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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
25KW-60Hz BED /20KW-50Hz BED
  MARINE DIESEL GENERATORS
     SINGLE PHASE & THREE PHASE


                 PUBLICATION NO. 040485
                      EDITION ONE
                    NOVEMBER 1998




~r~ 'WESTERBEKE
         WESTERBEKECORPORATION
     ~   MYLES STANDISH INDUSTRIAL PARK
         150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319


              N~A 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    WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness                  - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF 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 INSTRUCTIONS
INTRODUCTION                                                       PREVENT BURNS - FIRE
Read this safety manual carefully. Most accidents are
caused byfailure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
                                                                       A WARNING: Fire can cause injury or death!
necessary 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 filters.
PREVENT ELECTRIC SHOCK                                             ·     Do not operate with a Coast Guard Approved flame
                                                                         arrester removed. Backfire can cause severe injury or
                                                                         death.
    A WARNING: Do not touch AC electrical connections              ·     Do not operate with the air cleaner/silencer 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                    engine/generator 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 re-fueling safety instructions. Keep the vessel's
·    Do not connect utility shore power to vessel's AC                   hatches closed when fueling. Open and ventilate cabin
     circuits, except through a ship-to-shore double throw               after fueling. Check below for fumes/vapor before run-
     transfer switch. Damage to vessel's 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 well-ven-
                                                                         tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE                                               out of the reach of children.
                                                                   ·     Do not fill the fuel tank(s) 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 environment.




                                                         Engines & Generators
                                                SAFETY INSTRUCTIONS
ACCIDENTAL 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 T-22 (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 flu-like 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 exhaust/water 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 temples
BATTERY 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 components.




                                                             Engines & Generators

                                                                    ii
                                                 SAFETY INSTRUCTIONS
·     Do not wear loose clothing or jewelry when servicing                 ABYC, NFPA AND USCG PUBLICATIONS FOR
      equipment; tie back long hair and avoid wearing loose
      jackets, shirts, sleeves, rings, necklaces or bracelets that
                                                                           INSTALLING DIESEL ENGINES
      could be caught in moving parts.                                     Read the following ABYC, NFPA and USCG publications
                                                                           for safety codes and standards. Follow their 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 belt's 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 Association)
HAZARDOUS 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.
                                                                              U.S. Government Printing Office
                                                                              Washington, D.C. 20404
    A WARNING: 00 not work on machinery when you are
    mentally or physically incapacitated by fatigue!

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

ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
         H-2 Ventilation
         P-l Exhaust systems
         P-4 Inboard engines
         E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                              Engines & Generators

                                                                     iii
                             INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:

CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.

SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and posswle flooding of the boat.

EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.


       A detailed 40 page Marine Installation Manual covering gasoline and
       diesel, engines and generators, is available from your WESTERBEKE
       dealer.




                                 Engines & Generators

                                         iv
                                                          TABLE OF CONTENTS

Introduction ................................................................2       Engine Torque Specifications.......... .........................57
Engine Troubleshooting (Chart) .. ............................... .3                 Standard Hardware Torques .....................................58
Testing for Overhaul ...... .............................................7           Generator Information ..............................................59
Engine I Generator Disassembly .. ..............................8                    Generator Control Panel SWitches ...........................60
Engine Disassembly ....................................................9             Control Panel Troubleshooting .................................61
Engine Inspection ..................................................... 14           BE Generator ............................................................62
Engine Assembly ........ ...............................................24           Generator AC Voltage Connections .........................63
Exhaust ManifoldlHeat Exchanger .......................... .31                       Voltage Regulator Adjustments ...............................65
Fuel Injection Pump .... .............................................32             Internal Wiring Schematics... ...................................66
Fuel Injection Pump!Fuellift pump .........................33                        Internal Wiring Schematics ... ~ ..................................67
Fuel Injectors............................................................34         BE Troubleshooting ...................................................68
Fuel System Troubleshooting ...................................36                    Electronic Governor ...........................................................69
Glow Plugs ................................................................38        Troubleshooting the Electronic Governor ................70
Engine Adjustments ..................................................39              Shore Power Transfer Switch ...................................71
Coolant Circulating Pump ........................................41                  BED Generator Wiring Schematic ............................72
Lubricating Oil Pump .. ..............................................42             Remote Start/Stop Panel Wiring Diagram ................72
Oil Pressure ..............................................................43        BED Generator Wiring Diagram ................................73
Starter Motor ...... '" ...................................................45        BED Generator Wiring Diagram ...... ..........................74
Tachometer ......... '" ...................................................49        BED Generator Wiring Schematic ............................75
Alternator Testing .......... ...........................................50          Generator Specifications..... .....................................76
Engine Wiring Diagram .. ...........................................52               Special Tools· Generator .........................................78
Engine Wiring Schematic ........ .................................53                 Metric Conversions ..................................................79
Engine Specifications ...............................................54              Index..........................................................................80
Engine Standards and Limits ... .................................55




                                                                      Engines & Generators

                                                                                 1
                                                    INTRODUCTION
PRODUCT SOFTWARE                                                       CUSTOMER IDENTIFICATION CARD
Product software (tech data, parts lists, manuals,
brochures and catalogs) provided from sources other than
WESTERBEKE are not within WESTERBEKE'S control.                               / ....'WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
                                                                                         I
                                                                        Customer Identification
WARRANTIES OR REPRESENTATIONS WITH RESPECT
                                                                        WESTERBEKE OWNER
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS 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. #OOOOO-D911
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
                                                                        Expires 9/1/99
WESTERBEKE customers should also keep in mind the
time span between printings ofWESTERBEKE product
software and the unavoidable existence of earlier                      The WESTERBEKE serial number is an alphanumeric
WESTERBEKE manuals. Product software provided with                     number that can assist in determining the date of
WESTERBEKE products, whether from WESTERBEKE                           manufacture of your WESTERBEKE engine/generator. The
or other suppliers, must not and cannot be relied upon                 first character indicates the decade (A=1960s, B=1970s,
exclusively as the definitive authority on the respective              C=1980s, D=1990s), 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 representatives of WESTERBEKE or the                  month of manufacture.
supplier 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 housing.
NOTES, 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 engine/generator, critical              serial number is stamped into the generator housing on the
information will be highlighted by NOTES, CAUTIONS,                    flat surface on the left side of the generator.
and WARNINGS. An explanation follows:
                                                                       An identification plate on the engine manifold also displays
NOTE: 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 engine/generator.                                                    MODEL &
                                                                           SERIAL
                                                                           NUMBER

 A WARNING: Procedures, which if not properly
 followed, can result in personal injury or loss of life.


ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator            ENGINE OVERHAUL
serial number as they appear on the silver and black
name-plate located on the generator end. You must provide              The following sections contain detailed information
us with this information so we may properly identify                   relating to the proper operation characteristics of the major
your engine/generator. In addition, include a complete part            components and systems of the engine. Included are
description 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 engine
WESTERBEKE packaged parts because will fit or generic                  service and rebuilding facilities. The necessary procedures
parts are frequently not made to the same specifications               should be undertaken only by such facilities.
as original equipment.                                                 Additional detailed information and specifications are
                                                                       provided in other sections of this manual, covering the
                                                                       generator, alternator, starter motor, engine adjustments,
                                                                       cooling pumps, etc.



                                                            Engines & Generators

                                                                   2
                                             ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain                             NOTE: The engine's 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 recommendations to overcome                               mounted on the same bracket.
these problems.This chart may be of assistance in
determining the need for an engine overhaul.

       PROBLEM                                      PROBABLE CAUSE                                              VERIFICATION/REMEDY
 HARD STARTING              LOW CRANKING SPEED
                            1. Engine oil viscosity too high.                                  1. Replace engine oil with less viscous oil.
                            2. Run-down 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.


                                                                                                                                                (continued)


                                                                    Engines & Generators

                                                                              3
                                    ENGINE TROUBLESHOOTING
     PROBLEM                              PROBABLE CAUSE                                     VERIFICATION/REMEDY
LOW OUTPUT (cont.)   OVERHEATING
                     1. Low coolant level.                                     1. Add coolant.
                     2. Loose V-belt.                                          2. Adjust or replace V-belt.
                     3. Incorrect injection timing.                            3. Adjust injection timing.
                     4. Low engine oillevel.                                   6. Add engine oil.

EXCESSIVE OIL        OIL LEAKAGE
CONSUMPTION          1. Defective oil seals.                                   1. Replace oil seals.
                     2. Broken gear case gasket.                               2. Replace gasket.
                     3. Loose gear case attaching bolts.                       3. 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 guide.

EXCESSIVE FUEL       ENGINE BODY TROUBLES
CONSUMPTION          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 obstruction.

                     NOZZLE TROUBLES
                     1. Seized nozzle.                                         1. Replace.
                     2. Worn nozzle.                                           2. Replace.

                     IMPROPER FUEL                                             Replace with proper fuel.

                     FUEL LEAKS                                                Find fuel leaks.

SMOKY EXHAUST        WHITISH OR PURPLISH
                     1. Excessive engine oil.                                  1. Correct oil level.
                     2. Excessive rise of oil into combustion chamber.
                          a. Poor piston contact.                                   a. Check.
                          b. Seized piston ring.                                    b. Replace or clean.
                          c. Excessive piston-to-cylinder clearance.                c. Replace or correct.

                                                                                                                        (continued)




                                                        Engines & Generators

                                                                  4
                                         ENGINE TROUBLESHOOTING
     PROBLEM                                  PROBABLE CAUSE                                       VERIFICATION/REMEDY
SMOKY 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 fuel.

ABNORMAL SOUND          CRANKSHAFT AND MAIN BEARING
OR NOISE                1. Badly worn bearing.                                      1. Replace bearing and grind crankshaft.
                        2. Badly worn crankshaft.                                   2. Grind crankshaft.
                        3. 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. Replace.

