securely attached and no warping exists Pay close
Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and
starting exhaust pipe nipple
Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated
installed before starting the engine
In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection tenninal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the tenninals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the tenninals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
burns or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp
wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery are
Always turn the battery charger off before disconnecting Vomiting
the battery connections Remove the negative lead first
Dizziness
and reconnect it last when disconnecting the battery
Throbbing in ACID Muscular twitching
Intense headache
A WARNING Sulfuric acid in batteries can cause Weakness and sleepiness
severe injury or death
AVOID MOVING PARTS
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec
tion Batteries contain sulfuric acid which is destructive
A WARNING Rotating parts can cause injury
If it comes in contact with your skin wash it off at once or death
with water Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps Do not service the engine while it is running If a situa
tion arises in which it is absolutely necessary to make
operating adjustments use extreme care to avoid touching
moving parts and hot exhaust system Engines Generators
SAFETY 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 recommenda
Make sure all attaching hardware is properly tightened
tions when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 15 East 26th Street
be caught in these rotating parts New York NY 10010
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing National Fire Protection Association
loss 11 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 States 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 00 not work on machinery when you are
mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
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 Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and posswle flooding of the SYSTEM
The exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF Engine Torque Chart 3 Standard Hardware Torques for Overhaul Generator Information I Generator
Disassembly Generator Control Panel SWitches Disassembly Control Panel Inspection 14 BE Generator
Assembly Generator AC Voltage Connections ManifoldlHeat Exchanger 31 Voltage Regulator Adjustments Injection Pump
Internal Wiring Schematics Injection PumpFuellift pump Internal Wiring Schematics BE System
Electronic Governor Plugs the Electronic Governor Adjustments Shore Power Transfer Switch Circulating Pump
BED Generator Wiring Schematic Oil Pump Remote StartStop Panel Wiring Diagram Pressure BED Generator Wiring
Diagram Motor BED Generator Wiring Diagram BED Generator Wiring Schematic Testing Generator Wiring Diagram
Special Tools Generator Wiring Schematic Metric Conversions Standards and Limits
Engines Generators
SOFTWARE CUSTOMER CARD
Product software tech data parts lists and catalogs provided from sources other are not within WESTERBEKES control
CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE MAKES NO
Customer OR WITH RESPECT
WESTERBEKE INCLUDING ACCURACY TIMEUNESS THEREOF AND WILL IN NO EVENT MAIN STREET
BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY HOMETOWN USA
INCURRED IN CONNECTION WITH OR ARISING OUT
Model82B Ser THE FURNISHING OR USE OF SUCH SOFTWARE
Expires customers should also keep in mind the
time span between printings ofWESTERBEKE and the unavoidable existence of earlier The WESTERBEKE serial number is an manuals
Product software provided with number that can assist in determining the date of
WESTERBEKE products whether from WESTERBEKE manufacture of your WESTERBEKE The
or other suppliers must not and cannot be relied upon first character indicates the decade A1960s as the definitive authority on the
respective C1980s D1990s the second character represents the year
product It not only makes good sense but is imperative in the decade and the fourth and fifth number represents the
that appropriate of WESTERBEKE or the month of in question be consulted to determine the accuracy
and currentness of the product software being consulted by SERIAL NUMBER LOCATION
the customer
The engine and generator serial numbers and model numbers
are located on a decal on the generator CAUTIONS AND WARNINGS The engine serial number can also be found
stamped into the
As this manual takes you through the disassembly inspection engine block just above the injection pump The generator
and assembly procedure of your critical serial number is stamped into the generator housing on will be highlighted by NOTES CAUTIONS
flat surface on the left side of the WARNINGS An explanation follows
An plate on the engine manifold also An operating procedure essential to note the engine model and serial number
A CAUTION Procedures which if not strictly GENERATOR
10 DECAL
observed can result in the damage or destruction of
your MODEL
SERIAL
NUMBER
A WARNING Procedures which if not properly
followed can result in personal injury or loss of replacement parts are needed always provide the
generator model number engine serial number and generator ENGINE number as they appear on the silver and located on the generator end You
must provide The following sections contain detailed with this information so we may properly identify relating to the
proper operation of the major
your In addition include a complete part components and systems of the engine Included and part number for each part needed see
disassembly inspection and reassembly instructions for the
the separately furnished Parts List Also insist upon guidance of suitable equipped and staffed marine packaged parts because will fit
or generic service and rebuilding facilities The necessary are frequently not made to the same should be undertaken
only by such original equipment Additional detailed information and are
provided in other sections of this manual covering the
generator alternator starter motor engine adjustments
cooling pumps etc
Engines Generators
ENGINE following chart describes certain NOTE The engines electrical system is protected by a 20
problems relating to engine service the probable causes of ampere manual reset circuit breaker The preheat solenoid is
these problems and the to overcome mounted on the same problemsThis chart may be of assistance the need for an engine
overhaul
PROBLEM PROBABLE CAUSE HARD STARTING LOW CRANKING
SPEED
1 Engine oil viscosity too high 1 Replace engine oil with 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 starter 5 Repair or replace starter
DEFECTIVE INJECTION SYSTEM
1 Air trapped in fuel passage 1 Bleed air from fuel system
2 Clogged fuel filter 2 Clean or replace filter
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 early 6 Adjust injection timing
MAIN ENGINE TROUBLES
1 Low compression
a Incorrect valve clearance a Adjust valve clearance
b Inadequate contact 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 Replace gasket
Piston ring seized 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 check preheat solenoid
4 Incorrect governor lever position 4 Set lever to starting 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 adjust pressure
INSUFFICIENT FUEL
1 Air trapped in fuel system 1 Check and retighten connector
2 Clogged filter 2 Clean or replace filter
3 Contaminated fuel tank 3 Clean tank
INSUFFICIENT INTAKE AIR
1 Clogged air intake silencer 1 Clean or replace air cleaner
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT cont OVERHEATING
1 Low coolant level 1 Add coolant
2 Loose Vbelt 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low engine oillevel 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 attachment 4 Retighten banjo bolt and secure
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 Dead cylinder 1 Check compression
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 valve stem seal 1 Replace valve 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 TROUBLES
1 Seized nozzle 1 Replace
2 Worn nozzle 2 Replace
IMPROPER FUEL Replace with proper fuel
FUEL LEAKS Find fuel leaks
SMOKY EXHAUST WHITISH OR PURPLISH
1 Excessive engine oil 1 Correct oil level
2 Excessive rise of oil into combustion chamber
a Poor piston contact a Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST coni WHITISH OR PURPLISH coni
d Worn valve stem and valve guide d Replace
e Low engine oil viscosity e Replace
r Excessive oil pressure r 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 2 Clear intake
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 Melted 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 OPERATION INJECTION PUMP SYSTEM
1 Uneven injection 1 Adjust injection or replace parts
2 Worn delivery valve 2 Replace
3 Inadequate injection nozzle spray 3 Replace injection nozzle
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE 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 with proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See LOW COMPRESSION HARD STARTING
2 Injection pump a Check valve a Replace check valve
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 filter clogged 1 Clean or SOUND
2 Air leak in fuel supply side of system 2 Retighten pipe joints or replace pipe
3 Water mixed in fuel 3 Replace 1 Vbelt slackening or slippery with 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
B Moving parts seized or damaged B 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
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL of Low Compression
Compression pressure tends to increase a little in a the time at which an engine should be overhauled engine until piston rings and valve
seats have been broken in
is detennined 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 necessarily due to trouble with the engine itself but is limit the engine must be caused by injector nozzle wear or injection pump
wear The decrease in compression pressure is caused by The engine requires overhaul when oil consumption is high
many factors It is therefore necessary to determine a cause blowby evident and compression valves are at minimum or
or causes on the basis of data produced by periodic inspec below Engine compression should be 30 kgcm2 427 psi at
tion and maintenance Oil analysis on a seasonal basis is a 200 rpm Cylinder compression should not vary by more than
good means of monitoring engine internal wear When 427 psi 30 by worn cylinders or piston rings the will occur
DISASSEMBLY
1 Low engine power output 1 Before disassembly and cleaning carefully check for
2 Increased fuel consumption defects which cannot be found after disassembly and
3 Increased oil consumption cleaning
4 Hard engine starting 2 Drain water fuel and oil before disassembly
5 Noisy engine operation 3 Clean or wash the engine exterior
4 Do not remove or disassemble the parts that require no
These symptoms often appear together Symptoms 2 and 4
result also from excessive fuel injection improper injec
tion timing and wear of plugs and nozzles They are caused 5 Perform disassembly in a proper order using proper tools
also by defective electrical devices such as the battery alter Keep disassembled parts in order Apply oil when neces
nator starter and glow plugs Therefore it is desirable to sary Take special care to keep the fuel system parts from
judge the optimum engine overhaul time by the lowered intrusion of dust and pressure caused by worn cylinders and pistons
6 Carefully check gaskets packings and oil seals even if check
plus increased oil consumption Satisfactory combustion is ing is not specified Replace with new ones if only under sufficient
compression pressure If an
engine lacks compression pressure incomplete combustion
of fuel will take place even if other parts of the engine are
operating properly To determine the period of engine over
haul it is important to measure the engine compression pres
sure regularly At the same time the engine speed at which
the measurement of compression pressure is made should be
checked because the compression pressure varies with engine
rpm The engine rpm can be measured at the front end of To test engine compression see the section of this manual
Engines Generators
ENGINE the instrument panel wiring harness Drain the trans Disconnect the AC wiring and
unplug the engines DC
mission fluid and the transmission oil cooler hoses Detach wiring harness at the generator control panel Disconnect the
the oil cooler hoses and unbolt the transmission from the battery cable connections and the engine ground
Separate the exhaust hose at the water injected elbow and
Drain or pump out all the engine oil and drain the coolant disconnect the fuel supply and return lines
from the engine and engine hoses
NOTE Label any lines hoses or cables as you separate them
For transmission service and maintenance refer to manual To rebuild a transmission contact your Drain the engine oil and the coolant from
the dealer or an authorized transmission service Carefully support and then unbolt the generator backend
shop from the engine See SPECIAL TOOLS GENERATOR in
this Additional generator information will be found in the
If the transmission is not being rebuilt it should be visually GENERATOR section of this Flush out and pressure test the oil cooler and
replace the coolant hoses Inspect and lubricate the gear shift
linkage and the propeller shaft coupling Clean and repaint
the transmission and change the transmission fluid Refer in this manual
MARINE ENGINE
TABWASHER
THE ENGINE
SHOULD BE
SECURELY
MOUNTED ON
A SUITABLE
ENGINE STAND
LABEL THE TERMINAL
CONNECTIONS AS
YOU DISCONNECT THE
WIRING HARNESS
Engines Generators
ENGINE THE MAIN ENGINE
With the generator separated from the
engine begin the following step by step procedure the engine
NOTE Mount the engine on a suitable stand or work bench
1 Remove the transmission damper plate from the
engine flywheel C
O DAMPER PLATE
BOLTS
2 Remove the engine oil cooler and oil hoses Note oil
hose connections from the oil cooler to the engine
3 Remove the engine heat exchanger If possible leave
one end of each hose connected to the part being
removed 11 Remove the air intake silencer and the intake manifold
4 Remove the bell housing propulsion engine and the 12 Remove the oil filter and the oil cooler mounting bracket
circuit solenoid mounting bracket from the engine block
5 Loosen the front crankshaft pulley bolt and remove the
flywheel
ONE BOLT DEVIATES J
WHEN REMOVING FROM THE 6J SET UP
THE MOUNTING BOLTS
LOCK THE FLYWHEEL
WITH A RING GEAR
BREAK TOOL
PLUNGER 3
SPRING
ORING
PLUG
13 Unbolt the elbows and remove the exhaust OIL
6 Remove the engine back plate FILTER
manifold in its entirety
7 Remove the start motor drive belt and the alternator
Label the wires and cables
8 Remove the engine mounted raw water pump adap
Injection Pumpnnjectors Disassembly
tor mounting plate and drive from the front cover 14 Detach aU the high pressure injection lines from the
The drive is removed by turning in a counter clockwise injection pump to the injectors Leave the two upper line
direction See RAW WATER PUMP for parts breakdown clamps in place
9 With the hoses disconnected remove the thermostat NOTE Cap the ends of the lines and the connections at
housing and housing gasket leaving the temperature the injection pump and at the injectors to prevent entry of
sender in place foreign material
10 Remove the coolant recirculating pump See 15 Remove the fuel return line from the top of the injec
COOLANT RECIRCULATING PUMP for parts break tors and from the fuel injection pump by removing the
down four 12 mm attaching bolts Note the washer arrange
ment on fuel return line banjo bolts Cap all the openings
on the fuel return line injectors and injection pump
Engines Generators
ENGINE Remove the fuel injectors dust seals and sealing f Once loosened remove the holddown nuts and wash
washers from the cylinder head using a 27mm deep ers and carefully withdraw the pump from the drive
socket gear and engine so as to avoid losing the injection
17 Remove the glow plugs pump drive key inside the timing case
18 Remove the crankcase breather hose and rocker arm
cover
19 Remove the engine mounted fuel filter and fuel line to
the injection pump Note the arrangement of the seal
ing washers on the banjo bolts at fuel filter and the injec
tion pump
20 Remove the injection pump Scribe the mating marks
on the pump body flange and the timing gear case before
a Remove the cover and the locknuts
h Loosen the two injection pump holddown nuts Do not
remove entirely The holddown nut on the engine side
of the pump can be loosened by using a 114 universal NOTE If an extractor is not available replace the nut
socket and extension with ratchet on the injection pump shaft loosely and with a nylon
drift and hammer gently tap the injection pump shaft to
dislodge it from the keyed drive gear
Injection Pump
If the injection pump requires servicing it should be sent to
an injection service shop that can properly service a Kiki
type injection pump
If the injection pump does not require servicing it should be
wiped clean covered and set aside until reassembly
Adjustments to timing if needed can be performed after
assembly
c Remove the nut and lockwasher from the injection See FUEL INJECTION PUMP
pump shaft
NOTE Take care not to drop the nut and the washer
into the timing gear case
d Place the keyway on the injection pump shaft in the
1200 position with the aid of the front crankshaft
pulley bolt before attempting to remove the
injection pump
e With the use of extractor Mazda tool 49 SE 01 157
apply sufficient pressure to loosen the pump from the
keyed gear The loose holddown nuts will prevent the
pump from falling from the engine
Engines Generators
ENGINE DISASSEMBLY
Engine Block Disassembly 24 Lift the cylinder head off the engine and remove the
cylinder head gasket
Disassemble the engine in the following order
21 Remove the cylinder head rocker cover and gasket
ROCKER
COVER
HEAD
GASKET
22 Remove the cylinder head
NOTE Loosen the cylinder head bolts equally and gradually
and in the order shown
5 9 13 17 16 12 8
25 Disassemble the rocker arm assembly
3 26 Remove each valve from the cylinder head assembly
Use an appropriate valve spring compressor to aid in
disassembly Arrange or label the valves so as to replace
them in the cylinder and guide from which they
6 10 14 18 15 11 7
were removed
23 Remove the rocker arm assembly
TAPER PIN RECESS
TAPER PIN HOLE
a Remove the valve stem caps so as not to lose them JAM NUT SPRING WASHER
