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Westerbeke Diesel 90a Four Parts Manual




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SERVICE MANUAL
gOA FOUR
MARINE DIESEL ENGINE
320 KW60 Hz BEDA
250 KW50 Hz BEDA
MARINE DIESEL GENERATORS
SINGLE AND THREE PHASE
PUBLICATION NO 43750
15t 2000
r WESTERBEKE I
WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
WEBSITE
NMMA Member National Marine Manufacturen CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in quarters of your vessel
They are inexpensive and easily
mmtJ obtainable at your local marine store
SAFETY PREVENT BURNS FIRE
Read these safety instructions carefuUy Most accidents are
caused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or death
tions Know when dangerous conditions exist and take the
necessary precautions to protect yourself your personnel Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with the pump or other potential sources of spilled fuel or fuel
American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard
Approved flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do not touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will bum
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions from fuel vapors can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
with an insulated tool tilated area away from equipment and
out of the reach of BURNS HOT ENGINE Do not fill the fuel tanks while the engine is running
Shut off the fuel service valve at the engine when servicing
A WARNING Do not touch hot engine parts or the fuel system Take care in catching any fuel that might
spill DO NOT allow any smoking open flames or other
exhaust system components A running engine gets sources of fire near the fuel system or engine when servic
very hot ing Ensure proper ventilation exists when servicing the
fuel system
Always check the engine coolant level at the coolant
Do not alter or modify the fuel system
recovery tank
Be sure all fuel supplies have a positive shutoff valve
Be certain fuel line fittings are adequately tightened and
A WARNING Steam can cause injury or death free ofleaks
Make sure a fire extinguisher is installed nearby and is
In case of an engine overheat allow the engine to cool properly maintained Be familiar with its proper use
before touching the engine or checking the coolant Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas
or death
Ensure that the exhaust system is adequte 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 infonnation refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional infonnation 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 nulike 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 terminal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the terminals 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 loxic as
Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
bums 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 Dizziness Throbbing in Temples
the battery connections Remove the negative lead first Nausea Muscular Twitching
and reconnect it last when servicing the battery Weakness and Sleepiness ACID
Headache Inability to Think Coherently
A WARNING Sulfuric acid in batteries can cause AVOID MOVING PARTS
severe injury or death
A WARNING Rotating parts can cause injury
When servicing the battery or checking the electrolyte or death
level wear rubber gloves a rubber apron and eye protec
tion Batteries contain sulfuric acid which is destructive Do not service the engine while it is running If a situa
If it comes in contact with your skin wash it off at once tion arises in which it is absolutely necessary to make
with water Acid may splash on the skin or into the eyes operating adjustments use extreme care to avoid touching
inadvertently when removing electrolyte caps moving parts and hot exhaust system
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that
INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their recommenda
Make sure all attaching hardware is properly tightened
Keep protective shields and guards in their respective tions when installing your engine
places at all times ABYC American Boat and Yacht Council
Do not check fluid levels or the drive belts tension while Safety Standards for Small Craft
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 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD NOISE
NFPA National Fire Protection Association
Fire Protection Standard for Motor Craft
A WARNING High noise levels can cause hearing Order from
NFPA
loss
11 Tracy Drive
Never operate an engine without its muffler installed Avon Industrial Park
Avon MA 02322
Do not run an engine with the air intake silencer
removed USCG United States Coast Guard
USCG 33CFR183
Do not run engines for long periods with their enclosures
open Order from
US Government Printing Office
A WARNING 00 not work on machinery when you are Washington DC 20404