ROUGH 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.




                                                                                                                                  (continued)




                                                             Engines & Generators

                                                                     5
                                    ENGINE TROUBLESHOOTING
     PROBLEM                             PROBABLE CAUSE                                          VERIFICATION/REMEDY
KNOCKING           ENGINE KNOCKS WITHOUT MUCH SMOKE
                   1. Main engine troubles.
                   a. Overheated cylinder.                                           a. See OVERHEATING; LOW OUTPUT.
                   b. Carbon deposits in cylinder.                                   b. Clean.
                   2. Too early injection timing.                                 2. Correct.
                   3. Too high injection pressure.                                3. Correct.
                   4. Improper fuel.                                              4. Replace with proper fuel.

                   KNOCKING WITH DARK SMOKE
                   1. Poor compression.                                           1. See LOW COMPRESSION; HARD STARTING.
                   2. Injection pump malfunctioning.
                        a. Check valve worn/sticking.                                  a. Replace check valve.
                        3. Improper nozzle.
                        a. Poor spray.                                                 a. Clean or replace nozzle.
                        b. Poor chattering.                                            b. Repair or replace nozzle.
                        C.   After-injection drip.                                     c. Repair or replace nozzle.
                        d. Nozzle needle valve seized.                                 d. Replace.

INTERMITIENT       1. Fuel filter clogged.                                        1. Clean or replace.
EXHAUST SOUND      2. Air leak in fuel supply side of system.                     2. Retighten pipe joints or replace pipe.
                   3. Water mixed in fuel                                         3. Replace fuel.

OVERHEATING        1. V-belt 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

                                                                  6
                                            TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD                                OVERHAUL CONDITIONS
Cause of Low Compression                                               Compression pressure tends to increase a little in a new
Generally, 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 overhauled.
sometimes 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 kg/cm2, 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                    42.7 psi (3.0 kg/Cm2J.
caused by worn cylinders or piston rings, the following
symptoms 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
                                                                          disassembly.
can 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 dirt.
compression 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 defective.
obtained only under sufficient compression pressure. If an
engine lacks compression pressure, incomplete combustion
of fuel will take place even if other parts of the engine are
operating properly. To determine the period of engine 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 the
crankshaft.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.




                                                          Engines & Generators

                                                                   7
                                  ENGINE/GENERATOR DISASSEMBLY
PROPULSION ENGINE                                                     GENERATOR
Unplug the instrument panel wiring harness. Drain the trans-          Disconnect the AC wiring and unplug the engine's 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 cables.
engine.                                                               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 your
transmission manual. To rebuild a transmission contact your           Drain the engine oil and the coolant from the engine.
WESTERBEKE dealer or an authorized transmission service               Carefully support and then unbolt the generator backend
shop.                                                                 from the engine. See SPECIAL TOOLS - GENERATOR in
                                                                      this manual.
TRANSMISSION                                                          Additional generator information will be found in the
If the transmission is not being rebuilt it should be visually        GENERATOR section of this manual.
inspected. 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 to
TRANSMISSIONS 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

                                                                  8
                                            ENGINE DISASSEMBLY
DISASSEMBLING THE MAIN ENGINE
With the transmission/or generator separated from the
engine, begin the following step by step procedure to
disassemble 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
                      i~O~
                      ~t~0
                      o
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 breaker/preheat 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 6(J' SET UP
     THE MOUNTING BOLTS
     LOCK THE FLYWHEEL
     WITH A RING GEAR
     BREAK TOOL




                                                                                     PLUNGER 3
                                                                                       SPRING _ _
                                                                                       O-RING _ _

                                                                                        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

                                                                9
                                               ENGINE DISASSEMBLY
16. 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-
                                                                        Zexel-Distributer 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
       12:00 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

                                                                   10
                                                                  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
                    ,
                    ®
                         ~j
                                       ~


                                                                                    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 SC~OP J~;~NING
         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 RETAINER/


PUSHRODS~                    ~
                                                                                                                           VALVE SPRING
        OTAPPET                                                                                                            REMOVAL
                                                                        Engines & Generators

                                                                               11
                                              ENGINE DISASSEMBLY




                                 CRANKSHAFT
                                 PULLEY

27. Remove the crankshaft pulley bolt with the aid of a 38
   mm socket and draw the pulley off the front crankshaft.




                                                      --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

                                                                12
                                              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.       @. ~~
CRANKSHAFT
  PULL.EY                 ~~             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 reinstallation.
     crown.


                                                         Engines & Generators

                                                                  13
                                                 ENGINE INSPECTION
INSPECTING .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 renewed.)
Position        Cylinder Head Distortion Limit
1,2                   0.004 in (0.10mm)
ii, 4, 5, 6           0.010 in (0.25mm)                                SUITABLE PUNCH ~
        REMOVE LOCATING DOWELS
        BEFORE USING STRAIGHT-EDGE




              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 1.654 in (42mm)
   4--~~~~~~~~~~~~~H-                                                               Outer2.083 in (52.9mm)




   5   -~+-!,:=~~_~~~o......E~~~~:--                      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 0.049 in (1.25mm)
   insert the welch washer into the insert guide hole. Secure                            Outer 0.054 in (1.37mm)
   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

                                                                14
                                                           ENGINE INSPECTION
    NOTE: Measure the fitting pressure after compressing the
    spring several times.                                                                                                          VALVE GUIDE
Spring Fitting Pressure      Inner               Outer                                                                             INSTALLER
Fitting Length         1.49 in (37.8mm)    1.59 in (40.3mm)
Fitting Pressure Limit 24.92 Ib (11.3kg)   66.36 Ib (30.1 kg)




           VALVE SPRING
              TESTER~



                                                   SPRING FITTING
                                                     PRESSURE                             HEIGHT ABOVE
                                                                                          THE SPRING SEAT
                                       --+\---~                                           0.65 in (16.5mm)


                                                       I
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
    guide.
Clearance Limit 0.005 in (0.127 mm )                                           3. Dimension L. Check the protruding length of the valve
                                                 VALVE GUIDE CLEARANCE             stem, if it exceeds the specification, correct it as follows:
                                                                               Dimension L Standard 1.890 in (48.0 mm)

                                                                                   a. When dimension L becomes larger 0 - 0.0202 in
                                                                                      (0 - 0.5 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 0.20 - 0.059 in
    length of the protruding portion of the valve guide.                              (0.5 - 1 5 mm) from the standard, adjust the
Protrusion Standard   0.650 in (16.5mm)                                               dimension L to the standard by adding some washers
                                                                                      (inner diameter 0.504 in (12.8 mm), outer diameter
                                                                                      1.535 in (39 mm) between the lower spring seat and
                                                                                      the cylinder head.
                                                                                   c. When dimension L becomes too large (more than
                                                                                      0.059 in(1.5mm) from the standards, replace the
                                                                                      valve's seat.




                                                                    Engines & Generators

                                                                          15
                                                                      ENGINE INSPECTION




                                                                      '/:,.,-.. _ SEAT INSERT
                                                                                                                   J:HECKING 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 0.079 in (2.0 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   0.079in (2.0mm) Intake and Exhaust
                            INTAKE




           ~~
CONTACT FACE                      I
                 ...... ··4.5~"'if' ::,.:)""",.\"." .



   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.                                                                                                                                   1.25 in (31.7 mm)
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                0.351 in (8.904 mm)                                 c. Reface the valve and valve seat with a valve tapping
                          Exhaust               0.350 in (8.884 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

                                                                                         16
                                                       ENGINE INSPECTION
ROCKER 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
       1m-JAM NUT                  SPRING WASHER .        _~~ ~                      wire probe.           REMOVING LOCATING DOWELS
      Q;;II                                                   ~>@J ~                                                  BEFORE INSPECTING
       A. _____ ADJ. SCREW                                              \

       ~-~BUSHING'~
       lr
                  . .
                                                                            RETAINING
                                                                            RING
                                                                                                       ~-_B:e.)e_~
                                                                                                       ~C>  ~o _~
       :o~                                                                                             'Q~e~a~&
      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: 1,2     0.004 in (0.10mm)
_~                   ROCKER ARM ASSEMBLY                     SCALLOP                 1             3,4,5,6 0.010 in (0.25mm)
                                                                                                                                                     2
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.                                                           4----J~~~"""
Clearance Standard    0.0006 - 0.0024 in (0.016 - O.061mm)
Limit                 0.0028 in (0.07mm)
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 X-X and Y-Y directions as shown. If
                                                                                     wearing exceeds the limit, replace the liner.
                                                                                 Cylinder Liner Bore       3.7412 - 3.7422 in (95.025 - 95.050mm)
                                                                                 Wear Limit                0.008 in (0.20 mm)
                                                                                                                  y

                          REPLACING
                          THE BUSHING
                                                                                                  X--!+-- --t+--X


                                                                                                                          x -X IS THE THRUST DIRECTION



                                                                                                ~                                   CYLINDER LINER
                                                                                CYLINDER LINER ~~_~
                                                                                WEAR INSPECTION




                                                                    Engines & Generators

                                                                            17
                                                           ENGINE INSPECTION
2. Cylinder Liner Replacement. Hydraulic press or similar                          c. Measure the piston diameter at 90° (perpendicular) to
    device is needed.                                                                 the pin bore axis and 0.866in (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 of2,200-6,600lb.                Standard Piston Diameter    3.7381 - 3.7399 in (94.967 - 94.993mm)

    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 conditions
Protrusion Limits       0.0040 - 0 in (0.101 - 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.
                    LINER




PISTON 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        0.012 in (O.30mm)
       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
                                                           GAUGE