HINGO SCOP JNING
when removing the cylinder head
Label each cap as to which valve it belongs
b Remove the push rods
Label each rod as to which valve it belongs
RO BRACKET
ROCKER ARM ASSEMBLY
t SPRING
ROCKER
VALVE SPRING
VALVE SPRING
OTAPPET REMOVAL
Engines Generators
ENGINE CRANKSHAFT
PULLEY
27 Remove the crankshaft pulley bolt with the aid of a 38
mm socket and draw the pulley off the front TIMING GEAR
CASE
INJECTION
PUMP DRIVE GEAR
TIMING GEAR COVER
Remove the timing gear cover and remove the injec
tion pump washer injection pump friction gear and
the injection pump drive gear
29 Remove the camshaft gear
a Wedge a clean cloth between the camshaft gear and the
idler gear remove the retaining bolt
b Remove the retaining plate friction gear and using a
suitable bearing puller the camshaft gear
30 Remove the idler gear
REMOVING THE
a Remove the attaching nuts thrust plate idler gear and CAMSHAFT GEAR
idler gear hub
31 Remove the crankshaft gear
a Remove the wave washer the friction gear and
using a suitable puller remove the crankshaft gear
TIMING GEAR
CASE and its key
32 Tum the engine over and remove the oil pan
33 Loosen the oil pump assembly set screw at the side
of the block Remove the oil pump For oil pump
details see OIL PUMP
34 Remove the timing gear case from the front of the
engine block Discard the old gasket
35 Remove the camshaft Keep the engine turned
over when removing the camshaft This allows the
valve lifters to seat on the block bosses away from
the cam lobes
TIMING GEAR DIAGRAM
Engines Generators
ENGINE DISASSEMBLY
b Remove the wrist pin snap rings
c Using a nylon drift drive the wrist pin from the piston
and rod
d Protecting your eyes with safety glasses disengage
and withdraw the snap rings Although mechanics
generally press out and sometimes hammer out
pistons pins these practices should be discouraged
Instead take the time to heat the pistons either with a
heat gun or on a hot plate Pins will almost fallout
e While the piston is still warm check for bore integrity
Insert the pin from each side If the pin binds at the
center the bore might be tapered if the bore is
misaligned the pin will click or bind as it enters the
far boss
NOTE The number stamped on the rod shank and cap
should correspond to the cylinder number Sometimes
these numbers are scrambled or missing and the
mechanic must supply them Stamp the correct num
berson the pads provided and to prevent confusion
deface the originals
PISTON RING
REMOVING THE TIMING GEAR CASE
REAR OIL
SEAL
MAl BEARING
CRANKSHAFT GEAR J CAPS
SPRING
WASHER
SLiNGE PULLEY MAIN BEARINGS
36 Remove the rear oil seal by striking out the old seal
with a suitable mandrel
37 Disassemble the connecting rod caps and line up the
main bearing caps and bearings according to the order of
bearing numbers Also properly arrange the thrust wash 40 Remove the main bearing caps
ers taking care not to change the combination 41 Remove the main bearings and thrust bearings
38 Remove the piston and connecting rod assemblies 42 Remove the crankshaft
Temporarily install the connecting rod cap on the con
necting rod so as to not mix the rods and caps 43 Remove the tappets
39 Disassemble the piston assembly NOTE After removing the main bearings and bearing caps
a Using the piston ring remover remove the piston rings arrange them in order of removal Do not mix caps After
While removing the piston rings note the order they are removing the thrust bearings note their positioning for
removed and which side of the ring faces the piston proper crown
Engines Generators
ENGINE THE CYLINDER HEAD
1 Visual Inspection Check the cylinder head for cracks or
any other damage and if necessary repair or replace it
REMOVING THE
2 Distortion Inspection Measure the cylinder head sur
INSERT
face distortion with a straight edge and the thickness
gauge Take 6 measuring positions as shown in the dia
gram If the distortion exceeds permissible limit replace
the cylinder head The head has no allowance for plan
ing and must be replaced not Cylinder Head Distortion Limit
12 0004 in 010mm
ii 4 5 6 0010 in 025mm SUITABLE PUNCH
REMOVE LOCATING DOWELS
BEFORE USING FEELER GAUGE
DISTORTION INSPECTION VALVE SPRING
1 Free Length Check Measure the free length pf the valve
spring and if free length is less than the limit replace it
3 Valve Spring Inner 1654 in 42mm
Outer2083 in 529mm
5 5
6 6 VALVE
SPRING
1 2
3 Insert Inspection Check for cracks or damage on the
insert and if detected replace it
4 Insert Replacement To remove the insert place a 2 Squareness Check Check the squareness of the valve
suitable drift into the glow plug hole then tap the drift spring and if it is more than the limit replace the spring
with a hammer To install set the insert in position and Squareness Limit Inner 0049 in 125mm
insert the welch washer into the insert guide hole Secure Outer 0054 in 137mm
the welch washer by tapping the raised center of the
welch washer 3 Fitting Pressure Check Check the valve spring fitting
pressure with a valve spring tester and if the pressure is
a Use a new welch washer less than the limit replace the spring
h Insert the welch washer so that its convex surface is
toward the cylinder head gasket
c After installation check to see if the insert is com
pletely fixed in place
90 TEST ANGLE
Engines Generators
ENGINE INSPECTION
NOTE Measure the fitting pressure after compressing the
spring several times VALVE GUIDE
Spring Fitting Pressure Inner Outer Length 149
in 378mm 159 in Pressure Limit 2492 Ib 113kg 6636 Ib 301 kg
VALVE SPRING
TESTER
SPRING FITTING
PRESSURE HEIGHT ABOVE
THE SPRING SEAT
065 in 165mm
VALVE GUIDE
1 Inspecting clearance between valve and guide Set a
dial gauge with a magnet and check the clearance
between the valve stem and the valve guide If the clear
ance is more than the limit replace the valve or valve
Limit 0005 in 0127 mm 3 Dimension L Check the protruding length of the valve
VALVE GUIDE CLEARANCE stem if it exceeds the correct it as follows
Dimension L Standard 1890 in 480 mm
a When dimension L becomes larger 0 00202 in
0 05 mm from the standard it is still possible to
use both the valve and the cylinder head
2 Valve guide replacement To remove the valve guide
press out the valve guide towards the combustion cham
ber side using the valve guide installer 49 0636 165A
Again using the valve guide installer press in the valve
guide into the cylinder head until the valve guide height
reaches the indicated scale on the valve guide installer VALVE SEAT
INSERT
NOTE Be sure to press in the valve guide so that the
inside chamber on the valve guide end faces to the
combustion chamber side After the pressure fit check the b When dimension L becomes too large 020 0059 in
length of the protruding portion of the valve guide 05 1 5 mm from the standard adjust Standard 0650 in 165mm
dimension L to the standard by adding some washers
inner diameter 0504 in 128 mm outer diameter
1535 in 39 mm between the lower spring seat and
the cylinder head
c When dimension L becomes too large more than
0059 in15mm from the standards replace the
valves seat
Engines Generators
ENGINE SEAT INSERT
JHECKING VALVE STEM WEAR
VALVE SEAT
1 Valve Seat Angle Valve seat angle is 45 and 30
d Check for contact between the valve and valve seat respectively for intake and exhaust sides The standard
by applying a thin coat of Prussian Blue or Redlead contact width of the valve seat is 0079 in 20 mm for
on the valve seat contact face then insert the valve into both intake and exhaust sides If the valve margin is less
the valve guide and press fit the valve on the valve seat than the permissible limit replace the valve
NOTE Do not rotate the valve 2 Refacing the Valve and Valve Seat Reface in the fol
lowing order
a Reface the valve with a valve grinder to the specified
angle
h Reface the valve seat with a valve seat cutter while
checking the contact between the valve and the valve
seat
CONTACT FACE
NOTE Reface the valve seat taking care that the valve
seat contacts the center position of the valve
Valve Seat Angle 45 Intake 30 Exhaust
Valve Seat Width 0079in 20mm Intake and Exhaust
INTAKE
CONTACT FACE I
45if
e Check if the valve seat contact face contacts the center
position of the valve contact face If the contact posi
tion is not centered recut and surface the valve seat
and valve 125 in 317
4 Stem Wear Inspection If the valve stem is bent or its
EXHAUST
diameter is less than the limit replace the valve
Stem diameter limit Intake 0351 in 8904 mm c Reface the valve and valve seat with a valve tapping
Exhaust 0350 in 8884 mm compound
d Remeasure dimension L
e Adjust dimension L to the standard by adding some
washers between the lower spring seat and cylinder
head
Engines Generators
ENGINE ARM CYLINDER BLOCK
1 Visual Inspection Check each component part of the 1 VISUal Inspection Check the cylinder block for cracks
rocker arm assembly for cracks or other damage Check and damage If necessary repair or replace it entirely
if the oil passages of the rocker arm ana shaft are clog Check to see that oil or cooling water passages are not
ging and if necessary repair or replace the rocker arm clogged and if clogged remove ith compressed air or a
1mJAM NUT SPRING WASHER wire probe REMOVING LOCATING DOWELS
QII J BEFORE INSPECTING
A ADJ SCREW
BUSHING
RETAINING
RING
C o
o Qea
ROCKER t w JII to If
CJtt
TAPER PIN RECESS 2 Distortion Inspection Check the gasket face distortion
ROCKER SHAFT SPRING 0 of the cylinder block and if it exceeds the limit repair or
SUPPORT replace it
Distortion limit 12 0004 in 010mm
ROCKER ARM ASSEMBLY SCALLOP 1 3456 0010 in 025mm
2 Inspecting clearance between rocker arm and shaft
Check the clearance between the rocker arm and shaft
and if it exceeds the limit replace the rocker arm bush 6
ing or shaft Standard 00006 00024 in 0016 00028 in 007mm
3 Rocker Arm Bushing Replacement Using a suitable
mandrel and press press out the old bushing Aligning
the oil passages of the rocker arm bushing press the new
bushing into the rocker arm After the rocker arm bushing
has been replaced ream the bushing bore with a spiral
expansion reamer so that the clearance between the bush
ing and shaft becomes equal to the standard clearance
CYLINDER LINER
1 Wear Inspection Measure the liner bore at three
positions of upper middle and lower portions with a
cylinder gauge in XX and YY directions as shown If
wearing exceeds the limit replace the liner
Cylinder Liner Bore 37412 37422 in 95025 95050mm
Wear Limit 0008 in 020 mm
REPLACING
THE BUSHING
X tX
x X IS THE THRUST DIRECTION
CYLINDER LINER
CYLINDER LINER
WEAR Engines Generators
ENGINE INSPECTION
2 Cylinder Liner Replacement Hydraulic press or similar c Measure the piston diameter at 90 to
device is needed the pin bore axis and 0866in 22mm below the piston
a Attach the cylinder liner puller and installer to the top SUB COMBUSTION
lower rim of the cylinder liner then press out the liner CHAMBER
h Check for scratches on the cylinder block side and if
any remove them by using extremely fine emery paper
with engine oil
c To install the liner apply engine oil on the cylinder
block bore and the liner exterior then set the liner on
the cylinder block Using the cylinder liner puller and
installer press the liner into the cylinder block
NOTE Press the liner in straight When press fitting the
liner keep the pressure within a range Standard Piston Diameter 37381 37399 in 94967 94993mm
Measure the liner protrusion and correct it if necessary 2 Piston Ring Inspection Check the piston ring for
breaks seizure and wear and if any of these Limits 00040 0 in 0101 0 mm
exist replace the ring Check the clearance between the
piston ring and the ring groove and if it exceeds the
limit replace the ring
AND PISTON RING
1 Visual Inspection Check the sliding surface and
ring groove of the piston for wear scratches or any
other damage
a Inspecting the clearance between the piston and the
PISTON RING
cylinder liner
h Check the clearance between the piston and the cylin
der liner by measuring the cylinder bore and the piston Side Clearance Limit 0012 in O30mm
diameter and if the clearance exceeds the limit replace
the cylinder liner and the piston 3 Inspecting the piston ring end gap Position the piston
ring into the bottom of the cylinder liner Measure the
piston ring end gap and if it exceeds the limit replace the
ring Be sure to position the piston ring below the ring
sliding surface of the cylinder liner
DIAL INDICATOR
Clearance 00017 00028 in 0032 0083 mm
Piston Ring End Gap Limit 0591 in 15mm
Engines Generators
ENGINE ROD
1 Visual Inspection Check the connecting rod for cracks PISTON PIN
or other damage and if necessary replace it
CLEARANCE
BETWEEN THE
PISTON PIN AND
SMALL END BUSHING
4 Small end bushing replacement Using a press press
out the old bushing Align the oil passages of the connect
ing rod and the small end bushing press in the new bush
ing to the connecting rod bore After a small end bushing
CONNECTING has been replaced ream the bushing bore to obtain the
specified clearance between the small end bushing and
the piston pin
PRESS
LARGE REMOVING THE PRESSING IN
END SMALL END THE NEW
BUSHING AQIt ALIGNING BUSHING BUSHING
CAP MARKS SMALL END
OIL HOLES
2 Bend Inspection Using a connecting rod aligner check 7
the bend and twist of the connecting rod and if exceeding NOTE When reaming the bushing correctly insert the
the limit repair it with a press or replace it reamer in the bushing In order to prevent unevenness on
Bend Limit 0002 in per 39 in 005 mm per 100 mm the bushing surface the reaming should always be made
in the cutting direction Make certain the reamer is
stopped at different positions at all times
5 Inspecting connecting rod side play Check the connect
ing rod side play with the dial gauge and if it exceeds the
limit replace the connecting rod and crankshaft
Side Play Limit 0016 in 040 mm
3 Inspect the clearance between the piston pin and
smaIl end bushing Check the clearance between the
piston pin and the small end bushing and if it exceeds the
limit replace the piston pin or small Standard 00005 00015 in 0012 0039 mm
Clearance Limit 0002 in 005 mm
CONNECTING ROD
SIDE PLAY TEST
Engines Generators
ENGINE INSPECTION
6 Inspecting connecting rod bearing Check the connect 3 Inspecting crank pin and journal Support the crank
ing rod bearing for peeling and thennal damage If it is shaft on both ends using Vblocks Measure the diameter
severe replace the bearing of each crank pin and crankshaft main journal and if the
7 Inspecting connecting rod bearing clearance Using the diameter is less than the limit refinish the crank pin and
plastigauge measure the oil clearance of the connecting main journal to size for the next undersize bearing
rod bearing and if it exceeds the limit replace the Crank pin diameter
connecting rod bearing Standard 240601 24065 in 61112 61125 mm
Wear limit 0002 in 005 Rod Cap Torque 5641 5786 ftIb 78 80 mkg
Main journal Rod Bearing Clearance
Standard 29848 29853 in 75812 75825 mm
Standard 00005 00012 in 0012 0031 mm
Wear limit 0002 in 005 mm
Limit 00020 in Bearing 0010 in 0254 mm
a For the measurement on both the crank pin and the
0020 in 0508 mm main journal measure them at vertical and horizontal
0030 in 0762 mm directions on front and rear places
b When refinishing the crankshaft its finish to Rlmm
as shown in the diagram
c Refer to the chart for refinishing dimensions of the
crankshaft where an undersize bearing is used
REFINISHING DIMENSIONS
Undersize bearing Main journal 001 in 0254 mm
002 in 0508 mm
29748 29753 in 75558 75571 mm
29648 29675 in 75304 75317 mm
BEARING 0
0D3 in 0762 mm
Undersize bearing
0D1 in 0254 mm
29578 29554 in 75050 675063 mm
Crankpin diameter
23964 23965 in mm
1 Visual Inspection Check the crankshaft for cracks or 0D2 in 0508 mm 23874 23865 in 60604 60617 mm
other damage If cracking is suspected thoroughly clean 0D3 in 0762 mm 2376023765 in mm
the crankshaft and perfonn a magnafiux check of the
crankshaft If any cracks are detected replace the crank
shaft
MAGNAFLUX TEST
CRANKSHAFt
Check for clogging of oil passages and if clogged
remove with compressed air or a wire
2 Runout inspection Check the crankshaft runout and if it
exceeds the limit replace the Limit 00020 in 005 mm
CRANKSHAFT RUNOUT INSPECTING THE CRANKSHAFT
INSPECTION
RUNOUT
Engines Generators
ENGINE INSPECTION
4 Inspecting crankshaft end play Check the end play of 3 Inspecting camshaft journal Check the camshaft
the crankshaft and if the end play exceeds the limit journal and if wearing exceeds the limit replace the
replace the thrust washer with 0007 in 0178 mm over camshaft
size Crankshaft end play is measured by setting a dial
Diameter of Joumal Wear Limit
gauge on the rear end of the crankshaft and moving the No1 20437 20449 in 51910 51940 mm 0008mm
crankshaft in the axial direction No2 20339 20350 in 51660 51690 mm 00003 in
Crankshaft End Play Standard 00055 00154 in 014 039 mm NO3 20240 20252 in 51410 51440 mm
Crankshaft End play limit 00157 in 040 mm No4 20142 20154 in 51160 51190 mm
4 Inspecting camshaft oil clearance Check the clearance
MAIN BEARING between the camshaft journal and the camshaft support
bore as follows
1 Inspecting main bearing Check the main bearing
for peeling seizure or fusion and if necessary replace a Measure the camshaft journal diameter and the
the bearing camshaft support bore
b Calculate the clearance and replace the camshaft or
2 Inspecting main bearing clearance Using the cylinder block if the clearance exceeds the limit
plastigauge measure the oil clearance and if it exceeds
the limit replace the main bearing Oil clearance limit 00057 in 0145 mm
5 Checking camshaft alignment and if it exceeds the
limit replace the camshaft
Maximum allowable runout 00031 in 008 mm
6 Inspecting camshaft end play
a Install the thrust plate camshaft gear frictioear
PLASTIGAUGE lock plate and camshaft gear lock bolt on the camshaft
b Tighten the lock bolt to the specified torque
Lock Bolt Torque 19mm socket 46 691bft 64 95 kgm
c Measure the clearance between the thrust plate and
camshaft gear If it exceeds the limit replace the thrust
Oil Clearance Standard 00023 00035 in 0059 0090 mm plate
Oil Clearance Limit 0005 in 012 mm End play limit 00118 in 03 mm
CAMSHAFT CAMSHAFT
GEAR
1 Visual Inspection Check the camshaft for cracks and
damage If necessary replace the camshaft
NOTE If the damage is slight you may be able to correct
the camshaft with an oil soaked fine emery grindstone
Take special care to not damage the original cam form
2 Inspecting cam height Measure the cam height and if it
is less than the limit replace the camshaft
Cam height limit 16724 in 42478 mm IDLER GEAR BUSHING AND IDLER GEAR SPINDLE