Side Clearance 0.0017 - 0.0028 in (0.032 - 0,083 mm)

                                                                               Piston Ring End Gap Limit   0.591 in (1.5mm)




                                                                    Engines & Generators

                                                                          18
                                                        ENGINE INSPECTION
CONNECTING 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
              ROD
                                                                              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      0.002 in per 3.9 in (0.05 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 0.016 in (0.40 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 bushing.
Clearance Standard:    0.0005 - 0.0015 in (0.012 - 0.039 mm)
Clearance Limit:       0.002 in (0.05 mm)

                                                                                                                            . CONNECTING ROD
                                                                                                                             SIDE PLAY TEST



                                                               Engines & Generators

                                                                     19
                                                        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 V-blocks. 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 2.40601 - 2.4065 in (61.112- 61.125 mm)
                                                                            Wear limit 0.002 in (0.05 mm)
Connecting Rod Cap Torque 56.41- 57.86 ft-Ib (7.8 - 8.0 m-kg)
                                                                            Main journal diameter
Connecting Rod Bearing Clearance
                                                                            Standard 2.9848 - 2.9853 in (75.812 - 75.825 mm)
Standard:       0.0005 - 0.0012 in (0.012 - 0.031 mm)
                                                                            Wear limit 0.002 in (0.05 mm)
Limit:          0.0020 in (0.05mm)
Undersize Bearing:    0.010 in (0.254 mm)
                                                                                a. For the measurement on both the crank pin and the
                      0.020 in (0.508 mm)                                          main journal, measure them at vertical and horizontal
                      0.030 in (0.762 mm)                                          directions on front and rear places.
                                                                                b. When refinishing the crankshaft, it's 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 diameter


INSPECTING            ~                                                         0.01 in (0.254 mm)
                                                                                0.02 in (0.508 mm)
                                                                                                              2.9748 - 2.9753 in (75.558 - 75.571 mm)
                                                                                                              2.9648 - 2.9675 in (75.304- 75.317 mm)
BEARING CLEARANCE

CRANKSHAFT
                      0 '
                           '"             ~~
                                                                                0.D3 in (0.762 mm)
                                                                                Undersize bearing
                                                                                0.D1 in (0.254 mm)
                                                                                                              2.9578 - 2.9554 in (75.050 · 675.063 mm)
                                                                                                                       Crankpin diameter
                                                                                                              2.3964 - 2.3965 in (60.868·60.871 mm)
1. Visual Inspection. Check the crankshaft for cracks or                        0.D2 in (0.508 mm)            2.3874- 2.3865 in (60.604 - 60.617 mm)
   other damage. If cracking is suspected, thoroughly clean                     0.D3 in (0.762 mm)            2.3760·2.3765 in (60.350·60.363 mm)
    the crankshaft and perfonn a magnafiux check of the
    crankshaft. If any cracks are detected, replace the crank-
    shaft.


 MAGNAFLUX TEST


 CRANKSHAFt_
                                                                                                                      R1'o.146/O.157"(3.71/3.99mm)
                                                                                                                      R2'O.126/O.142"(3.20/3.61mm)


  --
   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 crankshaft.
Runout Limit     0.0020 in (0.05 mm)


                                    CRANKSHAFT RUNOUT                                               INSPECTING THE CRANKSHAFT
                                    INSPECTION

                                                        RUNOUT




                                                                 Engines & Generators

                                                                       20
                                                          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 0.007 in (0.178 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                     No.1       2.0437 - 2.0449 in (51.910 - 51.940 mm)       0.008mm
      crankshaft in the axial direction.                                         No.2       2.0339 - 2.0350 in (51.660 - 51.690 mm)       (0.0003 in)
  Crankshaft End Play Standard:    0.0055 - 0.0154 in (0.14 - 0.39 mm)           NO.3       2.0240 - 2.0252 in (51.410 - 51.440 mm)
  Crankshaft End play limit:       0.0157 in (0.40 mm)                           No.4       2.0142 - 2.0154 in (51.160 - 51.190 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    0.0057 in (0.145 mm)

                                                                                 5. Checking camshaft alignment, and, if it exceeds the
                                                                                     limit, replace the camshaft.
                                                                                 Maximum allowable runout 0.0031 in (0.08 mm)

                                                                                 6. Inspecting camshaft end play.
                                                                                    a. Install the thrust plate, camshaft gear,        frictio~ear,
                                                  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 - 691b/ft (6.4 - 9.5 kg/m)

                                                                                      c. Measure the clearance between the thrust plate and
                                                                                         camshaft gear. If it exceeds the limit, replace the thrust
  Oil Clearance Standard:     0.0023 - 0.0035 in (0.059 - 0.090 mm)                      plate.
  Oil Clearance Limit:        0.005 in (0.12 mm)                                 End play limit    0.0118 in (0.3 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:     1.6724 in (42.478 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  r::w-                                                                    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 and
INSPECTING THE                                                                       the spindle and, if it exceeds the limit, replace the idler
CAMSHAFT       _~~~~\1                                                               gear or spindle.
                                                                                 Clearance Standard:    0.0013 - 0.0033 in (0.034 - 0.084 mm)
                                                                                 Clearance Limit:       0.006 in (0.15 mm)




                                                                      Engines & Generators

                                                                            21
                                                                  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 0.0039 in (0.10 mm)
                           BETWEEN TUI: I\\f.oi ~l(\\~'t\
                           BUSHING
                           AND SPINDLE
CHECKING 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: 0.0075 in (0.19 mm)

                                               JIJ')J,LLUr.ttuo                            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 - 231t-lb (2.3 - 3.2 kg/m)
Standard end play                 0.0059 - 0.0118 in (0.15 - 0.30 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.
Backlash Standard     0.0039 - 0.0079 in (0.10·0.20 mm)
Backlash Limit        0.0118 in (0.30 mm)




                                                                        Engines & Generators

                                                                             22
                                                  ENGINE INSPECTION
TIMING 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 O.1I81in (3mm) so that the seal does not
   touch the worn down portion of the crankshaft.




                                                                              OIL SEAL



                                                      INSTALLATION

                REMOVAL




                                                            Engines & Gene;ators

                                                                    23
                                                 ENGINE ASSEMBLY
Reassembly Precautions                                                ENGINE ASSEMBLY
· Be careful not to mix bolts and nuts. Metric and S.A.E.             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, O-rings, 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 sealants.
NOTE: 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.                                                                 ~
                                                                          ~              ()
                                                                                              ®
                                                                                                               '-.... ...... ./SPRING
Insufficient Lubrication. Heavily oil sliding and                   #1 ROCKER                 _-"'II"IIlIJO         ~
                                                                                                                                  TAPER PIN RECESS
reciprocating parts, lightly oil head bolts and other fasteners,


                                                                                                    OC~SHAfT/(@4sf5
except those that penetrate into the water jacket. These
fasteners should be sealed with Permatex No.2 or the             WAVE WASHER
high-tack equivalent.
Reversed orientation. Most gaskets, many bolt washers, and                i\~   SNAP
                                                                           --RING
                                                                                               SUPPORT                      TAPER PIN HOLE
all thermostats are asymmetrical.
                                                                    3. Assemble the connecting rod, piston and piston rings.
Mechanical damage. Run fasteners down in approved                      Arrange the piston and the connecting rod as shown and,
torque sequences and in three steps-II2, 213, and 111 torque.          using the piston pin installer, insert the piston pin through
Exceptions are torque-to-yield bolts and rocker arm shaft              the piston and connecting rod until the piston pin (wrist
fasteners. The former are torqued as indicated. The                    pin) snap rings can be fitted. Fit the piston pin snap rings
latter-rocker shaft fasteners-should 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 ring
especially head gaskets, might be damaged during assembly,             upward using a suitable piston ring expander.
they should be positioned with great care.                                                                            I



               AT 9(J' INTERVALS

                               \
                                           ·
                                            TOP RING
 TOP RING & OIL
 EXPANDER SPRING



  FRONT ...__.......-
                                       ~SECOND
                                       -     ~RING
                                       _ - 5 0.............

  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.




                                                                 24
                                                            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 identification numbers on the cap and connecting



mnN~~
                                                                                 rod are matched.
                                                                         Cap Torque (14 mm socket)          59 - 65 ft-Ib (8.2 - 9.Om-kg)
                                                                         (install new connecting rod bolts)

THRUST 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   11.0 -11.7 m-kg (80 - 85 ft-Ib)



FITTING THE
BEARING CAPS




                                                                             b.Insert 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 (1/2 in socket) 11.6 -17.4 ft-Ib (1.6 - 2.4 m-kg)
     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

                                                                    25
                                                                      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 identification marks.
        Mount the injection pump on the gear case, then tighten
        the pump drive gear attaching nuts.
    Attaching Nut Torque 29 - 51 Mb (4.0 - 7.0 m/kg)

                                            ~'.
                                            ,.,-'         "
                                                          I




                                                                                                                                   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 ft-Ib (6.4 - 9.5 m-kg)
    Attaching Bolt Torque (1/2 in socket)           12 -17 Mb (1.6 - 2.4 m/kg)
                                                                                            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 (1/2 in socket)         16.6 - 23.1 ft-Ib (2.3 - 3.2 m-kg)


                        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          11.6 -17.4 ft-Ib (1.6 - 2.4 m-kg)
                                                     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
                                   CRANKSHAFT
ALIGNING THE TIMING MARKS.         GEAR                                                         oil pump drive gear and the driven gear mesh.