1 Visual inspection Check for damage on the bushing
INTAKE AND EXHAUST CAM inner surface of the idler gear and the spindle sliding sur
CAM ElGKT rw face and if necessary replace the idler gear or spindle
Check the oil passage for clogging and if necessary
clean the passage with compressed air or wire
2 Inspecting clearance between bushing and spindle
Check the clearance between the idler gear bushing THE the spindle and if it
exceeds the limit replace the 1 gear or spindle
Clearance Standard 00013 00033 in 0034 0084 mm
Clearance Limit 0006 in 015 mm
Engines Generators
ENGINE INSPECTION
TAPPET
1 Visual inspection Check the tappet for cracks and other
damage and if damaged replace the tappet Check for
abnormal wear of the portion of the tappets that contact
with the cam and if anyone is abnormally worn replace
the tappet
2 Inspecting Clearance Between Tappet and Tappet
Bore Check the clearance between the tappet and tappet
bore and if the clearance is greater than the limit replace
CHECKING the tappet or cylinder block
CLEARANCE Clearance Limit 00039 in 010 mm
BETWEEN TUI Ifoi lt
BUSHING
AND THE GEARS
1 Visual Inspection Check each gear idler gears injection
pump drive gear crankshaft gear camshaft gear for
cracks or other damage If necessary replace as required
2 Inspecting end play of idler gear Check the end play of
the idler gear with a dial indicator as shown If it exceeds TAPPET CLEARANCE
the specified limit replace the thrust plate or idler gear
PUSH RODS
1 Visual Inspection Check each push rod for damage to
eithfr end If damage is severe replace the push rod
2 Bend Inspection Check the push rod for bend and if it
exceeds the limit replace it Place the push rod on a flat
surface and measure the clearance between the center of
the push rod and the flat surface Replace the push rod if
the wear limit is exceeded
Bend limit 00075 in 019 mm
TESTING THE
NOTE Measure the end play after tightening the idler PUSH ROD
gear attaching nuts to the specified torque value
Thrust plate torque 1fl socket 17 231tlb 23 32 end play 00059 00118 in 015 030 mm
3 Check backlash between gears Check the backlash
between each gear with a dial indicator
NOTE Check the backlash after assuring that the idler
gear end play and the clearance between the idle gear PUSH RODS
bushing and spindle are within the Standard 00039 00079 in 010020 mm
Backlash Limit 00118 in 030 mm
Engines Generators
ENGINE GEAR COVER OIL SEAL OIL PAN
1 Inspecting timing gear cover oil seal Check the timing 1 Scrape and clean any dirt or metal particles from the
gear cover and the lip of the oil seal for any damage If inside of the oil pan
necessary replace the cover or oil seal 2 Check the oil pan for cracks and damaged drain
2 Oil seal replacement To remove the oil seal use the oil plug threads
seal puller and installer and pull out the oil seal To 3 Inspect for damage uneven surface at the bolt holes
install apply engine oil on the outside of a new oil seal caused by the over torquing of the bolts surfaces as
then press fit the oil seal with oil seal puller and installer required Repair or replace the oil pan
until the installer comes in contact with the cover
OIL JET UPPER BLOCK
OIL SEAL 1 Make certain the oil passage is not clogged
INSTALLER
TOOL 2
REAR OIL SEAL
1 Inspecting oil seal Check the oil seal lip for wear
fraying or other damage and if necessary replace it
2 Oil seal replacement OIL JET VALVE
a Strike out the old rear oil seal with a suitable mandrel
b Apply engine oil onto the outside of a new seal and
press fit the seal in the rear oil seal cap equally
NOTE In case the crankshaft is worn the oil seal must be
fitted on the oil seal cap with its fitting position moved by
approximately O1I81in 3mm so that the seal does not
touch the worn down portion of the OIL SEAL
REMOVAL
Engines Geneators
ENGINE Precautions ENGINE ASSEMBLY
Be careful not to mix bolts and nuts Metric and SAE 1 Install the valves in cylinder head Using the valve
bolts are used on various engine assemblies spring lifter arm and pivot assemble the valve lower
During assembly recheck clearances and insure that parts spring seat oil deflector inner valve spring outer valve
are being assembled in their proper order and facing in the spring upper spring seat and taper sleeve in this order
correct direction in relation to the engine block such as NOTE The oil deflector should be installed on the intake
pistons piston rings bearings and bearing caps valve only
Apply lubricating oil to moving parts during assembly 2 Assemble the rocker arm shaft rocker shaft brackets
Insure that moving parts when assembled on the engine
and rocker arms Note that the front end of the rocker
rotate or slide and are not subject to binding or
shatt is identified by a pin protruding from the top and a
excessive tension
larger oil hole between the supply holes serving 1 and
If there are mating marks scribed during disassembly 2 rocker arms This pin fits a slot in the 1 rocker shaft
reference them correctly for assembly support which prevents the shaft from turning and cutting
Use new gaskets lockwashers Orings etc off the lube oil to the rocker arms and valves Use the fol
lowing order of assembly
Tighten the holts and nuts on important parts of engine to
specified torques using a reliable torque wrench a Spring d Rocker
b Rocker e Wave washer
Use liquid sealants when required on nuts bolts and c Rocker shaft support f snap ring
gaskets Refrain from using tape Also refer to Sealants and Lubricants in this manual
JAM NUT TAPER PI
BUSHING
Be aware of these common problems that can occur during
assembly
Lubrication Heavily oil sliding and 1 ROCKER IIIIlIJO
TAPER PIN parts lightly oil head bolts and other fasteners
those that penetrate into the water jacket should be sealed with Permatex No2 or the WAVE orientation Most gaskets many bolt washers
and i SNAP
RING
SUPPORT TAPER PIN HOLE
all thermostats are 3 Assemble the connecting rod piston and piston damage Run
fasteners down in approved Arrange the piston and the connecting rod as shown and
torque sequences and in three stepsII2 213 and 111 torque using the piston pin installer insert the piston pin are bolts and rocker arm
shaft the piston and connecting rod until the piston pin The former are torqued as indicated The pin snap rings can
be fitted Fit the piston pin snap shaft be brought down in very to their respective grooves Install the piston rings to ring
small increments working from the center bolts out Gaskets grooves on the piston with the inscription mark on head gaskets might be damaged
during assembly upward using a suitable piston ring should be positioned with great care
I
AT 9J INTERVALS
TOP RING
TOP RING OIL
EXPANDER SPRING
FRONT SECOND
RING
5 FRONT OF PISTON
IS INDICATED BY CHECK THE PISTON RING
A BOSS ON THE GAPS WITH CARE NEW
BOTTOM NEAR THE RINGS ARE PACKAGED
OIL HOLE WITH DETAILED INSTRUCTIONS
THAT OFTEN SUPERSEDE
THE SERVICE MANUAL
ENGINE ASSEMBLY
PLACE A HEAW HAMMER AND
4 Main Bearings and Bearing Caps GENTLY PRESS DOWN WITH
THE FORCE OF YOUR HAND
NOTE Do not apply oil to the backsides of the main THE ENTIRE SURFACE SHOULD
bearing shells BE COATED WITH FRESH LUBE OIL
a Fit the main bearings on the cylinder block and the
bearing caps respectively Check that the oil ways align
perfectly with those in the block
b Fit the thrustwashers to the cylinder block so that the
oil grooves on thrustwashers face to crankshaft side
c Position the crankshaft to the cylinder block being
careful not to drop the thrustwashers as the crankshaft
r 1 r
settles into place c Install the caps to the connecting rods ensuring that
the numbers on the cap and rod are matched
Cap Torque 14 mm socket 59 65 ftIb 82 9Omkg
install new connecting rod WASHERS
d Fit the thrust washer to the main bearing cap so that
the oil grooves on thrust washer face to crankshaft 8 Installation of the crankshaft
side Then install the main bearing cap to the cylinder a Insert the tappets into the cylinder block Apply engine
block with arrow mark of the main bearing cap facing oil to the sliding face of the tappet
the crankshaft pulley side
Main Bearing Cap Torque 110 117 mkg 80 85 THE
BEARING CAPS
bInsert the camshaft into the cylinder block Apply oil to
the camshaft joumal and bearing surfaces
5 c Install the camshaft thrust plate
NOTE Ensure the crankshaft rotates smoothly after Thrust Plate Torque 12 in socket 116 174 ftIb 16 24 mkg
installing
9 Install the idler gear spindle Align the oil passages of
6 Install the rear oil seal Apply oil to the oil seal lip the idler gear spindle and cylinder block
7 Install the piston and connecting rod assembly
a Place the piston rings so that the ring ends are
properly spaced around the circumference of the piston
as shown on the previous page
b Using a ring compressor fit the piston into the cylinder
in the position as is shown Apply oil onto the sliding
face of the piston and the cylinder bore
Engines Generators
ENGINE ASSEMBLY
10 Fuel Injection Pump
NOTE It is easier to first install the injection pump to the
timing gear case and the entire assembly onto the engine
Install the injection pump aligning the marks
Mount the injection pump on the gear case then tighten
the pump drive gear attaching nuts
Attaching Nut Torque 29 51 Mb 40 70 mkg
TIMING GEAR COVER
13 Install the friction gear
11 Install the timing gear case Attach the straight edge on
14 Install the camshaft gear lock bolt
the cylinder block then match the surfaces of the timing
gear case end and that of the cylinder block If the gasket NOTE Wedge a clean cloth between the camshaft gear
protrudes from the mating surface cut away the excess and the idler gear
with a knife
Lock Bolt Torque 19 mm socket 46 69 ftIb 64 95 mkg
Attaching Bolt Torque 12 in socket 12 17 Mb 16 24 mkg
15 Install the injection pump drive gear lock nut
12 Install each gear While aligning the timing mark of
each gear install the following gears on each position
a Camshaft gear
b Idler gears
c Injection pump drive gear
d Install the idler gear thrust plate then tighten the nuts
Idler Gear Thrust Plate
Nut Torque 12 in socket 166 231 ftIb 23 32 mkg
TIMING GEAR CASE
INJECTION PUMP DRIVE
GEAR
16 Install the oil deflector on the crankshaft
17 Install the timing gear cover
a Install the bearing housing cover on the timing
gear cover
b Install the injection pump drive gear cover on the
timing gear cover
c Install the timing gear cover and tighten the timing
gear cover attaching nuts and bolts after the crankshaft
pulley has been installed temporarily to center the seal
LINE UP Timing Gear Cover Torque 116 174 ftIb 16 24 mkg
GEAR TIMING
MARKS 18 Mount the oil pump assembly Apply the sealing agent
KEY IS VERTICAL WHEN on the set screw thread and tighten the screw Ensure
THE TIMING MARKS GEAR oil pump drive gear and the driven gear mesh
Engines Generators
ENGINE ASSEMBLY
26 Position the cylinder head
27 Insert the pushrod Check if the push rod is securely set
19 Assemble the new gasket set lower block in the tappet concavity
a Position the gasket ends A on the gaskets B and C
INCORRECT
b Apply a silicon sealing agent on the mating surfaces of
the gasket and that between the cylinder block and the
timing gear case
c Install the lower block making certain the lower block
TAPPET
gasket is perfectly aligned Tighten the bolts evenly
Lower block Bolt Torquell2 in socket 12 17 ftIb 16 23 mkg
20 Install the oil pan gasket and the oil pan sump
Oil Pan Bolts Torque 9116 in socket 12 17 ftIb 16 23 mkg
21 Attach the back plate
Back Plate Torque 916 in socket 239 35 ftlb33 48 mkg 28 Position the valve cap on the top of the valve stem It
should beset squarely on the valve stem
22 Install the flywheel Install the flywheel onto the rear end
29 Install the rocker arm assembly onto the cylinder
of the crankshaft by placing it on the crankshaft and rotat
head Remember that the end of the rocker shaft having
ing it to properly align the mounting bolt holes Install the
the pin occupying the slot in 1 rocker support points
tabwasher and the attaching bolts After torquing bend
toward the front pulley end of the engine
one tab against the flat of each attaching bolt
30 Tighten the cylinder head bolts Tighten the cylinder
Flywheel Bolts Torque 19 mm socket 112 ftIb 155 mkg
head blts evenly in the sequence shown After tightening
the cylInder head bolts make certain the rocker arms
move smoothly
Cylinder Head Bolts
Torque 34 in socket 85 90 ftIb 118 125 mkg
23 Install the raw water pump Mount the raw water pump
on its adapter plate and assemble it to the engine Do not
tighten
24 Install the crankshaft pulley Apply engine oil onto the
lip of the oil seal Carefully slide the front crankshaft pul
ley onto the crankshaft ensuring that the key in the crank
shaft and the keyway in the pulley mate properly Apply
Loctite high temperature to the threads of the front
crankshaft pulley holddown bolt when installing it
Ensure the flat washer is under the head of the bolt
Front Crankshaft Pulley
Bolt Torque 38 mm socket 253 289 ftIb 3 40 mkg
Engines Generators
ENGINE ASSEMBLY
31 Adjust the valve clearance Adjust the No1 23 and 6 c Install a new thermostat and gasket the old
valves when the No 1 piston is on Top Dead Center thermostat can become a spare When installing the
IDC or the compression stroke new thermostat and gasket apply a thin coat of
Tum the crankshaft once setting the No 4 cylinder pis sealant to both sides of the gasket
ton at TDC compression and adjust the No4 5 7 and d The thermostat can be checked for proper operation
8 valves The valves are numbered 1 8 from front of the by placing it in a pan of cold water and then raising
engine the temperature of the water to a boil The thermostat
WHEN NO4 CYLINDER IS AT TOP DEAD CENTER should open noticeably with travel on the order of
I 41NTAKE 31NTAKE 14 in 112 in and be fully opened when the water
is boiling
4 EXHAUST EXHAUST 2
AIR BLEED
PETCOCK
WATERTEMP
SWITCH
2 INTAKE NTAKE 1
f EXHAUST I EXHtUST
WHEN NO1 CYLINDER IS T TOP DEAD CENTER
WATER TEMP
SENDOR
35 Attach the engine coolant circulating pump
Coolant Pump Assembly
Bolts Torque use 12 socket 16 23 mkg 12 17 ftIb
32 Adjust each valves clearance by inserting a 0012 in A complete breakdown of the COOLANT PUMP ASSEMBLY
003 mm feeler gauge between the rocker arm and the is covered elsewhere in this manual
valve stem
Valve Clearance 030 mm 12 in cold 36 Adjust the injection When the engine overhaul is complete run the
engine Refer to INJECTION TIMING elsewhere in this manual
under load to check its peiformance Allow the engine to 37 Mount the oil filter bracket 1 oil cooler to room temperature
and retorque the cylinder head When installing the new filter apply a thin coat of nuts and readjust valves The
cylinder head hold engine oil to the rubber gasket TIghten by hand
down bolts and valve adjustment should be rechecked again
after 50 hours and periodically thereafter 38 Mount the front engine mounting bracket
33 Install the cylinder head cover Mounting Bracket Torque 46 68 mkg 33 49 Head Cover Bolts
Torque 03 04 mkg 2 3 ftIb 39 Install the intake manifold Replace the four After the engine has been reassembled readjust the
Intake Manifold Torque 116 174 ftIb 16 24 mkg
valve clearances with a warm engine see ENGINE
40 Mount the fuel filter 41 Mount the rocker arm cover using a
new gasket
34 Install the thermostat and thermostat housing
Apply sealant to that portion of the gasket that contacts
a Inspect the thermostat housing and the housing the gasket only
gasket Apply some sealant to the gasket when
reassembling Rocker Arm Cover Torque 2 3 ftIb 03 04 mkg
b Install the temperature switch and sender and 42 Attach the crankcase vent hose
reconnect their wires
Engines Generators
ENGINE ASSEMBLY
43 Install the fuel injection nozzles and return lines Use 51 Install the raw water pump and drive belt Insure it is
new sealing washers throughout in the same order as in proper alignment with the crankshaft pulley Check the
were the old washers belt To Head BoH 27mm deep socket 43 51 f1lb 60 70 mkg
Refer to RAW WATER PUMP for pump FUEL INJECTORS for more details
44 Install the glow plugs and connectors Use antiseize
compound on the threads
Glow Plug Torque 72 108 f1lb 10 15 mkg
To test the glow plugs see GLOW PLUGS
45 Connect the fuel line to the engine mounted fuel filter
and the injection pump Use new sealing washers
46 Connect the high pressure injector lines from the
injection pump to injectors Reinstall the line Nuts Torque 18 22 f1lb 25 30 mkg
47 Install the Install the air intake silencer
49 Mount the engine heat heat exchanger should be serviced when the engine Refer to HEAT EXCHANGER for service Mount the fuel filter Nuts Torque
33 49 f1lb 46 68 mkg 52 Install the oil and water sender and switch
50 Install the alternator and drive belt 53 Install the starter motor
54 Install the breaker panel and the preheat solenoid
A CAUTION Connect the alternator properly 55 Reinstall the engine electrical harness
Should the polarity be reversed a powerful current
would flow from the battery into the alternator 56 Mount the complete exhaust manifold and the
damaging the diodes and wiring harness expansion tank to the cylinder head
a Install the alternator support bolt through the alternator Man Hold Mounting Bolts Torque 1217 f1lb 16 24 mkg
leg underside into the engine casting
See EXHAUST MANIFOW for service and inspection
b Swing the alternator into position on the adjusting
bracket and fasten Lightly tighten 57 Assemble the wiring harness and ground wires
c Adjust belt tension 58 Reconnect all DC wiring harness terminals to their
engines components
d Tighten both bolts and recheck belt bolt Torque 27 38 f1lbs 38 53 bracket bolt Torque 9 10 f1lbs 12 18 mkg
A CAUTION Check all AC and DC wiring
connections to WESTERBEKE wiring schematics and
NOTE Make certain the belts are perfectly aligned with diagrams
the alternator and engine pulleys If not insert or remove
spacers as needed to align the ALTERNATOR for testing
Engines Generators
ENGINE GENERATOR
59 Assemble the damper plate to the flywheel 59 Mount the generator back end assembly with its
control panel Reconnect all DC wiring and Plate Torque 1420 ftlb 17 27 mkg
all AC Reinstall the marine transmission and fill with ATF
DextronIII
A CAUTION Check all AC and DC wiring
NOTE Some such as the Borg Warner connections to WESTERBEKE wiring schematics and
Velvet Drive require oil coolers Oil coolers should be diagrams
cleaned pressure tested and repainted at engine over
haul The transmission oil cooler hoses should also be 60 Fill the engine cooling system with premixed coolant