                                                                                 Engines & Generators

                                                                                       26
                                                              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 Torque(ll2 in socket)    12 - 17 ft-Ib (1.6 - 2.3 m-kg)
 20. Install the oil pan gasket and the oil pan (sump).
                                                                                                                             CAM
 Oil Pan Bolts Torque (9116 in socket) 12 -17 ft-Ib (1.6 - 2.3 m-kg)
. 21. Attach the back plate.
 Back Plate Torque (9/16 in socket)        23.9 - 35 ft-lb(3.3 · 4.8 m-kg)          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 ft-Ib (15.5 m-kg)
                                                                                        head b?lts evenly in the sequence shown. After tightening
                                                                                        the cylInder head bolts, make certain the rocker arms
                                                                                        move smoothly.
                                                                                    Cylinder Head Bolts
                                                                                    Torque (3/4 in socket) 85 - 90 ft-Ib (11.8 -12.5 m-kg)
     TABWASHER




 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 ft-Ib (3~ - 40 m-kg)
                                                             --..        Engines & Generators

                                                                               27
                                                            ENGINE ASSEMBLY
31. Adjust the valve clearance. Adjust the No.1, 2,3, 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 No.4, 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 NO.4 CYLINDER IS AT TOP DEAD CENTER                             should open noticeably (with travel on the order of
                     I 41NTAKE     31NTAKE                                                   1/4 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 NO.1 CYLINDER IS ~T TOP DEAD CENTER

                                                                                             WATER TEMP
                                                                                             SENDOR


                                                                                     35. Attach the engine coolant circulating pump.
                                                                                     Coolant Pump Assembly
                                                                                     Bolts Torque (use 1/2" socket)    1.6 - 2.3 m-kg (12 - 17 ft-Ib)
32. Adjust each valve's clearance by inserting a 0.012 in                            A complete breakdown of the COOLANT PUMP ASSEMBLY
    (0.03 mm) feeler gauge between the rocker arm and the                            is covered elsewhere in this manual.
    valve stem.
Valve Clearance      0.30 mm (.12 in) cold                                           36. Adjust the injection timing.

NOTE: 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 assembly.
cool to room temperature and retorque the cylinder head                                  When installing the new filter apply a thin coat of clean
holddown 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     4.6 - 6.8 m-kg (33 - 49 ft-Ib)
Cylinder Head Cover Bolts Torque    0.3 - 0.4 m-kg (2 - 3 ft-Ib)                     39. Install the intake manifold. Replace the four gaskets.
NOTE: After the engine has been reassembled, readjust the                            Intake Manifold Torque      11.6 -17.4 ft-Ib (1.6 - 2.4 m-kg)
valve clearances with a warm engine, see ENGINE
                                                                                     40. Mount the fuel filter assembly.
ADmSTMENTS.
                                                                                     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 ft-Ib (0.3 - 0.4 m-kg)

     b. Install the temperature switch and sender and                                42. Attach the crankcase vent hose.
        reconnect their wires.




                                                                      Engines & Generators

                                                                                28
                                                             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 tension.
Injector To Head BoH (27mm deep socket)        43 - 51 f1-lb (6.0 - 7.0 m-kg)
                                                                                     Refer to RAW WATER PUMP for pump breakdown.
See FUEL INJECTORS for more details.
44. Install the glow plugs and connectors. Use anti-seize
    compound on the threads.
Glow Plug Torque       7.2 -10.8 f1-lb (1.0 -1.5 m-kg)

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 clamp.
Attaching Nuts Torque 18 - 22 f1-lb (2.5 - 3.0 m-kg)

47. Install the bellhousing.
48. Install the air intake silencer.
49. Mount the engine heat exchanger.
The heat exchanger should be serviced when the engine is
overhauled. Refer to HEAT EXCHANGER for service and
inspection.
49. Mount the fuel filter assembly.
Attaching Nuts Torque 33 - 49 f1-lb (4.6 - 6.8 m-kg)                                 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 f1-lb (1.6 -2.4 m-kg)
         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 tension.
Support bolt Torque                27 - 38 f1-lbs (3.8 - 5.3 m-kg)
Adjusting bracket bolt Torque      9 -10 f1-lbs (1.2 -1.8 m-kg)                            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.
See ALTERNATOR for testing.




                                                                        Engines & Generators

                                                                                29
                                                   ENGINE ASSEMBLY
MARINE ENGINEJTRANSMISSION                                             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 reconnect
Damper Plate Torque 14·20 ft·lb (1.7 - 2.7 m-kg)
                                                                           all AC connections.
60. Reinstall the marine transmission and fill with ATF
    DextronIII.
                                                                           A CAUTION: Check all AC and DC wiring
    NOTE: Some transmissions, 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 pre-mixed coolant
    inspected. Refer to the text on Heat Exchangers.                       (50/50 good quality antifreeze and distilled water).
                                                                           Fill the engine oil sump to the mark on the dipstick
61. Fill the engine cooling system with pre-mixed coolant
                                                                           with lube oil (A.P.I. spec. CF or CG 4).
    (50/50 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 (A.P.I. spec. CF or CG-4).
                                                                           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 re-check the valve
    hot engine.
                                                                           clearances.
    Allow the engine to cool to room temperature and
                                                                          See ENGINE ADJUSTMENTS.
    retorque the cylinder head bolts and re-check the valve
    clearances.
    See ENGINE ADJUSTMENTS.




      TYPICAL
    . TRANSMISSION
      OIL COOLERS




                                                          Engines & Generators

                                                                  30
                                 EXHAUST MANIFOLD I HEAT EXCHANGER
EXHAUST 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 O-rings.
                                                                                  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 exchanger/radiator service shop.
                                                                               They will also service transmission and engine oil coolers.
                                                                GASKETS        6. Repaint the assembled heat exchanger with Westerbeke
ASSEMBLY                                                                           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
      steps.
Manifold Mounting Bolts Torque 12 - 17 ft-Ib (1.6 - 2.4 m-kg)
2. Reinstall the exhaust connections. Use new gasket and
   check turbo clamp condition. Replace if suspect..
                                                                                                                                       \CLEAN OUT
                                                                                                                                         DEBRIS




                                                                                                                           HEAT EXCHANGER




                                                                   Engines & Generators

                                                                          31
                                            FUEL INJECTION PUMP
TESTING INJECTION TIMING                                              11. Remove the plug and sealing washer from the aft center
1. Remove the air intake/silencer 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. (No.1 piston is first
                                                                                                            v.mIN. WASHER
   from the front of the engine).
   NOTE: To verify, the rocker arms of No.4 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
   counterclockwise 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 0.039 inches (1 mm)
   gauge should be able to measure up to 0.3 inch of valve                of movement.
   movement).
                                                                      ADJUSTING INJECTION TIMING
                                                                      1. Loosen the nuts holding the injection pump to the engine.
           ~::.-_ _~tf====1~5.21
           r-
                                   mm
                              (0.205 in)BTDC                             (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 0.039 inches (1 mm). These
                                                                         adjustments are to tighten the gear backlash.
                                                                      Injection Pump Gear Lock Nut Torque 29 - 51 ft-Ib (4.0 - 7.4 m-kg)
                                                                          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 0.180 ± .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 0.039
    0.180 inches and then return to that figure to remove gear            inches (1 mm).
    lash. The No.1 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 o'clock position
    on the outboard side of the injection pump is a semi-oval
    cover with two screws. Remove this cover and locate the
    sealing O-ring and timing washer 0.032 inches in thickness.
    Remove this washer and replace the cover. ~         WESTERBEKE
                                                        Engines & Generators

                                                                 32
                                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   0.08 in (2.2 mm)
2. After this check, remove the measuring device and install
   the plug and sealing washer.
3. Reinstall the 0.032 inch thick timing washer in the injec-
   tion pump.

BLEEDING THE INJECTION PUMP                                                                                 {!md.~~VrINICOI\~ING 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 __~~-t--~\\
2. 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              Troubleshooting
   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 0.5 pints (225 cc) or
                                                                            more every fifteen seconds.
                                                                                                             TESTING THE FUEL PUMP
                                                                                FUEL LIFT ~UMP""

                                                                                                                          MEASURING
                                                                                                                          CYLINDER
                                                                                 -t
                                                                    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




                                                                             ~~~~L~~-~~
                                                  ~       WESTERBEICE :.--                         .
                                                          Engines & Generators

                                                                   33
                                                       FUEL INJECTORS
REMOVING THE INJECTORS                                                         c. Mount the nozzle and nozzle holder on the nozzle
                                                                                  tester.
NOTE: Injector must be serviced in a "clean room" environ-
ment.                                                                          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   1,920 Ib/in' (135 kg/em')
   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.                                                                      specification, 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 0.5 mm to 1.54 mm at 0.02 increments. An incre-
     NOTE: Clean the area around the base of the injector
                                                                                  ment of 0.4 mm causes the starting pressure to rise by
     prior to lifting it out of the cylinder head to help prevent
                                                                                  approximately 68 Ib/in2 (4.8 kg/cm2).
     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 reinstalled.

INJECTION TESTING/ADJUSTMENT                                                                                                   ~t          0.1 mm
1. Using the nozzle tester, check the spray pattern and injec-                                                                             0.2mm
     tion starting pressure of nozzle and, if it exceeds the limit,                                                                        0.3mm
     adjust or replace the nozzle. When using nozzle tester,                                                                               0.5mm
     take the following precautions:


      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

                                                                      34
                                                      FUEL INJECTORS
INSPECTING 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-            0.7092in (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)     8.0 -10 IMt (58 -72 kg/m)
                                                \\\\
                        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.