inspected Refer to the text on Heat Exchangers 5050 good quality antifreeze and distilled water
Fill the engine oil sump to the mark on the dipstick
61 Fill the engine cooling system with premixed coolant
with lube oil API spec CF or CG 4
5050 good quality antifreeze and distilled water
The engine should be test run under load prior to rein
Fill the engine oil sump to the mark on the dipstick
stalling At this time readjust the valve clearances on the
with lube oil API spec CF or CG4
hot engine
The engine should be test run under load prior to rein
Allow the engine to cool to room temperature and
stalling At this time readjust the valve clearances on the
retorque the cylinder head bolts and recheck the valve
hot engine
clearances
Allow the engine to cool to room temperature and
See ENGINE ADJUSTMENTS
retorque the cylinder head bolts and recheck the valve
clearances
See ENGINE TYPICAL
TRANSMISSION
OIL COOLERS
Engines Generators
EXHAUST MANIFOLD I HEAT MANIFOLD 3 Check the manifold pressure cap Open the valve by
pulling it and make sure it closes when released Make
The exhaust manifold which was disassembled from the
certain the upper and lower seals are in good condition If
cylinder head should be inspected before reassembly
any doubt replace the cap
1 Remove the exhaust nipples elbows and plugs from the
manifold
2 Examine all parts for defects corrosion and wear and CHECKING THE PRESSURE CAP
replace as needed RUBBER SEALS
3 Flush out the manifolds interior with a liquid cleaner and
rinse thoroughly with fresh water
4 Use a pipe cleaner to clear the passage that connects from
the filler neck to the coolant recovery tank tubing HEAT EXCHANGER
5 Flush out the coolant recovery tank and its connecting tube The heat exchanger should be inspected and serviced during
an engine overhaul
1 Disconnect the hoses and remove the hose fittings
petcock drain plugs and zinc anode Also remove the
CLEAR THIS PASSAGE end fittings and gaskets
2 Inspect the tube casing for wear and dents if at all
suspect replace the heat exchanger
3 Clean out any zinc debris and pressure test the coolant
and raw water passages
4 When reassembling install new gaskets and Orings
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them
5 Install a new zinc anode
NOTE All of the above can be accomplished by sending the
REPLACE
heat exchanger to a heat service shop
They will also service transmission and engine oil coolers
GASKETS 6 Repaint the assembled heat exchanger with heat resistant
spray enamel
1 If the manifold was removed as an assembly and left 7 Reconnect all hoses replacing them as needed
intact it can be replaced on the cylinder head in the 8 Refill the system with coolant as detailed above
reverse order of removal 9 Pressure test system and check for leaks
Do not reuse the gaskets install new ones
a Loosely attach the manifold elbows to the cylinder
head using new gaskets Do not use any gasket sealant
on these gaskets REPLACE
HOSES
b Gradually tighten each fitting to make sure of proper
alignment of all the parts This should be done in three
Mounting Bolts Torque 12 17 ftIb 16 24 mkg
2 Reinstall the exhaust connections Use new gasket and
check turbo clamp condition Replace if suspect
CLEAN OUT
DEBRIS
HEAT Engines Generators
FUEL INJECTION PUMP
TESTING INJECTION TIMING 11 Remove the plug and sealing washer from the aft center
1 Remove the air assembly of the injection pump The plug is centrally located where
the four high pressure injector lines attach to the pump In
2 Remove the four high pressure injector lines that connect place of the plug install the Mazda tool 49 9140 074
between the injection pump and injectors measuring device Ensure the measuring device rod con
3 Remove the bolt and gasket installed on the distributor tacts the plunger inside the pump and then zero the
head of the injection pump gauge
4 Remove the valve rocker cover
S Rotate the crankshaft in normal direction of rotation using PLUG AND
the front crankshaft pulley nut and place the No 1 piston
at IDe of its compression stroke No1 piston is first
vmIN WASHER
from the front of the engine
NOTE To verify the rocker arms of No4 cylinder should
be rocking one opening one closing
6 Remove the snap ring from the end of the rocker shaft at
cylinder No 1 along with the retaining washer
7 Loosen the rocker arm adjusting bolt so as to allow the
arm to be removed from the push rod and slide it off the
rocker shaft
FUEL INJECTION PUMP 0
8 Press down on the valve and spring assembly and ensure
the valve is hitting the top of the No 1 piston Then
remove the cap keepers and valve springs from the No 1
valve NOTE When setting the dial gauge confirm that the dial
gauge pointer does not deviate from the scale make of
NOTE Ensure the valve moves freely in its guide Take zero by slightly turning the engine crankshaft from left to
care to not drop the keepers down the push rod hole right
9 Position a dial indicator gauge on the valve stem and
using the front crankshaft pulley nut rock the crankshaft Turn the engine crankshaft in the normal direction of
and clockwise to to locate the exact rotation to bring the No 1 piston up to IDe The dial
IDe of the compression stroke for the No 1 piston indicator on the valve stem should zero and the indicator
Then zero the indicator gauge to the valve stem the on the injection pump should show 0039 inches 1 mm
gauge should be able to measure up to 03 inch of valve of movement
movement
ADJUSTING INJECTION TIMING
1 Loosen the nuts holding the injection pump to the engine
0205 inBTDC The high pressure injector lines should not be attached to
the injection pump
2 Make the adjustment by moving by moving the injection
pump itself When the amount of movement of the mea
suring device indicator on the injection pump is too large
first tum the injection pump in the reverse direction of the
t engine rotation so that the dial gauge pointer indicates
less than the scale mark of 0039 inches 1 mm These
adjustments are to tighten the gear backlash
Injection Pump Gear Lock Nut Torque 29 51 ftIb 40 74 mkg
When the amount of the measuring device indicator on
10 Slowly turn the crankshaft in the opposite direction of the injection pump is too small tum the injection pump in
normal rotation until the indicator reads 0180 005 the direction of normal engine rotation so that the measur
inches BIDe It is advisable to go slightly more than ing device indicator points to the scale mark of 0039
0180 inches and then return to that figure to remove gear inches 1 mm
lash The No1 piston is now at 30 BIDe
3 After the adjustment tighten the injection pump hold
Verify the scribe mark on the injection pump outboard
down nuts and then confirm again that the adjustment has
mounting flange is properly aligned with the scribe mark
been done correctly
on the engine mounting case At the six oclock position
on the outboard side of the injection pump is a semioval
cover with two screws Remove this cover and locate the
sealing Oring and timing washer 0032 inches in thickness
Remove this washer and replace the cover WESTERBEKE
Engines Generators
FUEL INJECTION PUMP I FUEL LIFT PUMP
CHECKING CAM LIFT FUEL LIFT PUMP EARLY MODELS
1 Turn the crankshaft in the direction of normal engine The fuel lift pump should be cleaned and repainted Install a
rotation and read the maximum value which the dial new filter as illustrated and clean the ground wire terminal
indicator pointer on the measuring device shows This
value is cam lift
Amount of Cam Lin 008 in 22 mm
2 After this check remove the measuring device and install
the plug and sealing washer
3 Reinstall the 0032 inch thick timing washer in the injec
tion THE INJECTION PUMP FUEL
1 The injector pump and injector high pressure lines will
have to be bled of air after the lines have been reinstalled
To bleed the injection pump first loosen the return con
nection a Then by priming with the lever on the engine
mounted fuel filter supply fuel to the injection pump to FILTER
remove the air from the injection pump Continue until
fuel clear of air passes out of the loosened return connec
tion FUEL LIFT PUMP
MAGNET Next bleed the high pressure lines by loosening them at
their attachment to the fuel injectors Loosen the attach
ing nuts one to two turns on all four fuel lines Tum the
key on and crank the engine with the starter until fuel spurts by the loosened connections Stop cranking the This pump
operates during the start sequence when preheat is
engine Tighten the attaching nuts and start the engine in pressed Simulate a start and depress preheat the pump
the usual manner should produce a clicking sound indicating the pumping
piston in the pump is working If no clicking is heard check
that 12 volts are present at the pump connection and the
pump is properly grounded
1 Test the pump by connecting a battery and fuel line as
illustrated Fuel delivery must be 05 pints 225 cc or
more every fifteen seconds
TESTING THE FUEL PUMP
FUEL LIFT UMP
MEASURING
CYLINDER
SUCTION HEAD
APPROX 500 mmi
KEROSENE KEROSENE
NOTE Later model WESTERBEKE engines and genera
tors use a solid state fuel lift pump that requires
FUEL INJECTION PUMP no maintenance The above tests can be performed on
these models
FUEL LIFT PUMP
WESTERBEICE
Engines Generators
FUEL THE INJECTORS c Mount the nozzle and nozzle holder on the nozzle
tester
NOTE Injector must be serviced in a clean room d Use the fuel at the
approximate temperature of 68 F
200 C
1 Disconnect the high pressure lines from the injectors and e Operate the hand lever of nozzle tester several times to
loosen the lines at their attachment to the injection pump bleed the air in the nozzle line then move the hand
and move them out of the way of the injectors Avoid lever at intervals of one stroke per second while read
bending the lines ing the injection starting pressure
2 Remove the fuel return line in its entirety from the top of Injector Starting Pressure 1920 Ibin 135 kgem
the injectors Take care not to lose the two sealing wash
ers and banjo bolt that attaches the fuel return line to each f If the fuel injection starting pressure is not within the
injector it can be adjusted by removing or adding
shims in the injector body to achieve proper pressure
3 Unscrew the injector from the cylinder head using a suit
able 27 mm deep socket NOTE The shims are available in 27 kinds ranging
from 05 mm to 154 mm at 002 increments An incre
NOTE Clean the area around the base of the injector
ment of 04 mm causes the starting pressure to rise by
prior to lifting it out of the cylinder head to help prevent
approximately 68 Ibin2 48 kgcm2
any rust or debris from falling down into the injector
hole If the injector will not lift out easily and is held in
by carbon build up or the like work the injector side to
side with the aid of the socket wrench to free it and then
lift it out
4 The injector seats in the cylinder head on a copper seal
ing washer This washer should be removed with the SHIM
injector and replaced with a new washer when the injec SHIM THICKNESS
tor is t 01 mm
1 Using the nozzle tester check the spray pattern and injec 02mm
tion starting pressure of nozzle and if it exceeds the limit 03mm
adjust or replace the nozzle When using nozzle tester 05mm
take the following A CAUTION The spray injected from the
nozzle is of such velocity that it may penetrate
deeply into the skin of fingers and hands destroying When replacing the shim grip the retaining nut in a
tissue If it enters the bloodstream it may cause vise and remove the body with a wrench Tighten the
blood pOisoning retaining nut to the specified torque
a If the diesel fuel of the nozzle tester is discolored
replace it At the same time clean or replace the filter
b Set the nozzle tester in a clean place where there is no
dust or dirt INJECTOR
INJECTION
PRESSURE TEST
Engines Generators
FUEL SPRAY PAnERN 5 Assure the needle valve when it is pushed in the nozzle
body comes down into the valve seat by its weight about
1 Operate the hand lever of the nozzle tester at intervals of
one stroke per second to check if the fuel is injected cor 07092in 18mm If it does not replace the assembly
rectly in its axial direction A nozzle is defective if it If any defect is found always replace the needle valve
and the nozzle body as a unit
injects fuel in an oblique direction or in several separate
strips Also a spray in the form of particles indicates a 6 Check that there is no flaw or other damage on mating
defect These defects may sometimes be caused by clog surfaces and sliding surfaces of the nozzle body and the
ging with dust and therefore all parts should be carefully needle valve and if present replace the nozzle assembly
cleaned before reassembly
ASSEMBLING THE INJECTOR
1 Assemble in the reverse order of 4isassembly
NOTE After assembling the injector test it
2 Tighten the nozzle body on the nozzle holder to the speci
fied torque
Nozzle Body Torque 24 mm socket 80 10 IMt 58 72 kgm
FAULTY ANGLE FAULTY DIRECTION
INSTALLING
2 Operate the hand lever to raise the pressure up to 1635
psi 115 kglcm2 which is 280 psi 20 kglcm2 lower than 1 Install in the reverse order of removal
the starting pressure If with pressure applied fuel does NOTE The copper washers should not be reused Replace
not drip from the nozzle oil tightness is satisfactory with new washers
Dripping of fuel with pressure applied is indicative of
damage to the needle valve or valve body or poor contact 2 TIghten the nozzle on the cylinder head to the specified
between both In that event both needle valve and valve torque
body should be considered defective and replaced Nozzle Torque 27 mm socket 43 511bft 60 70 kgm
INJECTOR
RETURN
lINE
WASHER
IlUP TEST AND INSPECTION
1 Clamp the nozzle holder in a vise remove the nozzle nut ADJUSTING
and disassemble the nozzle body spring and needle SHIM
2 Clean the disassembled parts with clean diesel fuel
SPRING
NOTE Greatest possible care should be taken in handling
the nozzles as they are precisely machined The nozzle
and the needle valve are matched parts Do not mix their
original combinations Disassemble and wash each noz
q NOZZLE
zle assembly separately
Carbon deposits on the nozzle body must be removed
with a piece of hard wood However it would be advis
able not to clean the surrounding area of the nozzle ori
fice to avoid possible damage to the orifice NOZZLE
lNUT
Iron dust on the magnetic filter top must be removed
completely
WASHERS
Engines Generators
FUEL SYSTEM PROBLEM PROBABLE CAUSE hard to start or
fails to start 1 No fuel at injectors 1 Check causes a through e
a No fuel in fuel tank andor fuel shut off a Fill tank Open shutoff and bleed system
b Fuel filter clogged b Replace filter and bleed
c Fuel filter clogged c Bleed pump Check fittings for suction leak
on fuel supply
d Fuel shutoff solenoid not working d Trouble shoot as described in previous section
e Injection pump faulty e Inspect pump Repair or replace pump as needed
2 Fuel injectors faulty 2 Remove and test nozzles Repair nozzles as needed
3 Water andor air in fuel filters 3 Remove water andor bleed air from system Check
system for leaks and fuel tank for water 4 Injection timing incorrect 4 Check and adjust
the timing
5 Glow plugs not working 5 Check glow plug circuit and repair as idling too low 1 Idle speed too low
1 Adjust idle stop as needed
2 Fuel filter clogged 2 Replace filter and bleed fuel system
3 Incorrect injection pump timing 3 Check timing and adjust as needed
4 High pressure injection line leaking 4 Slacken attaching nut and retighten
5 Fuel injector leaking at sealing gasket in head 5 Retighten injector andor replace sealing washer
6 Injection nozzle not operating properly 6 Check nozzle and adjust as needed
7 Engine air intake obstructed 7 Check air flow intake silencer and air flow into engine
consumption too high 1 Idle speed too high 1 Check engine speed
2 Engine air intake restricted 2 Check intake and correct
3 Injection timing incorrect 3 Check timing and readjust pump as needed
4 Injector nozzle leaking 4 Tighten nozzle or replace sealing gasket
5 Injector not operating properly 5 Remove injector and adjust nozzle spray pressure
6 Engine overloaded 6 Check propeller size and engine

Engines Generators
FUEL SYSTEM PROBLEM PROBABLE CAUSE output poor 1
Contaminated or inferior fuel 1 Purge fuel system and replace with quality fuel
2 Fuel filter obstructed 2 Remove and replace filter element
3 Air in fuel system 3 Bleed and check for source
4 Injection pump timing incorrect 4 Check the timing and adjust pump as needed
5 Injector high pressure lines leaking 5 Loosen and then retighten injector line attachment
nut or replace the complete line
6 Injectors not operating properly 6 Remove injectors and adjust spray pressure to proper set
ting
7 Shaft stuffing box too tight 7 Check shaft free movement and for heat
8 Valves improperly adjusted 8 Check valve adjustment and amount of
black exhaust smoke 1 Clogged fuel filter 1 Replace the fuel filter and bleed the system
2 Restricted air intake 2 Remove air obstruction
3 Engine overloaded 3 Check engine propeller size and engine
performance no load through fully loaded
4 Injection timing 4 Check the injection pump timing and adjust as needed
5 Fuel injectors not operating properly 5 Check nozzle spray noise from engine 1 Poor quality andor incorrect fuel
1 Use No2 diesel fuel
2 Incorrect injection timing Timing too advanced 2 Check injection timing
3 Fuel injector stuck open 3 Locate and remove faulty injector Replace or rebuild
Engines Generators
GLOW Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 20 to
The glow plugs are wired through the preheat solenoid
25 seconds If the plugs dont heat up quickly check for a
When PREHEAT is pressed at the control panel this solenoid
short circuit When reinstalling the glow plugs use click on and the glow plug should begin to get hot
compound on the inspect the plug remove the electrical terminal connec
A WARNING Do not keep a glow plug on for more
tions then unscrew or unclamp each plug from the cylinder than 30 Thoroughly clean each plugs tip and threads with a
Glow Plug Tightening Torque 7 11 ftIb 10 15 mkg
soft brush and cleaning solution to remove all the carbon and
oil deposits While cleaning examine the tip for wear and
burn erosion if it has eroded too much replace the plug TERMINAL accurate way to test glow plugs is with
an one prod to the glow plugs wire connection and the
other to the body of the glow plug as shown A good glow
plug will have a 10 15 ohm resistance This method can be
used with the plug in or out of the engine You can also use
an ammeter to test the power drain 8 9 amps per plug
A WARNING These glow plugs will become very hot
to the touch Be careful not to bum your fingers when
testing the plugs
GLOW PLUG
THE OHMMETER TEST
Engines Generators
ENGINE ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT 8 Adjust each valves clearance by inserting a 0012in
1 Warm the engine to nonnal operating temperature O03mm feeler gauge between the rocker arm and the
valve stem Make sure to adjust all valves when the
2 Pull off the air breather pipe from the rocker cover engine is cold
Remove the rocker cover bolts and remove the rocker
cover to expose the rocker shaft and valve assembly
3 Remove the glow plugs from each of the cylinders to
enable the crankshaft to be easily rotated by hand to posi
tion each cylinder for valve adjustment
Valves are adjusted with the piston in the cylinder being
adjusted at IDC of its compression stroke
NOTE Retorque the cylinder head bolts before adjusting the
engines valves
4 Loosen the head bolts in the reverse order of 9 Install the cylinder
head cover
Head Cover Bolt Torque 2 3 It Ib 03 045 mkg
ENGINE COMPRESSION
13 9 5 4 8 12
Check the compression pressure To do this warm the
5 Tighten the head bolts in the order shown engine remove all fuel injectors or glow plugs disconnect
Cylinder Head BoltTorque 8590 It Ib 118 125 mkg the fuel shutoff solenoid wire and install a compression
adapter in the injector hole or glow plug hole Connect a
6 Set the piston of No1 cylinder to IDC compression compression tester on the adapter and crank the engine with
and check the valve clearance at each position indicated the starter motor until the pressure reaches a maximum value
If the clearance is incorrect adjust to Repeat this process for each cylinder Look for cylinders with
Intake No1 and No2 cylinders and dramatically at least 20 lower compression than the aver
Exhaust No 1 and No3 cylinders age of the others Compression pressure should not differ by
7 Turn the crankshaft once setting the piston of No4 more than 427 psi 30 kglcm2 at 200 rpm
cylinder at IDC compression and adjust to the follow
ing Intake No3 and No4 cylinders and
Exhaust No2 and No4 cylinders
WHEN NO4 CYLINDER IS AT TOP DEAD CENTER
I
41NTAKE 31NTAKE
4 EXHAUST EXHAUST 2
INJECTOR HOLE
OR GLOW PLUG HOLE
Compression pressure standard 427 psi at 200 rpm 300 kgem
Compression pressure limit 384 psi at 200 rpm 270 kgem
If a weak cylinder is flanked by healthy cylinder the problem
is either valve or piston related Check the valve clearances
INTAKE 1 for the weak cylinder adjust as needed and test again
3 EXHAUST 1 EXHAUST If the cylinder is still low apply a small amount of oil into
I I I
the cylinder to seal the rings and repeat the test
WHEN NO1 CYLINDER IS AT TOP DEAD CENTER If compression comes up the rings are faulty
Engines Generators
ENGINE high readings on all cylinders indicates heavy When servicing the injection pump the service shop must be
carbon a condition that might be advised if the pump is to be used in a generator by high pressures and noise
The service shop will have to remove and replace the gover
nor spring with a propulsion spring Once the pump is set to
NOTE In case of severe vibrations and detonation noise have propulsion the generator spring is injectors checked and overhauled by an
authorized fuel in theinjection pump and the pump remounted on the
injection service center Poor fuel quality contaminates and
engine The throttle is then set for the proper engine noload
loss of positive fuel pressure to the injection pump will result speed hertz
in injector faults
For disassembly inspection reassembly and internal
When reinstalling the glow plugs use antiseize compound adjustments of the injection pump it is recommended the
pump be taken to a qualified injection service shop
SEnlNG THE IDLE SPEED PROPULSION ENGINE authorized to service Diesel KiKi injection equipment
1 Warm the engine to nonnal operating Stick a piece of suitable reflecting tape on the crankshaft
pulley
3 Idle the engine
4 Use the light of a photoelectric strobe type tachometer on
the reflecting tape and compare with the readings on the
electric idle speed 650 950 rpm
NOTE The idle speed may vary according to the
transmission and propeller
5 To adjust the engine idle speed loosen the lock nut of the ENGINE STOP SOLENOID idle adjustment bolt and turn the bolt clockwise to
This solenoid is installed on the top rear of the injection
increase idle speed and to reduce pump and is activated by 12 VDC electrical current
NOTE Should the engine rpm be in question verify the NOTE To service generator applications refer to the
tachometer readings as shown at the instrument panel GENERATOR section of this manual
See TACHOMETER
IDLE ADJUSTMENT 1 The solenoid does not operate when the keys witch is
rY OLT
turned ON Preheat depressed
a Are the engine batteries turned ON FROM
START
b Is the 20 amp circuit breaker set MOTOR
c Is 12 VDC present at the solenoid SOLENOID
connection
2 The solenoid does not stop the engine
when the keyswitch is switched OFF
ADJUSTING IDLE SPEED Stop switch depressed
a Check to see if 12 VDC is still present
SPEED ADJUSTMENT GENERATOR at the solenoid electrical lead with the Speed adjustment of the
generator hertz is controlled
by the electronic governor see ELECTRONIC GOVERNOR
key off Stop switch depressed
b Remove solenoid from injection
i SPRING
for speed and gain adjustments pump and ensure plunger and spring rPLUNGER
in the solenoid are not Models Without Electronic speed is maintained by the governor the fuel injection pump 615 620 hertz at noload
and 585 590 hertz at full rated generator output speed is adjusted by positioning the throttle lever
INJECTION PUMP
against the adjustable throttle stop screw lock wiring it at
that position and tensioning the throttle stop screw against
the throttle lever and securing it with its lock nut
Engines Generators
COOLANT CIRCULATING PUMP
REMOVING THE PUMP in the following order coolant drain as needed Assemble the water
pump in the reverse order of
Vbelt water hoses water pump attaching nuts and water disassembly using the following
1 Fill lithium grease lithium base NLGI No2 into the
following Ball bearings
1 Remove the pump pulley boss by using a support and Approximately 113 space between both ball bearings
press
Space between the ball bearing and water baffle plate
2 Remove the bearing shaft from the impeller and bearing
2 Apply a thin coat of engine oil to the press fit surface
housing by using a support block and press
of the water seal and press the larger end into the
3 Remove the snap ring with snap ring pliers and press out proper aperture of the pump using a tubular
the water pump shaft from the bearings mandrel Mazda tool 490636 145
SPRING LOADED SEAL
BEARINGS SEAL
RETAINING RING
Inspect the shaft bearings and impeller Look for cracks and
damage Check the housing gasket and inspect the rear seals
and small end gaskets Replace any parts that show wear
COLLAR TOOL
IMPELLER
NOTE Do not allow oil or grease to contaminate the
surfaces of the ceramic ring or the graphite small end
of the springloaded seal
3 After the water pump has been assembled check if the
pump shaft rotates smoothly
INSTALLING THE PUMP
1 Install in the reverse order of removal
NOTE Use a new gasket
2 After installing the pump fill the system with coolant and
operate the engine to check for leaks
Engines Generators
LUBRICATING OIL PUMP
REMOVING THE OIL PUMP 3 Inspect the clearance between the inner rotor and the
Remove from the engine in the following order outer rotor Check the clearance between the lobes of the
rotors with a feeler gauge If the clearance exceeds the
1 Oil Pan limit replace
2 Oil Pump Set Screw both rotors OUTER ROTOR
3 Oil Pipe Attaching Bolts and
4 Oil Pump INNER in the
following order Oil Pipe and Gasket 17TALLY MARKS
Oil Strainer and Gasket Oil Pump Cover Drive Gear use a
press and suitable mandrel Inner Rotor and Shaft Rotor Relief Valve Assembly and Oil Pump Body
Clearance Limit 0055 00100 in 014 025 Visually check the disassembled parts and replace 4 Inspect the clearance
between the outer rotor and the
faulty parts Check the sliding surface of pump cover pump body Check the clearance between the outer rotor
with special care and replace the cover if the surface has and pump body with a feeler gauge If the clearance
steps or excessive streaks Minor steps streaks may be exceeds the limit replace the rotor or pump body
repaired by rubbing them with a compound on a surface
OIL PUMP SHAFT
PUMP ROTORS OUTER
TORQUEAT
6 9 ft bs
08 12 mKg
Clearance Limit 0055 00100 in 014 025 mm
5 Check the clearance between the rotor and the pump
cover Inspect the end float of the rotors Place a straight
edge across the pump body and measure the clearance
between the rotor and straight edge with a feeler gauge If
the clearance exceeds the limit replace the drive gear
2 Inspect the clearance between the pump body and the drive shaft inner rotor outer rotor and pump body
shaft Measure the clearance with a dial gauge and mag
net base When the clearance exceeds the limit replace
the pump drive shaft inner rotor pump body and drive
Limit 00024 in 00079 in 006 015 mm
GAUGE
Clearance Limit
PUMP BODY
Engines Generators
LUBRICATING OIL PUMP
6 Measure the free length of the plunger spring Check ASSEMBLY
the relief valve for worn plunger and fatigued spring 7 Assemble in the reverse order of
PLUNGER
NOTE When installing the rotors into the body be sure
PLUNGE SPRING
that the tally marks on the rotors are positioned toward
the cover
MEASURING FREE RELIEF VALVE PLUG
Cover TIghtening Torque 716 socket 58 87 nIb 08 12 mkg
INSTALLING THE OIL PUMP
LENGTH Spring free Limit 161 in 40 mm
1 Install in reverse order of removal
NOTE When installing the set screw apply sealing com
RELIEF VALVE ASSEMBLY pound on the set screw threads
OIL OIL PRESSURE LOW OIL PRESSURE
The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 43 14 psi 03
oil pump The engine oil is drawn from the oil sump by the 01 kgcm2 A gradual loss of oil pressure usually indicates
oil pump which drives the oil under pressure through the a worn bearings For additional information on low oil pres
oil filter oil cooler and various lubricating points in the sure readings see the ENGINE The oil then returns to the oil sump to
repeat the con
tinuous cycle When the oil pressure exceeds the specified OIL PRESSURE the oil pushes open the relief valve in the oil pump
When performing an engine overhaul replace the oil pres
and returns to the oil sump keeping the oil pressure within
sure switch and the oil pressure sender
its specified range
When installing the new parts apply a teflon sealant to the
To test the oil pressure remove the oil pressure sender then
install a mechanical oil pressure gauge in its place After threaded ends being careful not to close off the oil hole in the
up the engine set the engine speed at 3600 rpm and
read the oil pressure gauge Oil Pressure Sender and SWitch Torque 9 13 HIb 12 18 mkg
350 IbJin2 38 kgcm2 or more at 1800 rpm
Oil Pressure
5404 IbJin2 38 kgcm or more at 3600 rpm
A CAUTION Oil Pressure Switch Do not use lock
pliers vise grips or pipe wrenches on the oil pressure
switch Use the correct socket which is available from
SnapOn Proto flew Britain and others Damage to the
switch will cause oil leaks andor switch failure
PROPULSION
4 YO
PRESSURE
SENDER
HOLE
r lALLY OPEN
GENERATOR FUEL SOLENOID J
Engines Generators
RAW WATER PUMP
PUMP OVERHAUL 5 Remove the housing assembly releasing the shaft
bearing and seal assembly This will allow the bearing and
NOTE Since completely rebuilding a damaged or worn pump seal to be disassembled for individually purchased parts would almost match
the NOTE It may be necessary to use a drift and arbor press
price of a new pump WESTERBEKE recommends that a new to press the bearing and seal assembly from the shaft
pump be purchased
6 Inspect all parts and replace those showing wear or disassembling the raw water pump inspect the
pump by rotating the drive shaft If it is rough frozen or 7 Use the illustration to assist in reassembling the raw water
seems to have excessive play replace the entire pump pump
a Apply a small amount of petroleum jelly to the inner race and to the impeller shaft
at pump as removed from the engine will have hose b When positioning the cam in the housing use a nipples threaded into its
inlet and outlet port amount of Pennatex 1 on the inner cam surface and
They may be left in place or removed if they interfere with cam screw head remove any excess from the impeller
the pump disassembly Note the port location and positioning housing
if removed c Apply a light film of silicon or petroleum jelly to the
1 Loosen the set screw with an allen wrench and remove inner surface of the housing for the impeller
the water pump pulley from the shaft Taking care not to 8 When the pump is assembled reposition and tighten the
lose the key hose nipples into the pump housing use Teflon sealant on
2 Remove the four cover screws the cover and the cover the nipple thread Assemble the pump to the engine and
gasket attach the hoses and the belt
NOTE Replacement of the cover gasket is recommended
however it you are going to reuse it keep the gasket well
lubricated until the pump is reassembled If its allowed
to dry the gasket will shrink and not be reusable
3 Pull out the impeller with long nose pliers or a pair
Remove the cam screw and cam
HOUSING GASKET
RAW WATER PUMP
Engines Generators
STARTER NoLoad Test
The starter 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 overrunning clutch section which transmits an arma 2 When the
switch is closed the pinion must protrude and
ture torque preventing motor overrun after starting the starter must run smoothly at 3000 rpm or more If
the current or starter speed is out of disas
A switch section solenoid which is operated when actu semble the starter and repair it
ating the overrunning clutch through a lever and which
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
arate from the motor shaft the pinion slides only on the pin
ion shaft 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 mechanism switch and overrunning clutch inner circuit
are identical to conventional AND REPAIR
If any abnormality is found by the following tests the starter A CAUTION Use thick wires as much as possible and
should be disassembled and repaired tighten every tenninal securely This is a solenoid shift
type starter which makes a rotating sound louder than
Pinion Gap Inspection that of a directdrive type starter When detecting
starter rotation at the pinion tip be careful not to come
1 Connect a battery 12V between the starter terminal S in contact with the pinion gear when it protrudes
and the starter body and the pinion drive should rotate
out and stop
SOLENOID
A CAUTION Never apply battery voltage for over 10 Perform the following tests If any test result is not
seconds continuously satisfactory replace the solenoid assembly
2 Lightly push the pinion back and measure the return
1 Inspect the solenoid for continuity between terminals
and and between terminals S and the body and M and
stroke called pinion gap
the body There should be no continuity found between
3 If the pinion gap is not within the standard range 00197 terminals S and M Continuity will be found between ter
00788in 05 to 2Omm adjust it by increasing or minals S and the body and terminal M and the body
decreasing the number of shims on the solenoid The gap
is decreased as the number of shims MULTIMETER
NOTE Disconnect the wire from terminal M
DS2DMM 2 Connect a battery to the solenoids terminal S for and
M for Have a switch in the lead and close it The
PINION GAP pinion drive should extend fully out
A CAUTION Do not apply battery current for more than
10 seconds when testing the Engines Generators
STARTER MOTOR
3 Holding test With a battery connected to the solenoid 4 Return test With a battery connected to the solenoid
terminal S and to the starter body manually pull out terminal M and to the starter body manually pull out
the pinion fully The pinion must remain at that position the pinion fully The pinion must return to its original
even when released from holding with your hand position when released from holding by hand
HOLDING TEST
RETURN TEST
ATTRACTION TEST
7 Pull out the reduction gear lever and lever spring from the
STARTER DISASSEMBLY front bracket
1 Disconnect 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 pinion and pinion shaft
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 a bearing puller It is impossible to replace the ball bear
fastening the brush holder Remove the rear bracket ing pressfitted in the front bracket If that bearing has
4 With the brushes pulled away from the armature worn off replace the front bracket assembly
remove the yoke and brush holder assembly Then pull
TERMINALM
the armature out
SOLENOID
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 for the pinion shaft end play
adjustment will come off
INSPECT FOR BRUSH HOLDER
WEAR CHIPPING
STARTER MOTOR
0
SNAPRING
j r PLAY NOISE
LEVER SPRG
I J
YOKE
NOTE CLEAN AND INSPECT ALL
COMPONENTS REPLACE ANY PARTS
THAT APPEAR BURNED OR ARE CORRODED
SHAFT
Engines Generators
STARTER MOTOR
STARTER the solenoid for continuity between terminals S and
M and between terminals 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 The Armature BRUSHES
1 Check the armature with a growler tester If its short NEW USED
circuited replace the armature Also check for insulation
Brush Height Standard 0669 in 17 mm
between the commutator and its shaft If poorly
Brush Height Limit 02363 in 6 mm
insulated replace the armature
2 Check the brush spring tension A weak or defective
spring will cause excessive brush wear replace the
ARMATURE springs if suspect
CHECK
BRUSH HOLDER
ASSEMBLY
ARMATURE
2 Measure the commutator OD and the depth of undercut
Repair or replace it if the service limit is exceeded Also 3 Check for insulation between the positive brush holder
check the commutator outside surface for dirtiness and and holder base If poorly insulated replace the holder
roughness If rough polish the commutator with fine assembly Also check the brush holders for proper staking
crocus 00
Commutator Outside Diameter Standard 1523 in 387 Outside Diameter Limit 0039 in 10 mm
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 smear the starter fitting surface
terminals brushes or commutator with grease
3 After reassembly check by conducting a noload
test again
ADJUSTING
YiASHER GEAR
FILED COIL TEST
SNAP RING
STARTER ADJUSTMENT AND REASSEMBLY
A CAUTION Before installing thoroughly clean the IO5 mm MAX
starter flange and mounting surfaces remove all Oil old
paint and rust Starter performance largely depends on