           .                           M
   body should be considered defective and replaced.                   Nozzle Torque (27 mm socket)          43 - 511b/ft (6.0 - 7.0 kg/m)


                                                                                                                  INJECTOR
                                                                                                                  RETURN
                                                                                                      ~:::=._ _ _ lINE




                                                                                                                         WASHER
     CORRECT'MAFTER IlUP TEST                 WRONG



DISASSEMBLY 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
                                                                                                      l-----NUT
   Iron dust on the magnetic filter top must be removed
    completely.
                                                                                               ~~          _ _- - WASHERS




                                                         Engines & Generators

                                                                  35
                                     FUEL SYSTEM TROUBLESHOOTING
       PROBLEM                                    PROBABLE CAUSE                                         VERIFICATION/REMEDY
Engine hard to start or
fails to start               1. No fuel at injectors.                                      1. Check causes a through e.
                                a. No fuel in fuel tank and/or 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 and/or air in fuel filters.                          3. Remove water and/or bleed air from system. Check
                                                                                              system for leaks and fuel tank for water contamination.

                             4. Injection timing incorrect.                                4. Check and adjust the timing.

                             5. Glow plugs not working.                                    5. Check glow plug circuit and repair as needed.

Engine 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 and/or 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
                                                                                              compartment.

Fuel 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 performance



                                                                                                                                          (continued)




                                                                    Engines & Generators

                                                                           36
                                     FUEL SYSTEM TROUBLESHOOTING
       PROBLEM                                      PROBABLE CAUSE                                    VERIFICATION/REMEDY
Engine output and
performance 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 maintain.
Large 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 pressure.setting.
Abnormal noise from engine   1. Poor quality and/or incorrect fuel.                     1. Use No.2 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

                                                                         37
                                                     GLOW PLUGS
DESCRIPTION                                                          Re-install 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 don't heat up quickly, check for a
When PREHEAT is pressed at the control panel this solenoid
                                                                     short circuit. When reinstalling the glow plugs, use anti-seize
should "click" on and the glow plug should begin to get hot.
                                                                     compound on the threads.

INSPECTION
To 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 seconds.
head. Thoroughly clean each plug's tip and threads with a
                                                                     Glow Plug Tightening Torque   7 -11 ft-Ib (1.0 -1.5 m-kg)
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 END


TESTING
An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and the
other to the body of the glow plug, as shown. A good glow
plug will have a 1.0 - 1.5 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

                                                                38
                                                           ENGINE ADJUSTMENTS
 VALVE CLEARANCE ADJUSTMENT                                                     8. Adjust each valve's clearance by inserting a 0.012in
 1. Warm the engine to nonnal operating temperature.                               (O.03mm) 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
 engine's valves.
 4. Loosen the head bolts in the reverse order of tightening.




18


                                                                                9. Install the cylinder head cover.
17
                                                                                Head Cover Bolt Torque    2 - 3 It -Ib (0.3 - 0.45 m-kg)


                                                                                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 (11.8 -12.5 m-kg)                   the fuel shut-off solenoid wire, and install a compression
                                                                                adapter in the injector hole or glow plug hole. Connect a
 6. Set the piston of No.1 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 specifications:                    Repeat this process for each cylinder. Look for cylinders with
    Intake - No.1 and No.2 cylinders; and                                       dramatically (at least 20%) lower compression than the aver-
    Exhaust - No. 1 and No.3 cylinders.                                         age of the others. Compression pressure should not differ by
 7. Turn the crankshaft once, setting the piston of No.4                        more than 42.7 psi (3.0 kglcm2) at 200 rpm.
    cylinder at IDC (compression) and adjust to the follow-
    ing specifications:
    Intake - No.3 and No.4 cylinders; and
    Exhaust - No.2 and No.4 cylinders.

         WHEN NO.4 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 (30.0 kg/em')
                                                                                Compression pressure limit      384 psi at 200 rpm (27.0 kg/em')

                                                                                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.
                                                    I
                     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 NO.1 CYLINDER IS AT TOP DEAD CENTER                   If compression comes up - the rings are faulty.


                                                                     Engines & Generators

                                                                           39
                                              ENGINE ADJUSTMENTS
Abnonnally high readings on all cylinders indicates heavy                When servicing the injection pump, the service shop must be
carbon accumulations, a condition that might be                          advised if the pump is to be used in a generator application.
accompanied 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 specifications, the generator spring is reinstalled
the injectors checked and overhauled by an authorized fuel               in the-injection 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 no-load
loss of positive fuel pressure to the injection pump will result         speed (hertz).
in injector faults.
                                                                         For disassembly, inspection, reassembly and internal
When re-installing the glow plugs use anti-seize 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 temperature.
2. 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 tachometer.
Nonnal 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· PROPULSION/GENERATOR
   idle adjustment bolt and turn the bolt clockwise to                   This solenoid is installed on the top rear of the injection
   increase idle speed and counterclockwise 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.
                                                                         Troubleshooting
                                                  IDLE ADJUSTMENT        1. The solenoid does not operate when the keys witch is
                                     -r-Y/_____     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    -   '-"'SOLENOID

NOTE: 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 sticking.
Early Models Without Electronic Governing
Engine speed is maintained by the governor mechanism
inside the fuel injection pump (61.5 - 62.0 hertz at no-load
and 58.5 - 59.0 hertz at full rated generator output). Engine
no-load 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

                                                                    40
                                     COOLANT CIRCULATING PUMP
REMOVING THE PUMP                                                    ASSEMBLY
Remove in the following order: coolant (drain as needed);            Assemble the water pump in the reverse order of
V-belt; water hoses; water pump attaching nuts; and water            disassembly, using the following procedure:
pump.                                                                1. Fill lithium grease (lithium base NLGI No.2) into the
                                                                         following positions.
DISASSEMBLY                                                             · 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 .




TUBULAR
SUPPORT




INSPECTION                                                                                                                 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
                                                                            (490636145)




                                                                                                IMPELLER
                                                                         NOTE: Do not allow oil- or grease to contaminate the
                                                                         surfaces of the ceramic ring or the graphite (small end)
                                                                         of the spring-loaded 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

                                                                41
                                                    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 ROTOR


DISASSEMBLY
Disassemble in the following order: Oil Pipe and Gasket;                                                     ~~~~'17~TALLY MARKS
Oil Strainer and Gasket; Oil Pump Cover; Drive Gear (use a
press and suitable mandrel); Inner Rotor and Shaft Assembly;
Outer Rotor; Relief Valve Assembly; and Oil Pump Body.
                                                                                  Clearance Limit 0.055 - 0.0100 in (0.14 - 0.25 mm)
INSPECTION
1. 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
   plate.)



LUBE OIL                                         PUMP SHAFT &
PUMP                                        ____ ROTORS                                     OUTER



                                                          TORQUEAT
                                                          6 - 9 ft /bs
                                                          (0.8 - 1.2 m-Kg)




                                                                                  Clearance Limit 0.055 - 0.0100 in (0.14 - 0.25 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
   gear.
Clearance Limit 0.0024 in - 0.0079 in (0.06 - 0.15 mm)

                                                  GAUGE


                                                                                  Clearance Limit


                                                                                                                                       PUMP BODY




                                                                   Engines & Generators

                                                                             42
                                                   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 disassembly.

                                                 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.

               J)~
                U
   MEASURING FREE                                      RELIEF VALVE PLUG
                                                                                Cover TIghtening Torque (7/16" socket) 5.8 - 8.7 n-Ib (0.8 - 1.2 m-kg)


                                                                                INSTALLING THE OIL PUMP
   LENGTH    . Spring free Limit     1.61 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 PRESSURE
TESTING OIL PRESSURE                                                            LOW OIL PRESSURE
The lubricating system is a pressure feeding system using an                    The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
oil pump. The engine oil is drawn from the oil sump by the                      + 0.1 kg/cm2). 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 TROUBLESHOOTING chart.
engine. The oil then returns to the oil sump to repeat the con-
tinuous cycle. When the oil pressure exceeds the specified                      OIL PRESSURE SWITCH/SENDER
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 it's place. After                    threaded ends being careful not to close off the oil hole in the
                                                                                sender.
warming up the engine, set the engine speed at 3600 rpm and
read the oil pressure gauge.                                                    Oil Pressure Sender and SWitch Torque 9 - 13 H-Ib (1.2 -1.8 m-kg)

               35.0 IbJin2 (3.8 kg/cm2) or more at 1800 rpm
Oil Pressure
               54.04 IbJin2 (3.8 kg/cm') 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
                                                                                 Snap-On, Proto, flew Britain and others. Damage to the
                                                                                 switch will cause oil leaks and/or switch failure.



                                                                                  PROPULSION
                                                                                                     +                                  4              'YO,..


                                                                                                                                                  J
                           OIL
                           PRESSURE
                           SENDER
                            HOLE
                                                                                                                r--_ _~)}---
                                                                                                                                                    GREEN
                                                                                                          RED            NOTE: This fuse
                                                                                                                         may be located
                                                                         BLUE
                                                                                                                         on the regulator.




                                                                                   YELLOW


          r------------,                                             THREE PHASE
                                                             6 WIRE RECONNECTABLE
                    EXCITER STATOR                                                                        1------,
                                                                                                          I        STATOR
          1.                                                                                                                                 BLACK
                                    r-----~----------, V2 ·                                       BLACK
          1                         1         1 ROTOR FIELD                                               I                                                      'VI
          1                         1         1                                                           I                                                            AC
                                                                                                                                             GREEN
                                    1 EXCITER 1             POZI V2 '                                     I                                                      VI TERMINAL
                                                                                                  GREEN
                                    1     ROTOR       1                 RESISTER                          I                                                            BLOCK

                              +:                  a
                                    I f-II_ _ _=-'~
                                                      l                                 W2
                                                                                                  RED
                                                                                                          I
                                                                                                          I
                                                                                                          I
                                                                                                                                 I
                                                                                                                                              RED
                                                                                                                                                                 WI


                                    1                                                                     I                      I
                                    1   '-1_ _=-+----1                                                    1 _____ JI
                                                                                                          I
                                    I
                                    I                       DIODES                                            AUX
                                    L _ _ _ _ _ ~----------                                                   WINDINGS
         L_          _        _ _ _ _ _ _ _ _ .1                                                                                                            :z
                                                                                             '"
                                                                                             u                fa                fa                          ~
                                                          REGULATOR                          :5
                                                                                             CD
                                                                                                              a:                a:                          '"
                                                                                                                                     FUSE
                                                                                                                                     6.3 AMP
              :<:
              o
              ..J
              ..J
              W
              >-

                         ~      Hertz
                                 Amp
                         __
                         Ec
                         o       Stab
                                                                                                                         NOTE: This fuse
                                 Volt                                                                                    may be located
                         *
                         ....                                                                                            on the regulator. .