the quality of the wiring Use wire of sufficient size and PINION SHAFT END PLAY
grade between the battery and starter and fully tighten
to the terminal
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 00197 00788in 05 to 2mm
by inserting an adjusting washer between the center
bracket and the reduction gear
a Fit the pinion shaft reduction gear washer and snap
ring to the center bracket
b Measure end play by moving the pinion shaft in the
axial direction If the end play exceeds 00788in
O5mm increase the number of adjusting washers
Engines Generators
TACHOMETER
METER Tachometer meter used in propulsion engine instru a With a handheld tach on the front of
the panels contains two separate electrical circuits with a pulley retaining nut or with a strobetype tach read the
common ground One circuit operates the hour meter and the front crankshaft pulley rpm at idle
other the tachometer The hour meter circuit operates on 12 b Adjust the tachometer with a small Phillips type screw
volts alternator charging voltage supplied to the terminal driver through the calibration access hole in the rear of
on the back of the instrument the tachometer Zero the tach and bring it to the rpm
The tachometer circuit operates on AC voltage 68 volts fed indicated by the strobe or hand tach Verify the rpm at
from one of the diodes in the alternator and supplied to the idle and at high speed 30003600 rpm Adjust the input terminal while the
engine is running and as needed
the alternator producing battery charging voltage DC
NOTE Current model tachometers use a coarse adjustment
dial to set the tachometer to the crankshaft pulley rpms The
The following are procedures to follow when calibrating screw is then used for fine tuning
a fault in either of the two circuits in a meter for the proper DC voltage between and COARSE
terminals ADJUSTMENT
1 Voltage present meter is defective repair or replace
2 Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter
II1 TERMINAL
terminal to verify the operation
TACHOMETER Inoperative ClJRRENT TACHOMETER AC for the proper AC voltage
between tachometer and terminal with the engine running
1 Voltage present attempt adjusting meter through calibra
tion access hole No results repair or replace meter
2 AC voltage not present check for proper alternator DC
output voltage
3 Check for AC voltage at tach terminal on alternator to
ground
4 Check electrical connections from tachometer input ter
minal to alternator Sticking
1 Check for proper AC voltage between tach inp terminal
and terminal GROUND
TERMINAL
2 Check for good ground connection between meter ter
minal and Check that alternator is well grounded to engine block at
alternator pivot bolt
GROUND 71
TACHOMETER INPUT
TERMINAL LIGHT
AC VOLTAGE
TERMINAL
EARLY MODEL Engines Generators
ALTERNATOR TESTING
DESCRIPTION 1 Start the Engine
The charging system consists of an alternator with a voltage 2 After a few minutes of running measure the starting bat
regulator an engine DC wiring harness a mounted DC cir tery voltage at the battery terminals using a multimeter
cuit breaker and a battery with connecting cables Because of set on DC volts
the use of integrated circuits ICs the electronic voltage The voltage should be increasing toward 14 volts If it is
regulator is very compact and is mounted internally or on the the alternator is working Tum to Step 4
back of the o
14 BROWN
14 14 14 BROWN
MULTIMETER
14 Fuel Solenoid 14 PINK to Tachomel8r
Fuel Lin Pump
51 AMP i 110RED
ALTERNATOR x BOUTPUT
GENERATOR to Starter Motor
GROUND
TESTING THE STARTING
BATTERY ALTERNATOR
ENGINE RUNNING
A WARNING A failed alternator can become very GROUND
hot Do not touch until the altemator has cooled down 3 If the starting battery voltage remains around 12 volts
after the engine is started and run for a few minutes a
This section is to determine if a problem problem exists with the alternator or the charging circuit
exists with the charging circuit or with the alternator If it is
determined that the alternator or voltage regulator is bad it is a Turn off the engine Inspect all wiring and connections
best to have a qualified technician check it out Ensure that the battery terminals and the engine ground
connections are tight and clean
The alternator charging circuit charges the starting battery and
the service battery An isolator with a diode a solenoid or a
battery selector switch is usually mounted in the circuit to iso A CAUTION To avoid damage to the battery
late the batteries so the service battery is not discharged along charging circuit never shut off the engine battery
with the service battery If the alternator is charging the start switch when the engine is running
ing battery but not the service battery the problem is in the
service battery charging circuit and not with the alternator h If a battery selector switch is in the charging circuit
ensure that it is on the correct setting
Testing the Alternator c Tum on the ignition switch but do not start the engine
d Check the battery voltage If your battery is in good
A WARNING Before starting the engine make certain condition the reading should be 12 to 13 volts
that everyone is clear of moving parts Keep away from
sheaves and belts during test A WARNING MULTIMETERS AND DC CIRCUnS
DC and AC circuits are often mixed together in marine
applications Always disconnect shore power cords
isolate DC and AC converters and shut down generators
before performing DC testing No AC tests should be
made without proper knowledge of AC Engines Generators
ALTERNATOR TESTING
e Now check the voltage between the alternator output Alternator is Working
tenninal B and ground If the circuit is good the
4 Check the voltage of the service battery This battery
voltage at the alternator should be the same as the bat
should have a voltage between 13 and 14 volts when the
tery or if an isolator is in the circuit the alternator volt
engine is running If not there is a problem in the service
age will be zero If not a problem exists in the circuit
battery charging circuit Troubleshoot the service battery
between the alternator and the battery Check all the
charging circuit by checking the wiring and connections
connections look for an opening in the charging cir
the solenoid isolator battery switch and the battery itself
cuit
MU LTIMETER
MULTIMETER G
WITCH COM
TESTING THE STARTING
BATTERY ALTERNATOR
ENGINE RUNNING ENGIN E
GROUND SERVICE
BATIERY
f Start the engine again Check the voltage between the
alternator output and ground TESTING THE SERVICE
The voltage reading for a properly operating alternator BATTERY ENGINE RUNNING
should be between 135 and 145 volts If your alterna
tor is over or have it repaired at a reli
able service shop
A CAUTION When perfonning tests on the alter
NOTE Before removing the alternator for repair use a nator charging circuit do not use a high voltage
voltmeter to ensure that 12 volts DC excitation is pre tester ie Megger You can damage the altemator
sent at the EXC terminal if the previous test showed diodes
only battery voltage at the B output terminal
If 12 volts are not present at the EXC terminal trace
the wiring looking for breaks and poor connections ALTERNATOR INSPECTION
Jump the 12 V to the Exc terminal from a known 12V When rebuilding the engine the alternator should be cleaned
source and operate the alternator If the voltage output and inspected The housing can be wiped off with a solvent
is 1314 volts the alternator is ok Trace the cause for and the alternator tenninal studs should be cleaned with a
12 volts not present at the Exc terminal wire brush Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness
Turn the rotor pulley by hand It should tum smoothly
Depending on when the alternator was last serviced the
brushes may need replacing If the alternator is at all suspect
send it to a service shop for testing and Engines Generators
828 FOUR MARINE ENGINE
WIRING DIAGRAM 039144
110 It D
llilllU
NOTE An onoff switch I
should be installed in this
circuit to disconnect the
starter from the battery in
an emergency and when
leaving the boat Twelve
volt diesel engine starters
t
ALARM
eUZlnt
ADMIRAL
draw 200 to 300
amps when cranking A
switch with a of 175 amps at 12
VDC will normally serve
this junction but a switch
must never be used to
make the starter circuit
L 0 liED
CAPTAIN
PANEL
r
11 au
lIeu
11 au
l I
Engines Generators
828 FOUR MARINE ENGINE
WIRING SCHEMATIC 039144
II YDe START
SOL 1
LifT UM
FUEL tno
IEDEI
1
Pi I j1P1i iu Pi j n
TACIIOMETEI
ADMIRAL
S PANEL
tAUG
IPI1 pt
CAPTAIN
PANEL
T1 DI
51 AMP ALTERNATOR
srANDARD ALTERNATOR ON THE
PRESTOLITE 72 AMP ALT
ma IHi ii IlI 828 IlI
lie BRN
lie GRA
114 PINK
UN I VERSAL PROPUI S I ON
PRESTOI I IE 51 AMP AI T
OPTIONAL AI IERNATORS
mlLdlf O 1M As CAw 1K 1 9ll
Engines Generators
828 FOUR MARINE ENGINE
ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming 1 bleed point
watercooled vertical inline overhead valve Fuel No2 diesel oil cetane rating of 45 or higher
mechanism
Fuel Injection Pump ZEXEL Model VE Distributor Diesel Naturally aspirated
Fuel Injection Timing 0 TDC Top Dead Electronic Goveming
Nozzle Th rottle Chamber Swirl type
Fuel Filter Spinon type full flow
Bore Stroke 374 x 413 inches 95 x 105 mm on Displacement 182 cubic inches 298 liters
Air cleaner Metal screen type Order 1342 Air Flow
946 cfm 27 of Rotation Clockwise when viewed from the front engine Ratio 21 1
Dimensions Height 273 inches 6940 mm
COOLING SYSTEM
Width 255 inches 6477 mm General Fresh watercooled block Length 388 inches 9858
mm controlled with heat 6781bs 307 kgs
Operating Temperature 170 190 F 77 88 Continuous 15 Fresh Water Pump
Centrifugal type metal impeller beltdriven
Temporary 25 not to exceed 20 min Raw Water Pump Positive displacement rubber Power Take Off 40 HP Maximum
Raw Water Flow
190 gpm 719Ipm measured
TUNEUP at 3600 rpm before discharging into exhaust Pressure 427 psi 30 kglcm2 at 200
rpm System Capacity 130 qts 123 of difference between
472 psi 30 kgcm 2
Valve Timing Intake Opens 17 BTDC LUBRICATION SYSTEM
Intake Closes 47 ABDC General Pressure fed system
Exhaust Opens 51 BBDC Oil Filter Full flow paper element spinon type
Exhaust Closes 13 ATDC Sump Capacity 65 US qts Seat Angle Intake 45
not including filter plus filtercooler assembly
Exhaust 30 Operating Oil Pressure 50 60 psi 35 42 kglcm 2
Valve Clearance Intake 0012 inches 03 mm engine hot
engine warm Exhaust 0012 inches 03 mm Oil Grade API Specification CF or Pressure
1920 71 0 psi 135 5 0 kglcm 2 SAE 30 10W30 15W40
Engine Timing Static timed drop valve method
0205 005 inches BTDC ELECTRICAL SYSTEM
Starting Battery 12Volt negative ground
EXHAUST EMISSIONS SYSTEMS Battery capacity 400 600 Cold Cranking Amps Control
Indirect Fuel Injection Starter 12Volt
Starting Aid Glow plugs sheathed type
Battery Charging 51 Amps
Engines Generators
SERVICE DATA I STANDARDS AND LIMITS 828 FOUR MARINE Specified Value I Standard Repair Limit
Component Specified Value I Standard Repair Limit
inchesmm inchesmm inchesmm I TIMING
Valve Spring Inner
Wire Diameter Compression psi at 200 rpm psi Outer Coil Diameter 300 kgcm
270 kgcm Free Length 441 420
Fitting Length between psi Fitting Load 29321b 121 133Kg 24921b1113 kg
Cylinders Max 30 kgcm Squareness 125
VALVE TIMING Spring Constant 202Kgmm
Intake Valve Opens BTDC TIMING GEARS
Intake Valve Closes ABDC
Exhaust Valve Opens BBDC Backlash Between
Exhaust Valve Closes 13 ATDC Gears in Mesh 00005 001 014 0012 HEAD
Idler Gear Distortion Text 01 Clearance Between
Bushing and Shaft 0010 003 007 00078 02
Intake Valve Seat Angle ROCKER ARM
Exhaust Valve Seat Angle Rocker Arm Bore
0626 15876 Valve Seat Width 20 01
Rocker Arm Shaft
Exhaust Valve Seat Width 20 01 Outer Diameter 06234 06244 15835 15860
00024 0016 0061 00028 007
Valve 030 Exhaust TAPPET
VALVES Outer 05610 14224 14249
Valve Head Diameter Bore in Cylinder Block 05630 05640
14288 14319
Intake 159 160 404 406
Exhaust 148 3740 3760 Clearance In
Cylinder Block Bore 00015 00037 0039 0095 00039 010
Valve Head Thickness
Intake Exhaust 15 0039 10 VALVE Length
Joumal Diameter
Intake 1145 No 1 Front 20449 51910 51940
Exhaust 1146 No2 20351 51660 51690
No3 20250 51410 51440
Valve Stem OD No4 Rear 20154 51160 51190
Intake 0354 8955 8980 0351 8904
0353 8935 8960 0350 8884 Wear Limit Guide
Cam Elevation
Protrusion from Intake and Exhaust 42580 42478
Cylinder Head 165 Camshaft End 00071 0020 0180 00118 030
Cylinder Inner 0356 9018 9040
Camshaft RunOut 00031
Stem to Guide Clearance
Intake 00015 00033 0038 0085 OOOSO 0127 Camshaft Support Bore
Exhaust 00041 0058 0105 00050 0127 No1 Front 20485 52000 52030
No2 20374 20386 51750 51780
Valve Contact Width 20 No3 20280 20290 51500 51530
No 4Rear 20177 20189 51250 51280
Valve Face Angle
Intake Oil Clearance 00024 00047 0060 0120 00057 0145
Exhaust Backlash Between Gears 00039
00067 010 017 00118 L Sinking 480 495
IDLER GEAR
Valve Spring Outer
Wire Diameter 45 Boss Bore 18908 48000 48025
Outer Coil Diameter 380 Boss Bore Limit 00118 020 030
Free Length 557 529
Fitting Length 403 Bushing
Fitting Load 75401b 324 342Kg 6636Ib 301 Kg Inner Diameter 17336 44009 44034
Squareness 137 Outer Diameter 18915 18925 48043 48068
Spring 216Kgmm Spindle
Length 11437 2895 2905
Outer Diameter 17303 17313 43950 43975
Spindle and
Bushing Clearance 00033 0034 0084 00059 015
End Play 00118 015 028
Engines Generators
SERVICE DATA I STANDARDS AND LIMITS 828 FOUR MARINE Specified Value Standard Repair Limit
Component Specified Value Standard Repair Limit
inchesmm inchesmm inchesmm ROD
MAIN BEARING
Small End Bore Clearance 00037 0059 0090 00047
Piston Pin and
Small End Bushing 0005 00015 0012 0039 00020 005 Available Undersize 001 002 003 0254 0508 0762
Bend and Twist 0002 in 4 005 in 100 CYlINDER BLOCK
Side Clearance 00094 00134 0239 0340 00157 040 Warpage Iimit 010
Small End Bore 11816 11824 30012 ROD BEARING
Cylinder Liner
Inner Diameter 37422 95025 95050 00079 020
Oil Clearance 00030 0036 0076 0039 010 Protrusion 00000 0101 Undersize 001 002 003 0255 0508 0762
Flywheel to Crankshaft Runout 020
PISTON FUEL SYSTEM
37399 94967 94993 Idle Speed 650 rpm
Piston Ring Hole Bore 11809 11814 29996 30008 Fuel Injection Pump
Plunger diameter 100
Ring Groove Width Gam Lift 22
Top 0966 2433 2453
Second 0962 2423 2443 Injection Timing TDC
Oil 01895 4793 4813
Injector Nozzle 080
PISTON RINGS
Injection Order 3 4 Clearance O0017 00028 0032 0083
Width Injection Pressure 1920 710 psi
135 50 kgcm
Top LUBRICATION SYSTEM
Second 00962 2423 2443
Oil 01895 4793 4813 Oil Pressure psi 38 kgcm
Min Safe pressure idle 43 14 psi 03 01 Top 0938 2363 2383 Oil Capacity sump 63 Qts 60 L
Second 0938 2363 2383
Oil 01875 4743 4763 Oil Pump
Outer Rotor and
Side Clearance Body Clearance 00100 014
025 00118 030
Top 00070 0050 0180 0118 030 Rotor Lobe
Second 00031 0040 0080 Clearance 00059 004 015 00118 030
Oil 00028 0030 0070 Rotor End Float 00039 004 010 00059 015
End Gap 00240 040 060 15 Pump Shaft and
Body Clearance 00079 006 015 00039 010
PISTON PIN
STARTER 11811 29994 30000
Depth of Brush Undercut 05 02
Pin to Piston Clearance 0 0006 0 0016
Height of Brush 17 Spring
Pressure IbM 3 kgcm
Main Joumal 29853 75812 75825
Commutator 387 Limit 7505
Pinion Shaft End Play Diameter 24060 24065 61112 Diameter 0030 0762
End Play 00154 0140 0390 00157 040
Runout 005
Engines Generators
TORQUE 828 FOUR MARINE FHB MKG COMPONENT FHB
Bracket 27 38 38 53 Injection Pipe Flare Nut 22 16 30
Back Plate 35 33 48 Injection Pump Gear Locknut 29 51 40 70
Camshaft Gear 69 64 95 Injector to Head 51 60 70
Camshaft Thrust Plate 17 16 24 Intake Manifold 17 16 Rod Cap 59 65 82 90 Main Bearing Cap
8029 110 117
Coolant Pump 12 17 16 24 Oil Pan 1716 23
Coolant Pump Pulley 17 16 24 Oil Pan Pipe 17 16 23
Coolant Temperature Sender 9 13 12 18 Oil Pressure Sender 9 13 12 18
Coolant Temperature Switch 9 13 12 18 Oil Pressure Switch 9 13 12 Pulley Nut 289 350 400 Oil
Pump Cover 9 08 12
Cylinder Head Bolts 85 90 118 125 Oil Pump Pipe 9 08 12
Cylinder Head Cover 2 3 03 045 Rear Oil Seal Cap 15 15 20
Damper Plate 14 20 19 27 Rocker Arm Assembly 80 85 110 117
Engine Mounts 34 32 47 Rocker Arm Cover 29 025 040
Fuel Filter Assembly 46 68 Thermostat Housing 2 3 03 045
Exhaust Manifold 17 16 24 Thrust Plate 23 23 32
Fuel Solenoid Locknut 362 40 50 Timing Gear Case 17 16 24
Flywheel Bolt 137 131 190 Timing Gear 17 16 24
Glow Plug 11 10 15
Idler Gear 23 22 32
Injection Nozzle to Body 8 10 11 20
Engines Generators
STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt Metric bolt class numbers identify bolts by their strength with 109
Customary inch bolts are identifed by markings two to grade eight The marks correspond to two marks less than the actual grade
ie a grade seven bolt will display five embossed 1 Use the torque values listed below when specific torque values are not available
2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used
3 Reduce torques by 30 or more when threading capscrews into aluminum
STANDARD BOLT NUT TORQUE METRIC BOLT NUT TORQUE SAE Grade 5 SAE
Grade 67 SAE Grade 8
Capsrew Body Size Torque Torque Torque Boll Grade 46 Grade 48 Grade B8 9B
Grade 109
Inches Thread RLb Nm FILbNm ALbNm Dia Wrench Size ALbNm ALb Nm FtLb Nm FILbNm
14 20 8 11 10 14 12 16
28 10 14 14 19 M3 55mm 03 05 05 07 1 13 15 2
M4 7mm 08 11 1 15 2 3 3 45
511618 17 23 19 26 2433 M5 8mm 15 25 2 3 45 6 65 9
24 19 26 27 37
31816 31 42 34 46 44 60 M8 10mm 3 4 4 55 75 10 11 15
24 35 47 49 66 M9 13mm 7 95 1013 18 25 35 26
7116 14 49 66 55 75 70 95 Ml0 16mm 14 19 18 25 37 50 55 75
20 55 75 78 106
12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 63 85 97 130
20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205
M16 24mm 59 80 85 115 159 215 232 315
91612 110 149 120 163 155 210
18 120 163 170 231
M18 27mm 81 110 118 160 225 305 321 435
51811 150 203 167 226 210 285 M20 30mm 118160 166 225 321 435 457 620
18 170 231 240 325 M22 33mm 159 215 225 305 435 590 620 840
314 10 270 366 280 380 375 508
16 295 400 420 569 M24 36mm 203 275 288 390 553 750 789 1070
M27 41 mm 295 400 417 565 811 1100 1154 1565
78 9 395 536 440 597 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130
14 435 590 675 915
1 8 590 800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900
14 660 895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720
NOTE Formula to convert FtLbs to Nm Newton Meters multiply FtLb x 1356
SEALANTS based PERMATEX 2 and its HIGH TACK equivalent are excellent all Use LIQUID TEFLON for sealing pipe plugs and fillings that
connect sealers They are effective in just about any joint in contact with passages Do not use tape raw water oil or fuel
A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets BOLTS Orings
Lightly oil head bolts and other fasteners as you assemble them Bolts and
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil plugs that penetrate the water jacket should be sealed with
PERMATEX 2 or
filter assembly HIGH TACK
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When assembling the flywheel coat the bolt threads with LOCTITE
blue
When installing gaskets that seal around water coolant passages coat both Antiseize compounds and thread locking adhesives such as LOCTITE
protect
sides with WHITE SILICONE grease threaded components yet allows them to came apart when necessary
LOCTITE offers levels of locking according to the ADHESIVE SPRAYS are useful for holding gaskets in position dur
ing assembly LITHIUM based grease is waterproof ideal for water pump bearings
and stuff
ing gasket sealers such as HYLOMAR work well in applications requir
ing nonhardening properties HYLOMAR is particlarly effective on Heavily oil all sliding and reCiprocating components when assembling
Always
copper cylinderhead gaskets as it resists fuel oil and water use clean engine oil
Engines Generators
GENERATOR OF ELECTRIC MOTORS Generator Frequency power required to start an electric motor is
considerably Frequency is a direct result of speed as
more than is required to keep it running after it is started indicated by the motors require much more current to start them than
When the generator is run at 1800 rpm the AC Splitphase AC motors require more current to start output frequency is 60 Hertz
under similar than other types They are
commonly used on easystarting loads such as washing When the generator is run at 1500 rpm the AC voltage
output frequency is 50 or where loads are applied after the motor is
started such as small power tools Because they require 5 to Therefore to change the generators frequency the genera
7 times as much current to start as to run their use should be tors drive engines speed must be changed Along with a
avoided whenever possible if the electric motor is to be dri reconfiguring of the AC output connections at the by a small generator
Capacitor and a regulator board voltage output adjustment must also be
motors require from 2 to 4 times as much current to start as made See ELECTRONIC GOVERNOR in this manual
to run The current required to start any motor varies with the
load connected to it An electric motor connected to an air Generator for example will require more current than a
Maintaining reasonable cleanliness is to which no load is connected Connections of terminal boards and
rectifiers may become
In general the current required to start 115Volt motors con corroded and insulation surfaces may start conducting if
nected to medium starting loads will be approximately as salts dust engine exhaust carbon etc are allowed to
follows build up Clogged ventilation openings may cause exces
MOTOR SIZE AMPS FOR AMPS FOR sive heating and reduced life of windings
HP RUNNING STARTING For unusually severe conditions thin AMPERES
AMPERES
16 32 64 to 224 coatings should be sprayed or brushed
14 46 92 to 322 over all surfaces to reduce rusting and corrosion
13 52 104 to 728 In addition to periodic cleaning the generator should be
12 72 144 to 292 inspected for tightness of all connections evidence of
34 102 204 to 408 overheated terminals and loose or damaged wires
1 13 26 to 52 The drive discs on single bearing generators should be
checked periodically if possible for tightness of screws
NOTE In the above table the maximum Amps for Starting is and for any evidence of incipient cracking failure Discs
more for some small motors than for larger ones The reason
should not be allowed to become rusty because rust may
for this is that the hardest starting types splitphase are not
accelerate cracking The bolts which fasten the drive disc
made in larger sizes to the generator shaft must be hardened steel SAE grade
Because the heavy surge of current needed for starting 8 identified by 6 radial marks one at each of the 6 cor
motors is required for only an instant the generator will not ners of the head
be damaged if it can bring the motor up to speed in a few The rear armature bearing is lubricated and sealed no
seconds If difficulty is experienced in starting motors tum maintenance is required However if the bearing becomes
off all other electrical loads and if possible reduce the load noisy or have it replaced
on the electric motor
Examine bearing at periodic intervals No side movement
of shaft should be detected when force is applied if side
Required Operating Speed motion is detectable bearings are wearing or wear on
Run the generator first with no load applied then at half the shaft of bearing socket outside bearing has capacity and finally loaded to
its full capacity as Repair must be made quickly or major components will
indicted on the generators data plate The output voltage rub and cause major damage to be checked periodically to ensure proper
operation of
the generating plant and the appliances it supplies If an AC Carbon Monoxide Detector
voltmeter or ampmeter is not installed to monitor voltage and
WES1ERBEKE recommends mounting a carbon
load check it with a portable meter and ampprobe
monoxide detector in the vessels living quarters Carbon
NOTE When the vessel in which the generator is installed monoxide even in small amounts is AC equipment of 120 volts only it is
recommended The presence of carbon monoxide indicates an exhaust
that the generators AC terminal block be configured to pro leak from the engine or generator from the exhaust
vide one 120 volt AC hot leg for the vessels distribution elbowexhaust hose or that fumes from a nearby vessel
panel This will ensure good motor starting response from the are entering your
If carbon monoxide is present ventilate the area with clean
air and correct the problem Engines Generators
GENERATOR CONTROL PANEL 3 START The START toggle switch is a double pole single
This manually controlled series ofWESTERBEKE marine throw switch The switch serves two purposes generators is equipped with
toggle switches on the the engine and defeating of bypassing the engine oil pres
engine control panel and optionally at remote panels The sure switch The defeat function turns on the fuel instructions and methods
of correcting minor prob noid instrument power and alternator apply only to such toggle switch controls
While the PREHEAT switch is still depressed depressing
the START switch engages the start solenoid Panel
All three switches are momentary contact type and serve the power and the fuel solenoid will be activated When the
following functions engine begins to fire the START switch should be
1 PREHEAT The PREHEAT toggle switch is a double pole released The PREHEAT switch should not be released
single throw switch The switch serves two purposes pre until the oil pressure reaches alarm stops
heating the engine for easy starting and defeating of
bypassing the engine oil pressure switch The defeat func NOTE When the engine is shut down the water tempera
tion turns on the fuel solenoid instrument power and ture gauge and the oil pressure gauge will continue to
alternator excitation register the last temperature and oil pressure readings
When the PREHEAT switch is depressed the voltmeter displayed They will return to zero once electrical power
panel lights gauges and meters and fuel solenoid will is restored
activate The PREHEAT switch should be depressed for 4 EMERGENCY STOP The EMERGENCY stop switch at
twenty seconds the rear of the control box is normally closed When
2 STOP The STOP toggle switch is a single pole single depressed it will open the DC circuit to the control panel
throw normally closed switch The switch provides and shut the engine down As the switch is not toggled it
power to the fuel solenoid instrument cluster and alterna can be used when performing maintenance
tor excitation after the oil pressure switch has closed
upon starting Opening of this switch opens the power
REMOTE PANEL
circuit to the fuel solenoid stopping the flow of fuel to For remote operation of the generator system the same three
the engine and shuts down the engine switches are used The PREHEAT and START switches are
To stop the engine depress the STOP switch When the connected in parallel with the gauge panels switches and
STOP switch is depressed the power feed to the fuel serve the same functions as in the gauge panel The STOP
solenoid is opened and the fuel flow to the engine is switch is in series with the gauge panels STOP switch and
stopped The STOP switch should be depressed until the serves the same function
generator stops rotating
2 0
STOP
RElEASE
STAHlER
START
3 MUST
PRESS PRESS 2ND
FIRST
GENERATOR
0 0
REMOTE PANEL OPTIONAL
CONTROL PANEL
Engines Generators
CONTROL PANEL MANUAL STARTER DISCONNECT TOGGLE SWITCHES
NOTE The engine control system is protected by a 20 amp manual reset circuit breaker
located on the engine as close as possible to the power source
Problem Probable Cause PREHEAT depressed no panel indications 1 Oil Pressure
switch 1 Check switches andor battery connections
electric fuel pump and preheat solenoid
not energized 2 20 amp circuit breaker tripped 2 Reset breaker If it opens again check preheat solenoid cir
cuit
and run circuit for shorts to ground
START SWITCH DEPRESSED no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Low DC voltage to solenoid terminal 2 Check voltage Jump voltage to S terminal
3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
NO IGNITION cranks does not start 1 Faulty fueling system 1 Check for fuel
2 Check for air in the fuel system 2 Allow system to bleed
3 Faulty fuel lift pump 3 Replace fuel lift pump
4 Faulty fuel solenoid 4 Check fuel solenoid
NOT CHARGING BATTERY 1 Faulty alternator drive 1 Check the drive belt and its tension Be sure the alternator
turns freely Check for loose connections Check the
output with a voltmeter Ensure 12V are present at the
regulator Terminal
BATTERY RUNS DOWN 1 Oil pressure switch 1 Observe if the gauges and panel lights are activated when the
engine is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check the wiring Insert sensitive 025 amp meter in battery
lines Do NOT start engine Remove connections and replace
after short is located
WATER TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the bat
2 Connect the sender terminal at the gauge to ground and tery is connected to the starter both plus and minus termi
see if the gauge reads full scale which is the normal nals the ground side will not necessarily be connected to the
reading for this situation block
Engines Generators
THE BE GENERATOR
SINGLE AND THREE CIRCUIT BREAKER
This generator is a fourpole brushless selfexcited generator A circuit breaker is installed on all WESTERBEKE genera
which requires only the driving force of the engine to pro tors This circuit breaker will automatically disconnect gener
duce AC output The copper and laminated iron in the exciter ator power in case of an electrical overload The are responsible for the
selfexciting feature of this gen breaker can be manually shut off when servicing the The magnetic field produced causes an AC voltage to
tor to ensure that no power is coming into the boat
be induced into the related excitor rotor windings Diodes located in the exciter rotor rectify this volt NOTE This circuit breaker is
available as a to D and supply it to the windings of the rotating field addon kit for earlier TlWdel generations contact your
This creates an field which rotates through WESTERBEKE dealer
the windings of the main stator inducing an AC voltage PART CIRCUIT is supplied to a load An AC voltage is
produced in the 42702 25Kw windings of the main stator and is in turn supplied 42711 20 Kw
60Hz
to a voltage regulator The regulator produces a DC voltage 43271 25Kw 50Hz
42711 20Kw 50Hz
to further excite the exciter stator windings enabling the gen
erator to produce a rated AC output The voltage AC voltage output and adjusts DC excitation to the
exciter stator winding according to amperage load the gener
ator is furnishing To maintain a constant voltage output
DISC PLATE
Engines Generators
GENERATOR AC VOLTAGE regulator is equipped with seven numbered terminals 0
to 6 and their related brass jumpers The illustrations points and jumpers for the 3 phase the generator The sensing leads connect between pin 1
and pin 2 on the AC terminal block and connection 2 and
0 on the voltage regulator board
NOTE Series Delta requires the installation of a jumper on
the regulator board between terminal B and 10 170 270 V 80 160 V
160 Hz
J
U1 V1
CASE GND
3 PHASE VOLTAGE REGULATOR
L1 L2 L3 RNAVR
BE THREE PHASE SIX WIRE
CONNECTIONS FOR BOTH 60 50 HERTZ
PARALLEL WYE STAR SERIES WYE STAR SERIES DELTA
L L 208 VAC 38 50 Hz L L 450 VAC 3 60Hz L L 240 VAC 20 60Hz
L N 120 VAC 1 60 Hz L N 265 VAC 18 60 Hz L2 L3N 120 VAC 10 60Hz
L L 190 VAC 38 50 Hz L L 380 VAC 30 50Hz L L 220 VAC 38 50Hz
L N 110 VAC 10 60 Hz L N 220 VAC 18 50Hz L2 L3N 110 VAC 18 50Hz
A SERIES DELTANote the
BE THREE PHASE TWELVE WIRE repositioning of the ground
lead from neutral to
generator housing
J Jumper using 10 AWG
wire
Engines Generators
GENERATOR AC VOLTAGE VOLTAGE CONNECTIONS Generator The frame ground wire whitegreen must be prop
1 Frequency is a direct result of speed
erly positioned when changing the AC output configuration 1800 rpm 60 hertz 1500 rmp 50 hertz
of the AC terminal block For making connections to the AC 2 To change generator frequency follow the steps block use terminal endsfor 114
inch studs that will
Configure the AC terminal block for the desired multi strand copper wire siW1 for the amperage rating
frequency as shown Ensure that the case ground wire is
from the hot lead connection The frame ground wire is white
connected to the correct terminal block neutral ground
or white with a green strip It connects between the neutral
stud
stud and the generator frame
NOTE The whitegreen ground wire may be removed in those
installations where the AC circuit has a separate neutral and
ground circuit This will prevent the unit from being a ground
source in the vessel
120240V OHz 120V60Hz 230V50Hz 115V 50Hz
o 0 o 0
0 0 0
L1 L1 N 1Jt
4
L1 N
A JUMPER IS
REQUIRED
BETWEEN LOAD
ILLUSTRATION SHOWS
230V50Hz
Engines Generators
VOLTAGE REGULATOR AmpHertz
The voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the two
optimum AC alternator performance It is equipped with protection circuits in the voltage regulator that are protection circuitry to
guard against operating by the illumination of a colored LED that could be detrimental to the AC alternator 1 Delay
overload protection yellow LED
2 Low speed protection red LED
Both systems have an intervention threshold which can be
adjusted using the respective Each of the two
circuits are able to cause an adequate reduction in excitor
voltage to safeguard the excitor windings and prevent their
overheating
The overload protection system has a delay which permits
temporary overloading of the generator during times such as
motor startup or other similar load surge demands The regu
lator also has a third LED green that glows during genera
tor operation to indicate correct operation of the regulator
with the potentiometer is used to adjust output voltage At proper
engine operating speed the output voltage should be held at Setting the Overload Protection
1 from a noload condition to a full rated generator output In order to set the AMP overload protection the from power factor 10 08 with
engine drive speed vari must be loaded to its full output up to 6 1 Load the
alternator to its rating then decrease the speed of
Prior to starting the engine turn the VOLT and STAB trim the engine by 1010 54 Hertz on 60 hertz units 45
mers using a mini phillips screwdriver fully in a counter hertz on 50 hertz Minimum direction until you feel them hit their
2 Rotate the AMP adjustment until it hits
stops its stop Wait about 1520 seconds after which the AC out
Turn the AMP and HER1Z trimmers completely clockwise put of the alternator should drop and the yellow LED in the same manner
should come on
With the alternator running at noload at normal speed and 3 Slowly rotate the AMP adjustment clockwise until the
with VOLT adjust at minimum it is possible that output volt output voltage increases to approximately 97 of the volt
age will oscillate Slowly rotate the VOLT adjust clockwise age output at the start of the adjustment At this point the
The voltage output of the alternator will increase and stabi yellow LED light should come on
lize Increase the voltage to the desired value In this situa 4 Return to nominal speed the yellow LED will turn off
tion only the green LED will stay lit and the alternator voltage will rise to its normal
Should this not happen repeat the potentiometer permits variation of the regulators NOTE
When changing from 60 hertz to 50 hertz to generator load changes so as to limit overcom remove the 60 hertz jumper bar from the
regulator and obtain a minimum recovery time to the output Setting the Underspeed
Protection
In order to adjust the regulator stability the alternator must be NOTE If the unit is operating at 60 Hertz ensure that the
running at noload and the output must be monitored jumper strap is in place on the regulator board between the
Turn the STAB adjust slowly clockwise until the voltage two 60 Hertz terminals In order to adjust the to fluctuate At this point
rotate the STAB adjust coun setting the alternator should be running at until the voltage is stable within 1 or 2 tenths of
1 To adjust the underspeed low frequency protection circuit
a volt
lower the engine speed at 90 of its normal running speed
54 hertz on 60 hertz units 45 hertz on 50 hertz units
2 Rotate the Hertz adjustment slowly until
the alternators AC output voltage starts to decrease and at
the same time the red LED light comes on
3 Increase the engine speed to its normal speed frequency
The red LED light will go out and the AC voltage out
put will return to normal
With the above adjustments made the regulator should func
tion normally
VOLTAGE REGULATOR DIAGRAM
Engines Generators
INTERNAL WIRING SCHEMATICS
SINGLE EXCITER STATOR
EXCITER
ROTOR 1 1
I STATOR
I RED
TERMINAL
BLOCK
J AUX
WINDINGS W2
U1 V1
BLACK
GREEN
RED NOTE This fuse
may be located
BLUE
on the YELLOW
THREE PHASE
6 WIRE EXCITER STATOR 1
I STATOR
1 BLACK
V2 BLACK
1 1 1 ROTOR FIELD I
1 1 1 I
AC
GREEN
1 EXCITER 1 POZI V2 I VI TERMINAL
GREEN
1 ROTOR 1 RESISTER I BLOCK
I fII
l W2
1 I I
1 1 1 1 JI
I DIODES AUX
L WINDINGS
L 1 z
u fa fa
REGULATOR 5
a a
FUSE
63 AMP
Hertz
o Stab
NOTE This fuse
Volt may be located
on the regulator
BLUE
YELLOW
Engines Generators
INTERNAL WIRING SCHEMATICS
3 PHASE TWELVE WIRE 1 1
I STATOR I
EXCITER STATOR r