                                                                                      BLUE

                                                                                      YELLOW




                                                                      Engines & Generators

                                                                           66
                          INTERNAL WIRING SCHEMATICS
                          3 PHASE TWELVE WIRE RECONNECTABLE

                                                                           1---- 1
                                                                           I     STATOR    I
r-------.,
I                                I
  EXCITER STATOR r - - - + - - - - - - - ,
                                                                           !               I
                                                                         ~.--~2~-+!-------4:11
                                                                                                                     12


I
I                II   EXCITER    II         ROTOR FIELD          I
                                                                         L-j:r-1IiI
                                                                                 3      -...:1---_____
                                                                                                     : 1~
                      ROTOR                                      I       r-+r---'::4~~:--------:'
                                                                         4 ____+----4 8           7 TERMINAL
                                                                                                    AC
I       +        I                                               I
I                                                                        I:!i:~5~;::::::==:::                         ~   BLOCK
I
I
                                                                           :        6:
                                                                         ~~~~~~~!!::::::::
                                                                                                                 :    ~
                                                                                                                      2
                                                                              7                                       1
I                                                                                   8     ,I
I
L      _ _ _ _ _ ....
                                                                     AUX    ~              ,
                                                                                           I

                                                                     WINDINGS
                                                                                               FUSE
                                                                                               6.3 AMP      NOTE: This fuse
                                                                                                            may be located
                                                                                                            on the regulator.
          red
        green
        )Q11ow




                                REGULATOR
                                                          BLUE
                                                          YELLOW




       BE GENERATOR WINDING RESISTANCE VALUES (IN OHMS)
                           SINGLE PHASE                                  20 & 25 BE                      32 BE
    EXCITER STATOR                                                              18.06                    18.20
    EXCITER ROTOR _ a - b                                                        0.68                     0.72
                     b-c                                                         0.68                     0.72
    ROTATING FIELD                                                               1.75                    2.01
    MAIN STATOR                       1-2                                        0.05                    0.05
                                      3-4                                        0.05                    0.05
    AUXILLARY WINDING                                                            1.19                    0.98
                           THREE PHASE                                 20, 25, &32 BE

    EXCITER STATOR.                                                             18.20
    EXCITER ROTOR _                   a- b                                       0.7
                                      b-c                                        0.7
    ROTATING FIELD                                                               2.01
    MAIN STATOR                                                                  0.06 (each winding)
    AUXILLARY WINDING                                                            0.98


                                                   Engines & Generators

                                                          67
                                                    BE TROUBLESHOOTING
                                                   NOTE: AC GENERATOR TROUBLESHOOTING 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 pozi-resistor                            5. Short or open in rotating
                                                                      on exciter rotor.                                   field winding.

                                                                   3. Four or more shorted or
                                                                      open diodes on exciter rotor.

Residual 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 regulator

Low AC vO.llage 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 regulator.
150 VAC or higher.

Unstable voltage output.                                           1. STB pod on regulator                             2. Faulty voltage regulator.
                                                                      needs adjustment.

AC voltage drop under load                                         1. Diode(s) on exciter rotor
60 ·100 volts AC.                                                     breaking down when load is
                                                                      applied (inductive) 1-3 diodes.

      r--·----------,
                        EXCITER
                        STATOR
                                                                                                       RED




                                     rIDJ
                                  r-----~----------,
                                  I     I                                                                                      RED
                                  I     I
                                  I   EXCITER   I    ROTOR FIELD                                  1--- -     -   --1
                                                                                                  1
                                  :   ROTOR     :                                                 I    STATOR      :


                                  ili~
                                                                                                                               RED

                                                                                                                         REO

               _ _..J
                                  I
                                  I
                                                I
                                                I
                                                                                                                   I
                                                                                         AUX          ______ 1
                                                                                                             I
                      L_
                       _ _ _ _ _.J
                                                                                                                                     ®
                                 ~-~--------
                  ____   _ _ _ _
      L_
                                                                                                                                     W2
                             REGULATOR
               w
               =
               ....
               CD
                                                                                                                       FUSE
                                                                                  RED                                                 U1          V1

        §
        ....               ret!                                                                                                                        BLACK
        >-       CI areen
                 ~      "now . . .                                                                                                    GREEN
                ~eIIz                                                                                  RED
                  ...    lIIIIp                                                                                        NOTE: This fuse
                  I
                  ~
                          ~                                                BLUE                                        may be located .
                                                                                                                       on the regulator.



                                                                                    YELLOW



                                                                    Engines & Generators

                                                                           68
                                            ELECTRONIC GOVERNOR
Electronic Governor System
The system is composed of three basic components:                                          ·
                                                                                                  I

                                                                                                  I   1,--.-..,.-----,
                                                                                                                                 ·
                                                                                           ~
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
   pump.

Controller Adjustment
1. Speed. This adjustment is used to raise or lower the
   engine's speed to the desired hertz.
2. Gain. This adjustment affects the reaction time of the
   actuator to the generator/engine 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 GOVERNOR
Calibration
                                                                                                                     LINEAR ACTUATOR
1. With no power to the governor, adjust the GAIN to 9:00
   o'clock.
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 no-load, 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 counterclockwise
   until stable.                                                              TO ELECTRONIC
                                                                              CONTROLLER




                                                                         TO TERMINAL
                                                                         BOARO 11




                                                                         Til SENSOR
                                                                                               (DC +)114 RED

                                                                                               '14 BLACK




                                                                                                SHIELDED
                                                                                                CABLE
                                                                                                                                ~.
                                                                                                                                RED




                                                                                                                                BLACKIWHITE


                                                                                                                                 WHITE
                                                                                                                                              l
                                                                                                                                              TO GOVERNOR
                                                                                                                                              CONTROL

        FLYWHEEL HOUSING                                                                                                        PURPLE
                                                                                               114 PURPLE

                                       ELECTRONIC GOVERNOR
                                       MAGNETIC SENSOR
                                                                     (TO LINEAR ACTUATOR
                                                                                               114 PURPLE
                                                                                                                         6
                                                                                                                                PURPLE
                                                                                                                                              J
                                                                                                            TERMINAL BOARD #3
                 SENSOR

            LOCKNUT-===..b~ ~F-- O.030in

                                              !

                       ----
        FLYWHEEL _____ ~ r\"7=\
        TEETH        7  v   v  \




                                                         Engines & Generators

                                                                69
                         TROUBLESHOOTING THE ELECTRONIC GOVERNOR
              Problem                          Probable Cause                                          VerificationJRemedy
System appears dead                   1. Low battery voltage at controller.           1. Check wiring for cause. Check battery state of charge.
(Engine 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 2.5 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 (1.20-2.0 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 other.
Actuator 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 lead.
Actuator hunts (oscillates) and       1. Linkage between actuator and throttle        1. LubricateJfree-up.
engine 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 - 9.6 VDC or higher
                                                                                         24 VDC System -19.2 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 controller.




                                                               Engines & Generators

                                                                      70
                                                    SHORE POWER TRANSFER SWITCH

    SHORE POWER CONNECTIONS (60 HERTZ)                                                                     120 VOLT/60 HZ THREE WIRE CONFIGURATION
    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
         I
         I                                                                                                    Generator                 NOTE: Diagram shoWI connections for a two-

                                                                                                            ~
         I          /~-- ...                                                                                                            wire, 120-Yolt system trom the generator.
         L ____ ~       $\                                                                                                              with thre.-wlr ·· 120-Volt boat system.

         r   -----t.<3>
                     \
                        <1)i-
         I           ' __ '" /
j
Z
         I
         I
         I
         I
                                                                  Ship .. to- Shore Switch (3 Pole)
                                                                        PH 32008
                                                                        (40Amps/Pol.)
                                                                        PH 32009
                                                                        (80 Amps' Pol.)
                                                                        PH 320'0                                                                                                                Ship-to .. Shor. Switch (3 Pole)
                                                                        ('25 Am",,' Pole)                                                                                                          PN 32008
                                                                        PH 32133                                                                                                                   (40Amp8,pol.)
                                                                        (200Ampe/PoJ.)

                                                                                                                                       .... - - .....,
                                                                                                                                                                             <21
                                                                                                                                                                             l1
                                                                                                                                                                                                   r8~~~~~~
                                                                                                                                                                                                   PH 32010
                                                                                                                                                                                                            POle)
                                                                                                             '---+-+--+0:..;;::t-...,       JUMPER WHEN   ,     (6l
                                       '---1:020         I.      CONNECTING A    I~~~-!=-----.
                                    ~               REMO~P~L t~~0~~~~t=f=t----------~
                              L~~wi=~~                       'M""
                                         .-~         LL~~ ·'·"'"..,fOil-.=="--+1-+-++__________
                                                                rur
                                                                     0<

                                             ',.IIn> K IllIti               "I




NOTE 2: An on-off switch
should be installed in this                                                                    ... ...,
circuit to disconnect the                                                                      · ···nlt


starter from the battery in                                         .~          ~
an emergency and when              r- -----------                                        1-----                   ---,
leaving the boat. Twelve
volt diesel engine starters
                                  ! ~..1~!                                                      ~~ ~T i
                                           ~~
                                            .· !~; jlh~
typically draw 200 to 300                                                                                                        STANDARD
amps when cranking. A
                                                                                                                        i
                                                                                                                                 INSTRUMENT



                                           @  . ~~ E.J                                                       =.                  PANEL
switClz with a continuous
rating'o!17S'amps at 12
                                  :
VDC will normally serve           (!
                                  I
                                               .~~
                                                                             "'-I>+--+...J                   STOP
                                                                                                                        I
                                                                                                                        (
this function, but a switch        I                                                                         SWITCH     I
must never be used to              I
                                   L   ______________________                                                          .JI
"make" Ihe starter circuit.