I II EXCITER II ROTOR FIELD I
Ljr1IiI
3 1
ROTOR I 4 4 8 7 TERMINAL
I I I
I BLOCK
7 1
I 8 I
L
AUX
WINDINGS
FUSE
63 AMP NOTE This fuse
may be located
on the regulator
green
Q11ow
REGULATOR
BLUE
YELLOW
BE GENERATOR WINDING RESISTANCE VALUES IN OHMS
SINGLE PHASE 20 25 BE 32 BE
EXCITER STATOR 1806 1820
EXCITER ROTOR a b 068 072
bc 068 072
ROTATING FIELD 175 201
MAIN STATOR 12 005 005
34 005 005
AUXILLARY WINDING 119 098
THREE PHASE 20 25 32 BE
EXCITER STATOR 1820
EXCITER ROTOR a b 07
bc 07
ROTATING FIELD 201
MAIN STATOR 006 each winding
AUXILLARY WINDING 098
Engines Generators
BE NOTE AC GENERATOR MUST
BE PERFORMED WITH ENGINE OPERATING AT 60 HER1Z
PROBLEM PROBABLE CAUSE
No AC voltage output at no load 1 Short or open in the 4 Short or open in exciter
main stator winding stator winding
2 Shorted poziresistor 5 Short or open in rotating
on exciter rotor field winding
3 Four or more shorted or
open diodes on exciter voltage produced at no load 1 Blown 6 AMP buse fuse 3 Shorted or open
main
15 20 vOlls AC auxiliary circuit feed to AVR stator auxiliary winding
2 Faulty voltage AC vOllage output at no load 1 Open or shorted diodes in 3 Faulty voltage
regulator
60 100 VAC exciter rotor 1 to 3 diodes
2 Open or shorted exciter
rotor winding
High AC output voltage 1 Faulty voltage VAC or voltage output
1 STB pod on regulator 2 Faulty voltage regulator
needs voltage drop under load 1 Diodes on exciter rotor
60 100 volts AC breaking down when load is
applied inductive 13 diodes
EXCITER
STATOR
rIDJ
I I RED
I I
I EXCITER I ROTOR FIELD 1 1
ROTOR I STATOR
AUX 1
REGULATOR
FUSE
RED U1 V1
ret BLACK
CI areen
now GREEN
eIIz RED
lIIIIp NOTE This fuse
BLUE may be located
on the YELLOW
Engines Generators
ELECTRONIC Governor System
The system is composed of three basic components
I
1 Controller Mounted in the instrument panel
2 Sensor Installed on the bellhousing over the flywheel
ring gear
3 Actuator Mounted at the front of the engine and
attached with linkage to the throttle arm of the injection
Adjustment
1 Speed This adjustment is used to raise or lower the
engines speed to the desired hertz
2 Gain This adjustment affects the reaction time of the
actuator to the load changes
NOTE A high gain adjustment can induce an oscillating
of the actuator producing a hunting mode In such cases
SENSOR
lessen the gain adjustment
ELECTRONIC LINEAR ACTUATOR
1 With no power to the governor adjust the GAIN to 900
oclock
2 Start the engine and adjust the speed by turning the speed
pot clockwise to desired speed KEEP ACTUATOR
NOTE Controllers are factory adjusted to minimum rpm LINKAGE WELL
LUBRICATED
However for safety one should be capable of disabling
the engine if an overspeed should exist
3 At noload tum the GAIN potentiometer clockwise until
the engine begins to hunt if the engine does not hunt
physically upset the governor linkage LINEAR ACTUATOR
4 Tum the GAIN potentiometer until stable TO ELECTRONIC
TO TERMINAL
BOARO 11
Til SENSOR
DC 114 RED
14 BLACK
SHIELDED
CABLE
WHITE
TO GOVERNOR
CONTROL
FLYWHEEL HOUSING PURPLE
114 PURPLE
ELECTRONIC GOVERNOR
MAGNETIC SENSOR
TO LINEAR ACTUATOR
114 PURPLE
PURPLE
TERMINAL BOARD 3
SENSOR
F O030in
FLYWHEEL r7
TEETH 7 v v
Engines Generators
THE ELECTRONIC GOVERNOR
Problem Probable Cause appears dead 1 Low battery voltage at
controller 1 Check wiring for cause Check battery state of runs at idle
2 Stuck linkage 2 Lubricate free up linkage between controller and throttle arm
3 No signal or weak signal from sensor 3 Check for improperly installed or damaged sensor in flywheel
Measure AC voltage from sensor while housing Replace or adjust
engine is running at idle Voltage should
be 25 volts or greater
4 Check Actuator depress PREHEAT and
check for battery voltage between
negative black lead at terminal block
a Purple lead to black 4 Replace controller if battery voltage is not present at both
leads
b Second purple to black
5 Perform the following check between
terminals at the actuator and the negative
DC lead at the controller terminal block
Preheat depressed
a Low voltage 12020 VDC at either a Broken actuator lead
actuator connection
b Battery voltage at both actuator b Broken actuator lead
connections
c Battery voltage at one actuator lead c Replace the actuator
but not the fully extends when PREHEAT 1 Check controller Lift one of the purple
is depressed and stays extended actuator leads from the terminal block
Depress PREHEAT
a Actuator fully extends a Short in lead to actuator
b Actuator does not fully extend and b Replace controller
connections
NOTE Release PREHEAT and reconnect
the purple hunts oscillates and 1 Linkage between actuator and throttle 1 running binding
2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the Controller
controller
3 Inadequate DC power supply to
controller complete the following tests
Connect a DC voltmeter across the
plus and negative leads at the
controller terminal block
Lift both purple leads from the
terminal block
Connect one purple lead to the
C plus terminal and the other to the
DC negative
Momentarily depress PREHEAT
The actuator should fully extend 3 If actuator does not fully extend check the actuator leads
If the voltage is less than specified check for loose or poor
connections low battery voltage voltage drop in DC circuit
due to remote panel installation and small wire sizes making
connections
DC voltage registering on the meter should be
12 VDC System 96 VDC or higher
24 VDC System 192 VDC or higher
NOTE Reconnect actuator leads properly after making this test
3a Sensor positioned marginally too far 3a Check the position of the sensor
away from flywheel teeth giving
erratic signal voltage to Engines Generators
SHORE POWER TRANSFER SWITCH
SHORE POWER CONNECTIONS 60 HERTZ 120 VOLT60 HZ THREE WIRE Generator
Notice the repositioning of the white wire ground load on the
NOTE Diagram shows connections for a two
r N G1 4G2 l wir 120 Volt system For a thr wire system terminal block to the generator case
use dotted lines ror the other hot leg
I Generator NOTE Diagram shoWI
connections for a two
I wire 120Yolt system trom the
generator
L with threwlr 120Volt boat
system
r t3
I
Ship to Shore Switch 3 Pole
PH 32008
PH 32009
80 Amps Pol
PH 3200 Shipto Shor Switch 3 Pole
25 Am Pole PN 32008
PH 32133


PH 32010
POle
m 25 Ampa Pole
I Ships Load PN 32133
VOlt 200 AmpPole
Ground II Equipment
Z GRN
If the installer connects shore power to the vessels AC cir l52 S1 T N
cuit this must be done by means of the Shore Power Transfer Shore Power
Switch Set the transfer switch shown in the diagrams to the
OFF position TIlls switch prevents simultaneous connection
of shore power to generator output SWitching Shore Power to Generator Power
A CAUTION Damage to the generator can result if A CAUTION Heavy motor leads should be shut off
utility shore power and generator output are connected before switching shore power to generator power
at the same time This type of generator damage is not riceversa because voltage surges induced by
switching
covered under the warranty it is the installers responsi with heavy AC loads on the vessel being operated
bility to make sure all AC connections are correct cause damage to the exciter circuit components
in the
Engines Generators
BED GENERATOR
WIRING SCHEMATIC 039422
12VDC
J BATTERY
START
SWITCH
SOL STARTER
i Ml
L j
PREHEAT
1o J
J 20A
l J
L 7 LIFTPUMP
1 STOP Pl
SWITCH
FUEL SOL
Ie K IS
REMOTE STARTSTOP 1
I RED
A 5A SURGE
3A START
RUN Current Models
wfwo Relays
TO TB114 TBl2r to TB11to Stop Switch
Models wI
Terminal Blocks
Models wout
Terminal Blocks
STOP
14 BLACK 1A cO BLACK I I
TB1Groundto Panel Ground
SWITCH I
22 I
BLACK
22 RED G I
1 to TB21to Preheat Switch
10 RED
I I TB22
4APURPLE I to TB22Ito Preheat Switch
PREHEA 5 nw
SWITCH 3A RUN
14 RED 14 RED
14 RED I
I I I
TBl3 to TBl2 to Preheat Switch
j TBl5 to TBl4to Start Switch
15A START I I
REMOTE PANL REAR VIEW
Engines Generators
BED GENERATOR
WIRING DIAGRAM 039422
AL TRNATOR 51 A
liFT PUMP
1
FUEL SOLENOID
WATER TEMP SENDER
r
Ii A
OIL PRESSURE SW
OIL PRESS
SENDER
T
u v
Et4P
EXHAUST SW
AWNT n
J W r
REMOVE THIS 1Gi0
JUMPER WHEN 6l
1020 I CONNECTING A REMOPL Lwi
LL rur
IIn K IllIti I
NOTE 2 An onoff switch
should be installed in this
circuit to disconnect the from the battery in

an emergency and when r 1
leaving the boat Twelve
volt diesel engine starters
1 T i
draw 200 to 300 STANDARD
amps when cranking A
EJ PANEL
switClz with a at 12
VDC will normally serve
IJ STOP
this function but a switch I SWITCH I
must never be used to I
L JI
make Ihe starter circuit
BED GENERATOR
WIRING SCHEMATIC 039422 WITH DUAL RELAYS
BATTERY
SWITCH STARTER STARTER
SOLENOID
I I M
I I
I I
PREHEAT L I
SOLENOID GLOWPLUGS
I I
L I
ALTERNATOR
110 AMP T823
870 IT ICIRCUIT
jBREAKER
120 AMP KI L
ICIRCUIT 30
jBREAKER
START START 0
SWITCH KI
L I 86 85
1 EMERGENCY
I STOP r
SWITCH I I PREHEAT
SWITCH
L j K2 0
30 87
r I
I b FUEL PUMP
L j
OIL PRESS EXH TEMP WATER TEMP
SW SW SW
FUEL SOLENOID
Engines Generators
BED GENERATOR
WIRING DIAGRAM 039422 WITH DUAL RELAYS

ltlf ORN
114 PUR 4 PUR 14 PUR
114 PUR
II REDPUR
Ljl WATER
WAlEB TEMEBAIUBE
illI1EB
tl4 PUR
FUE QEQIQ
QI REUBE
Q Z
AeE fJWirAI
ACTUAIQR QLEQ IQ
110 Oftlrl 110 REI
rT
BATTERY SWITCH
VI

1 I 14 PURWNT
oc Q
MQIQR
QI eBE
illI1EB
112 YlIRED
0 TO BlOCK
114 TAN
rMIELDED

if EXHAUUBE
JJ
tl2 RED 12 REI
JlilLG
20A ClBCUII EMERGENcy
fJllltE MEMEB HQ wII

114 8RN or
SEEHOTIE J
4 PUR 112 RED
is S
r 14 RED
r1 i
114 RED
1
i
RED
I liQIE REMOVE TH I S JUPER WHEN
II NSTALLI NG ONE REOTE ST ARTSTOP
BLK
BLKWHT
14011
lOllED
41111 PANEL IF INSTALLING TWO PANELS
REOVE BOTH JUPERS
I 1 4 YEL 10liEDWHT
AT I
I OIL 1WATR
HNQABQ
I I
INSTBUMENI
10 I
UliEJ
P o 1 ITART
Vo I
I RDWMT I
I HOUR
I VOLT
STOP
METER METER
J I
Engines Generators
WESTERBEKE 25 KW BED GENERATOR
ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming 1 bleed point
watercooled vertical inline overhead valve Fuel No2 diesel oil cetane rating of 45 or higher
mechanism
Fuel Injection Pump ZEXEL Model VE Naturally aspirated
Fuel Injection Timing 0 TDC Top Dead Electronic Goveming
Nozzle Th rottle Chamber Swirl type
Fuel Filter Spinon type full flow
Bore Stroke 374 x413 inches 95 x 105 mm on Displacement 182 cubic inches 298 liters
Air cleaner Metal screen type Order 1342 Air Row
946 cfm 27 of Rotation Clockwise when viewed from the front engine Ratio 21 1
Dimensions Height 286 inches 7265 mm
COOLING SYSTEM
Width 233 inches 5918 mm General Fresh watercooled block Length 449 inches
11494 mm controlled with heat 678 Ibs 307 kgs
Operating Temperature 170 190 F 77 88 Continuous 15 Fresh Water Pump
Centrifugal type metal impeller beltdriven
Temporary 25 not to exceed 20 min Raw Water Pump Positive displacement rubber Power Take Off 40 Horsepower Maximum
beltdriven
Raw Water Flow 150 gpm 567lpm measured
TUNEUP at 3600 rpm before discharging into exhaust Pressure 427 psi 30 kgcm at 200
rpm System Capacity 130 qts 123 of difference between
472 psi 30 Timing Intake Opens 17 BTDC LUBRICATION SYSTEM
Intake Closes 47 ABDC General Pressure fed system
Exhaust Opens 51 BBDC Oil Filter Full flow paper element spinon type
Exhaust Closes 13 ATDC Sump Capacity 65 US qts Seat Angle Intake 45
not including filter plus filtercooler assembly
Exhaust 30 Operating Oil Pressure 50 60 psi 35 42 kgcm
Valve Clearance Intake 0012 inches 03 mm engine hot
engine warm Exhaust 0012 inches 03 mm Oil Grade API Specification CF or Pressure
1920 71 0 psi 135 5 0 kgcm SAE 30 10W30 15W40
Engine Timing Static timed drop valve method
0205 005 inches BTDC ELECTRICAL SYSTEM
Starting Battery 12Volt negative ground
EXHAUST EMISSIONS SYSTEMS Battery Capacity 300 600 Cold Cranking Amps Control
Indirect Fuel Injection Starter 12Volt
Starting Aid Glow plugs sheathed type
Engines Generators
WESTERBEKE 25 KW BED GENERATOR
ELECTRICAL SYSTEM AC GENERATOR THREE Battery 12Volt negative ground
General 3 Phase Brushless six pole revolving field
Sealed lubricated single Capacity 400 600 Cold Cranking Amps CCA design 12 Lead reconnectable
for low voltage
DC Charging A1temator 51 Amp rated beltdriven WYE and for Delta Solid State voltage regula
tor with protection 12Volt Reduction Gear
Voltage 3 Phase Low voltage WYE 208 Aid Glow plugs sheathed type 60 Hertz
High voltage WYE 480 volts
DELTA 240 volts
DC NoLoad Current 2 of rated Amps
Voltage 3 Phase High voltage WYE 380 volts
DC Cranking Current 250 300 Amps engine cold 50 Hertz DELTA 240 volts
Amperage 3 Phase Low voltage WYE 867 Amps
AC GENERATOR SINGLE PHASE 60 Hertz High voltage WYE 376 Amps
General Single Phase Brushless fourpole revolving field Sealed DELTA 752 Amps
lubricated single bearing design Amperage 3 Phase High voltage WYE 380 Amps
Reconnectable single phase for 120240 volts 50 Hertz DELTA 656 Amps
with solid state voltage Single Phase 120 or 120240 Volts 60 Hertz
230 VoUs 50 Hertz
GENERATOR regulation 2 no load to full load
Air Requirements 10 Power Factor 425 cfm 1274 regulation 3 Hertz no load to full load 60 Hertz at 1800 RPM
Rating Volts AC 20 KW 60 Hertz 1800 rpm Note Increase air supply 15 for 50 Hertz operation 1500 rpm
120 Volts 208 Amps
120240 Volts 208109 Amps Engine Combustion Air 946 cfm 27 cmm
Requirements
20 KW 50 Hertz 1500 rpm 60 Hertz at 1800 RPM
230 Volts 87 Amps
Engines Generators
SPECIAL TOOLS FABRICATED TOOLS Lifting Eye Tool
These drawings provide a means by which simple tools can This tool allows a mechanic to safely remove the generator
be made to assist in the removal of the generator end from end from the engine by attaching this Generator End Lifting
the engine and in the replacement of the generator end on the Eye to the four screw holes located under the control A local
machine shop should be able to fabricate these To use this Lifting Eye remove the generators control panel
tools at a modest price but first check with your local WEST and screw the Lifting Eye to the generator end
ERBEKE dealer to see if these tools are on hand for Puller Tool
This tool allows the bearing in the generator housing to be
gently pushed straight off the housing without any twisting
If a nut of the same as that of the tapped hole
in the pilot tool were to be welded on the end of the eye bolt
this tool would be able to pull the bearing back into place
without any twisting Please refer to these drawings before
1 212
635 mm
the generator end is removed 4
HOLES
1213 UNC Storebought 6 mm
eye bog with tapered tip
HOUSING PULLER TOOL
FIELD I
101 mmI Taper
Disk Alignment Tool
Center lining eye on
baseplate and weld securely
This tool allows a mechanic to safely remove and install the
r10 generator drive disks by aligning the disks with the Drive
2
Plate Guide Pin The Pin screws into the flywheel and acts as
a guide Also the pin helps to support some of the rotor and
the drive plates weight while removing or replacing these
Weld 1213 UNC Hex Nut
one silfe of this center hole
parts
OiWmWHHJm t
12 127 mm Gia
Drill Typ 4 holes Material Coldrolled Steel Material One M8 bolt with the hex head machined off and a
screwdriver slot cut in the machined end
Pilot Tool
The tool below helps keep the rotor from damaging the
windings in the generator housing to be removed straight off
the engine or to be placed straight on the engine Refer to the
removal and replacement diagram at the bottom of the page
I 8
2032 mm ROUND TIP
li fF1
155 mm Drill
1201
3048
I
114 3175 mm Deep
M18 x 15 Pilch
Tap 1 254 mm Deep
PROPER USE OF HOUSING PUllER
Material Aluminum
Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMmRS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT MmRS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VAlUES eg 6000 MmRS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO Liters Gallons Liters Liters Gallons Liters
Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 OF
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
Engines Generators
INDEX
AC Voltage Connections 63 Raw Water Pump Testing Rear Oil Seal 23
Camshaft Reassembly Rocker Arm Rod 19
54
Control Panel Standards and Limits 55
Coolant Circulating pump 41 Starter Motor Stop Solenoid 40
Cylinder Block 17 Tappets 22
Cylinder Head Bolt Pattern 2735 Thermostat Liner 17 Timing Gears Cover 23
Electronic Governor Timing Gears 12 22
Electronic Governor 70 Testing for Overhaul
Torque 57
Adjustments 3940 3
Assembly 24 Valve Clearance 28 39
Camshaft Valve Guide 15
Checking gears 22 Valve Seat 16
Coolant Pump 41 Valve Spring 14
Compression 39 Valve Spring Removal 11
Connecting Rod 19 Wiring Diagram 52
Crankshaft Wiring Schematic Cylinder Block 17 Exhaust Manifold 31
Cylinder Head Bolt Pattern Frequency Adjustment 50 53
Cylinder Liner 17 Fuel Injection Pump 32 33
Disassembly 8 Fuel Injectors 34 35
Exhaust Manifold 31 Fuel Lift Pump 33
Fuel Injection Pump 32 Fuel System 36
Fuel Injectors 34 Generator
Fuel Lift Pump 33 AC Voltage Connections 63 64
Glow Plugs Testing 38 BE Single and Three Phase 62
Heat Exchanger 31 Circuit Breaker 62
Injection Pump 10 32 Control Panel Switches 60
Injection Timing 32 Control Panel 61
Injectors 34 Disassembly 8
Inspection 14 Electronic Governor Low Oil Pressure 43 Electronic Governor
Lubricating Oil Pump 42 Frequency Adjustment 59
Main Bearing Information 59
Oil Jet Upper Block 23 Maintenance Oil Pan Overload Protection Setting 65
Oil Pressure 43 Remote StartStop Panel diagram 60 72
Oil Pressure SwitchSender 43 Shore Power Transfer Switch Overhaul 7 Special
Tools Piston and Piston Ring 18 Push Rod 22
Engines Generators
INDEX
Wiring Diagram Tappets Wiring Schematic Testing for Overhaul Plugs Testing 38 Timing Gear Cover 23
Heat Exchanger 31 Timing Gear 12
Injection Pump 10 Timing 32 Standard Hardware 58
Injectors 32 57
L Dimension 15 Westerbeke Components Oil Pump 42 Transmission Oil Coolers 30
Metric Conversion Chart 8
Oil Pressure 43 Pressure Testing 43 BE Generator 68
Pumps Control Panel 61
Coolant Circulating 41 Electronic Governor 70
Fuel Lift 31 Engine 3
Injection 30 Fuel System 36
Raw Water Overhaul 44 Valve Clearance 28 39
Raw Water Pump 44 Valve Guide 15
Rear Oil Seal Valve Seat 16
Remote StartStop Panel diagram Valve Spring 14
Sealants and Lubricants 58 Voltage Regulator 65
Shore Power Transfer Switch Wiring Diagrams Tools Generator Generator 039422 diagram Engines 54 82B Four
Engine 039144 diagram Generators 82b Four Engine 039144 schematic 53
Standard Hardware 58 BE Single Phase schematic and Limits 55 BE Three Phase 12 wire schematic 67
Starter Motor 45 BE Three Phase 6 6366
Starter Motor Adjustment and Repair 45 Remote StopStart 49 Generator 038422 schematic
Engines Generators
r9Y rWESTERBEKE
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA WMDW 1298

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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.