                                                                                  73
                                       BED GENERATOR
               WIRING SCHEMATIC #039422 (WITH DUAL RELAYS)




    : BATTERY
    ! SWITCH                                                       STARTER                 STARTER
                                                                  SOLENOID
                                                                 r---I
                                                                 I         I                  M
                                                                 I         I
                                                                 I         I
                                      PREHEAT                    L- _      __ I
                                     SOLENOID                                                        GLOWPLUGS
                                     r---
                                     I        I
                                     I
                                     I
                                     I
                                     L... _ _ _ I
                                                                                                     ALTERNATOR


                                                                                          110 AMP                      T82-3
                                                       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

                                                                                                 o
                                                                                                                  86




         HOURMETER




                                                    Engines & Generators

                                                             74
                                                                                                    BED GENERATOR
                                                               WIRING DIAGRAM #039422 (WITH DUAL RELAYS)                                                                                                                   -             ...   --    --
,~

                                                                                                                                                                                                                               ~
                                                                              'ltlf) OR.N




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                                114 PUR                                                 "4 PUR                                                              .14 PUR
        r>
                                                                                                                                                                                                                               ((=f)


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                                                                                                                                                                                                                               \:'
                               114 PUR
                                                                                                                                                         II .. RED/PUR

    L--jl"                                                               WATER      NrrNATUR~®
L~MP                   -
                                                                                                                                                 WAlEB TEM~EBAIUBE
                                                                                                                                                            ill..I1.E.B.
                                                                                                                                                            -----"'l
                                                                                                                        =

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                                                                                                                                                                                                 19
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                                                                                                                                                                                                                                     ~
                                                        110 Oftlrl                            110 REI)

                                                                                                                              :rT                                                                                                    ;
                      BATTERY SWITCH                                     /

                       r
                             V-I                                                                                                                                                                                                ®
                                   ~----------~
                             1.: _ _ I                                                                     .14 PUR/WNT




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                                          -:'0"'. TO BlOCK :
                                                                                    114 TAN
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                                                                     i                                                          ~
                                                        RED                                                                                                                                                          I liQIE.: REMOVE TH I S JU~PER WHEN
                                 ;      '-~I
                                                                                                                                                                                                                     II NSTALLI NG ONE RE~OTE ST ART'STOP
                                     '---~
    ~
~
                                                        BLK                                                                                       :
--                                    .r-- ~
                                         )~~
                                                     BLK/WHT
                                                                     I
                                                                     I
                                                                                                              14011"
                                                                                                                                                            lOllED
                                                                                                                                                                                       '41111                           PANEL. IF INSTALLING TWO PANELS
                                                                                                                                                                                                                     : RE~OVE BOTH JU~PERS .
                                                                     I
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                                                                                                                                                                                         ~ ~ i
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                  I                                                                  HOUR
                                                                                                      ..,..,.. I VOLT
                                                                                                                                                                                                             STOP'

                                                                     ;                                                                                                                                               I
                                                                                    METER                       METER
                                                                     L__________________________________ ..--J                                                                                                       I




                                                                                                                Engines & Generators

                                                                                                                                    75
                                            SPECIFICATIONS
                                    WESTERBEKE 25 KW BED GENERATOR
                    ENGINE SPECIFICATIONS                                                                   FUEL SYSTEM
Engine Type                 Diesel, four-cylinder, four-cycle, fresh              General                    Open flow, self priming - 1 bleed point.
                            water-cooled, vertical in-line overhead valve         Fuel                       No.2 diesel oil (cetane rating of 45 or higher)
                            mechanism.
                                                                                  Fuel Injection Pump        ZEXEL Model VE Distributor.
Aspiration                  Naturally aspirated
                                                                                  Fuel Injection Timing      0° TDC (Top Dead Center)
Govemor                     Electronic Goveming.
                                                                                  Nozzle                     Th rottle type
Combustion Chamber          Swirl type
                                                                                  Fuel Filter                Spin-on type, full flow
Bore & Stroke               3.74 x4.13 inches (95 x 105 mm)                       (on engine)
Piston Displacement         182 cubic inches (2.98 liters)                        Air cleaner                Metal screen type - cleanable
Firing Order                1-3-4-2                                               Air Row                    94.6 cfm (2.7 cmm)
Direction of Rotation       Clockwise, when viewed from the front                 (engine combustion)
Compression Ratio           21 : 1
Dimensions                  Height 28.6 inches (726.5 mm)
                                                                                                           COOLING SYSTEM
                            Width: 23.3 inches (591.8 mm)                         General                    Fresh water-cooled block, thermostatically-
                            Length: 44.9 inches (1149.4 mm)                                                  controlled with heat exchanger.
Weight                      678 Ibs (307 kgs)                                     Operating Temperature      170 - 190° F (77 - 88° C)
Inclination                 Continuous 15°                                        Fresh Water Pump           Centrifugal type, metal impeller, belt-driven
                            Temporary. 25° (not to exceed 20 min.)                Raw Water Pump             Positive displacement, rubber impeller,
Generator Power Take Off    40 Horsepower ( Maximum)                                                         belt-driven.
                                                                                  Raw Water Flow,            15.0 gpm (56.7lpm) (measured
                   TUNE-UP SPECIFICATIONS                                         at 3600 rpm                before discharging into exhaust elbow).
Compression Pressure         427 psi (30 kg/cm') at 200 rpm                       System Capacity            13.0 qts (12.3 liters)
(Limit of difference between                                                      (coolant)
cylinders)                   (47.2 psi {3.0 kg/cm'})
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, spin-on type
                            Exhaust Closes 13° ATDC                               Sump Capacity              6.5 U.S. qts (6.15Iiters)
Valve Seat Angle            Intake 45°                                            (not including filter)     plus filter/cooler assembly
                            Exhaust 30°                                           Operating Oil Pressure     50 - 60 psi (3.5 - 4.2 kg/cm')
Valve Clearance             Intake 0.012 inches (0.3 mm)                          (engine hot)
(engine warm)               Exhaust 0.012 inches (0.3 mm)                         Oil Grade                  API Specification CF or CG-4,
Injector Pressure           1920 + 71 - 0 psi (135 + 5 - 0 kg/cm')                                           SAE 30, 10W-30, 15W-40
Engine Timing               Static timed - drop valve method
                            0.205 ± .005 inches BTDC                                                      ELECTRICAL SYSTEM
                                                                                  Starting Battery           12-Volt, (-) negative ground
              EXHAUST EMISSIONS SYSTEMS                                           Battery Capacity           300 - 600 Cold Cranking Amps (CCA)
Emission Control            Indirect Fuel Injection                               Starter                    12-Volt, reduction
Systems                                                                           Starting Aid               Glow plugs, sheathed type




                                                                       Engines & Generators

                                                                            76
                                          SPECIFICATIONS
                                  WESTERBEKE 25 KW BED GENERATOR
                      ELECTRICAL SYSTEM                                                  AC GENERATOR (THREE PHASE)
Starting Battery          12-Volt, (-) negative ground                        General - 3 Phase           Brushless six pole, revolving field.
                                                                                                          Sealed lubricated single bearing
Battery Capacity          400 - 600 Cold Cranking Amps (CCA)                                              design. 12 Lead reconnectable for low voltage
DC Charging A1temator     51 Amp rated, belt-driven                                                       WYE and for Delta. Solid State voltage regula-
                                                                                                          tor with protection circuitry.
Starter                   12-Volt, Reduction Gear
                                                                              Voltage - 3 Phase           Low voltage WYE              208 volts
Starting Aid              Glow plugs, sheathed type                           (60 Hertz)                  High voltage WYE             480 volts
                                                                                                          DELTA                        240 volts
DC No-Load 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              86.7 Amps
               AC GENERATOR (SINGLE PHASE)                                    (60 Hertz)                  High voltage WYE             37.6 Amps
General - Single Phase    Brushless, four-pole, revolving field Sealed                                    DELTA                        75.2 Amps
                          lubricated single bearing design.                   Amperage - 3 Phase          High voltage WYE             38.0 Amps
                          Reconnectable single phase for 120/240 volts        (50 Hertz)                  DELTA                        65.6 Amps
                          with solid state voltage regulator.
Voltage - Single Phase    120 or 120/240 Volts - 60 Hertz
                          230 VoUs - 50 Hertz
                                                                                                   GENERATOR COOLING
Voltage regulation:       ± 2% no load to full load.
                                                                              Air Requirements            1.0 Power Factor 425 cfm (12.74 cmm)
Frequency 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
                          120/240 Volts 208.109 Amps                          Engine Combustion Air       94.6 cfm (2.7 cmm)
                                                                              Requirements
                          20 KW - 50 Hertz (1500 rpm)                         (60 Hertz at 1800 RPM)
                          230 Volts 87 Amps




                                                                   Engines & Generators

                                                                         77
                                                     SPECIAL TOOLS · GENERATOR
FIELD 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 panel.
engine. A local machine shop should be able to fabricate these                          To use this Lifting Eye, remove the generator's 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 loan.

Housing 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 specifications 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   2-1/2"
                                                                                                                                (63.5 mm)
the generator end is removed.                                                                                                                    4 HOLES
                                                                                                                                                   1/4"
                                      1/2-13 UNC Store-bought                                                                                    (6 mm)
                                      eye bog with tapered tip.
  HOUSING PULLER TOOL
   (FIELD FABRICATED)



                              I
                              4"

                                      2"...J
                                             45"
                                                ,
                          (101.~ mm)---"'"I Taper

                 .....---/---<17-!-.-,\-.----I
                                                 \
                                                     \




                                                     '®
                                                       J ;'
                                                              I'
                                                                   /
                                                                       1




                                                                                        Disk Alignment Tool
                                                                                                                     Center lining eye on
                                                                                                                     baseplate and weld securely.



                                                                                        This tool allows a mechanic to safely remove and install the
            r-1--+----\:0              ) ,                                              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 plate's weight while removing or replacing these
          a
    Weld 1/2-13 UNC Hex Nut
    one silfe of this center hole.
                                     to.....t::::===;;;Z===:I                           parts.

                                                                                                     OiWmWHHJm                               t
                   1/2" (12.7 mm) Gia.
                     Drill Typ. 4 holes          Material: Cold-rolled 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"
                                                                                                                 (203.2 mm)                        ROUND TIP



                                                                               (.li':   =f~F#1
                                                                                15.5 mm Drill
                                                                                                                            1201
                                                                                                       ~<-----(304.8 mm)---------.....po!.
                                                                                                                                                                 ~I
                                                                                1-1/4" (31.75 mm) Deep
                                                                                M18 x 1.5 Pilch
                                                                                Tap 1" (25.4 mm) Deep

                                   PROPER USE OF HOUSING PUllER

                                                                                                                                            Material: Aluminum


                                                                           Engines & Generators

                                                                                  78
                            METRIC CONVERSIONS
            INCHES TO MILLIMETERS                              MILLIMETERS TO INCHES
Inches          mm         Inches          mm            mm           Inches       mm         Inches
  1          25.40            15       381.00              1          0.0394       15        0.5906
  2          50.80            20       508.00              2          0.0787       20        0.7874
  3          76.20            25       635.00              3          0.1181       25        0.9843
  4         101.60            30       762.00              4          0.1575       30        1.1811
  5         127.00            35       889.00              5          0.1969       35        1.3780
 10         254.00            40      1016.00             10          0.3937       40        1.5748
                       =
      10 MILLIMETERS 1 CENTIMETER, 100 CENTIMmRS 1 METER      =         =39.37 INCHES (3.3 FEET)
                INCHES TO METERS                                    METERS TO INCHES
Inches       Meters        Inches         Meters        Meters        Inches     Meters       Inches
  1          0.0254            7          0.1778         0.1           3.937       0.7       27.559
  2          0.0508            8          0.2032         0.2           7.874       0.8       31.496
  3          0.0762            9          0.2286         0.3          11.811       0.9       35.433
  4          0.1016           10          0.2540         0.4          15.748       1.0       39.370
  5          0.1270           11          0.2794         0.5          19.685       1.1       43.307
  6          0.1524           12          0.3048         0.6          23.622       1.2       47.244
      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          0.91440         6            5.48640          1          1.09361       6        6.56168
  2          1.82880         7            6.40080          2          2.18723       7        7.65529
  3          2.74320         8            7.31520          3          3.28084       8        8.74891
  4          3.65760         9            8.22960          4          4.37445       9        9.84252
  5          4.57200        10            9.14400          5          5.46807      10       10.93614
         MOVE DECIMAL POINT FOR HIGHER VAlUES -          e.g. 6,000 MmRS = 6,561.68 YARDS
            POUNDS TO KILOGRAMS                                KILOGRAMS TO POUNDS
  Ib            kg           Ib             kg            kg            Ib          kg             Ib
  1           0.454            6           2.722           1            2.205        6        13.228
  2           0.907            7           3.175           2            4.409        7        15.432
  3           1.361            8           3.629           3            6.614        8        17.637
  4           1.814            9           4.082           4            8.818        9        19.842
  5           2.268           10           4.536           5           11.023       10        22.046

                GALLONS TO LITERS                                   LITERS TO GALLONS
Gallons      Liters        Gallons        Liters         Liters       Gallons     Liters     Gallons
   1          3.79          10             37.86           1           0.26        60         15.66
   2          7.57          20             75.71           2           0.53        90         23.77
   3         11.36          30            113.57           5           1.32       120         31.32
   4         15.14          40            151.42          10           2.64       150         39.62
   5         18.93          50            189.28          20           5.28       180         47.54

                 PINTS TO LITERS                                     LITERS TO PINTS
 Pints        Liters        Pints         Liters         Liters        Pints      Liters       Pints
   1          0.47            6            2.84           1            2.11          6        12.68
   2          0.95            7            3.31           2            4.23          7        14.79
   3          1.42            8            3.79           3            6.34          8        16.91
   4          1.89            9            4.26           4            8.45          9        19.02
   5          2.37           10            4.73           5           10.57        '10        21.13

                                          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

                                                   79
                                                                     INDEX
AC Voltage Connections .................53, 63                                     Raw Water Pump .......................44
Alternator Testing .........................50                                     Rear Oil Seal .......................... 23
Camshaft ................................21                                        Reassembly ............................ 23
Compression-Engine .......................39                                       Rocker Arm .......................... .17
Connecting Rod .......................... 19                                       Specifications ......................... .54
Control Panel Troubleshooting ...............61                                    Standards and Limits ..................... 55
Coolant Circulating pump .................. .41                                    Starter Motor ..........................45
Crankshaft ...............................20                                       Stop Solenoid ......................... .40
Cylinder Block ........................... 17                                      Tappets ............................... 22
Cylinder Head Bolt Pattern .............. .27,35                                   Thermostat ............................28
Cylinder Liner ........................... .17                                     Timing Gears Cover ..................... 23
Electronic Governor .......................69                                      Timing Gears ....................... 12, 22
Electronic Governor Troubleshooting ..........70                                   Testing for Overhaul ......................7
Engine                                                                             Torque Specifications .................... 57
  Adjustments ....................... .39,40                                       Troubleshooting ........................ .3
  Assembly ............................. 24                                        Valve Clearance ..................... 28, 39
  Camshaft ..............................21                                        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 ............................20                                       Wiring Schematic .......................53
  Cylinder Block ......................... 17                                   Exhaust Manifold ........................ .31
  Cylinder Head Bolt Pattern ................27                                 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 Troubleshooting ............... .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 ....................9, 10, 32                                    Control Panel Switches ................... 60
  Injection Timing ....................... .32                                    Control Panel Troubleshooting ............. 61
  Injectors ............................. .34                                     Disassembly ............................ 8
  Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14          Electronic Governor .....................69
  Low Oil Pressure ...................... .43                                     Electronic Governor Troubleshooting ........ 70
  Lubricating Oil Pump ................... .42                                    Frequency - Adjustment .................. 59
  Main Bearing ..........................21                                       Information ............................ 59
  Oil Jet (Upper Block) ................... .23                                   Maintenance ...........................59
  Oil Pan ...............................23                                       Overload Protection Setting ................ 65
  Oil Pressure .......................... .43                                     Remote Start/Stop Panel (diagram) .......60, 72
  Oil Pressure Switch/Sender ............... .43                                  Shore Power Transfer Switch ..............71
  Overhaul ........................... '" .7                                      Special Tools ...........................78
  Piston and Piston Ring ................... 18                                   Specifications ..........................76
  Push Rod ............................. 22                                       Troubleshooting ........................68



                                                                Engines & Generators

                                                                           80
                                                INDEX
   Wiring Diagram ........................73              Tappets .................................22
   Wiring Schematic .......................72             Testing for Overhaul ........................7
Glow Plugs - Testing ...................... .38           Timing Gear Cover ........................ 23
Heat Exchanger .......................... .31             Timing Gear ............................ .12
Injection Pump .........................9, 10             Torques
Injection Timing ......................... .32              Standard Hardware ...................... 58
Injectors ............................... .32               Specifications .......................... 57
L Dimension ............................. 15                Westerbeke Components ..................68
Lubricating Oil Pump ..................... .42            Transmission - Oil Coolers .................. 30
Metric Conversion Chart ....................79            Transmission-Service ....................... 8
Oil Pressure ............................. .43            Troubleshooting
Oil 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 .............................23             Valve Seat .............................. .16
Remote Start/Stop Panel (diagram) ............72          Valve Spring ............................ .14
Sealants and Lubricants ..................... 58          Voltage Regulator ......................... 65
Shore Power Transfer Switch ................71            Wiring Diagrams/ Schematics
Special Tools - Generator ...................76             Generator #039422 (diagram) ...........73, 74
Specifications - Engines .................... 54            82B Four Engine #039144 (diagram) ........52
Specifications - Generators ..................74            82b Four Engine #039144 (schematic) ....... 53
Standard Hardware ........................ 58               BE Single Phase (schematic) ...............66
Standards and Limits ....................... 55             BE Three Phase 12 wire (schematic) ......... 67
Starter Motor ............................ .45              BE Three Phase 6 wire(schematic) ....... 63,66
Starter Motor - Adjustment and Repair ........ .45          Remote Stop/Start Panel(diagram) ...........72
Tachometer ............................. .49                Generator #038422 (schematic) .............72




                                             Engines & Generators

                                                     81
             ~r"9Y" rWESTERBEKE
                      WESTERBEKECORPORATION
                  ~   MYLES STANDISH INDUSTRIAL PARK
                      150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319




1008 WMDW 12/98


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