mentally or physically incapaCitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that strict attention be
paid to the following AND regulations ABYC guidelines and safety codes must be complied with when and generators in a marine installations where
the exhaust exhaust elbow is close to or will be
below the vessels waterline provisions must be made to install a siphonbreak in the raW water
supply hose to the exhaust elbow This hose must be looped a minimum of20 in 51 em above
the vessels waterline Failure to use a siphonbreak when the exhaust manifold is at or below the load waterline will result in raw water damage to the
engine and
possible flooding ofthe boat
If you have any doubt about the position of the exhaust elbow relative to the
vessels waterline under any of the vessels various operating conditions or when the vessel is not
underway install a siphonbreak This precaution is necessary to protect your engine
NOTE A Siphonbreak requires periodic inspection and cleaning to ensure proper to properly maintain a siphonbreak can result in catastrophic engine
damage Consult
the siphonbreak manufacturer for a proper maintenance SYSTEM
The exhaust hose must be certified for marine use The system must be designed to prevent
water from entering the exhaust under any sea conditions and at any angle of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF 2 32 KW BEDA Generator Parts 102
90A Four Propulsion Engine 4 Generator Information 103
90A Four Propulsion Engine Parts 5 Generator Control Panel Switches 104
Testing for Overhaul 6 Control Panel 105
Engine 7 The BE Generator Single and Three 106
Engine 14 Generator AC Voltage Connections l07
Engine Inspection and 20 Voltage Regulator Adjustments 109
Engine 31 Internal Wiring Schematics 110
Exhaust 47 BE 112
Engine Adjustments 48 Electronic 51 the Electronic 114
Cooling 54 Shore Power Transfer Switch 115
Fuel System 59 32 KW BEDA Generator Wiring Diagram 64 Single Relay 116
Admiral Control Panel 32 KW BEDA Generator Wiring Schematic 040425
Single Relay 117
Captain Control Panel 32 KW BEDA Generator Wiring
Diagram Panel 80 Two Relays 118
DC Electrical 81 32 KW BEDA Generator Wiring Schematic 82 Two Relays 119
Dual Output Alternators 84 32 KW BEDA Generator Wiring Diagram 44737
Two Relays plugin Remote StartStop Panel 120
90A Four Propulsion Engine
Wiring Diagram 41343 86 32 KW BEDA Generator Wiring Schematic 44737
Two Remote StartStop Panel 121
90A Four Propulsion Engine
Wiring Schematic 41343 87 32 KW BEDA Generator Wiring Diagram 041128
Single Relay 24 VDC Special Spec 122
Hurth HSW Transmissions 88
32 KW BEDA Generator Wiring Schematic 041128
Hurth HBW 250 Transmission 91 Single Relay 24 VDC Special Spec 123
Borg Warner Velvet Drive Transmission 93 32 KW BEDA Generator Wiring Diagram 96 Two Relays
Plugin Remote StartStop Panel 124
Standard Hardware Sealants Lubricants 98 32 KW BEDA Generator Wiring Schematic 44806
90A Four Torque 99 Two Relays Plugin Remote StartStop Panel 125
32 KW BEDA Generator lOO Special Tools 126
Index 128
Metric Conversions 130
Standard and Metric Conversion 131
Engines Generators
OVERHAUL CUSTOMER CARD
This service manual contains detailed information relating to
the overhaul of the 90A Four Diesel Engine and the 320
KW2S0 KW BEDA Diesel Generators For the major overhaul procedure refer to the ENGINE ENGINE INSPECTION AND REPAIR and
ENGINE I
REASSEMBLY sections Additional service information for Customer generators and other specific components and systems MR
ENGINE OWNER
may be found by referring to the TABLE OF CONTENTS and
the INDEX Refer also to your WESTERBEKE Parts MAIN HOMETOWN USA
These service procedures are intended for the guidance of Model 90A FOUR equipped and staffed marine engine
service and Expires facilities and should only be undertaken by and their personnel
The WESTERBEKE engine serial number is an SOFTWARE meric number that can assist in determining
the date of man
Product software tech data parts lists manuals brochures ufacture of your WESTERBEKE engine The catalogs provided from sources other than
WESTER date code is placed at the end of the engine serial number and
BEKE are not within WESTERBEKES control consists of a character followed by three numbers The char
acter indicates the decade A1960s B1970s CANNOT BE RESPONSIBLE FOR THE D1990s 2000s the first number represents the
year in
CONTENT OF SUCH SOFTWARE MAKES NO WAR the decade and the second and third numbers represent the
RANTIES OR WITH RESPECT month of INCLUDING ACCURACY TIMEliNESS THEREOF AND WILL IN NO EVENT
ORDERING PARTSSERIAL NUMBER LOCATION
BE LMBLE FOR ANY TYPE OF DAMAGE OR INJURY Whenever replacement parts are needed always provide the
INCURRED IN CONNECTION WITH OR ARISING OUT engine model number and engine serial number as they
OF THE FURNISHING OR USE OF SUCH SOFTWARE appear on the silver and black nameplate customers should also keep in mind
the ed on the side of the engines exhaust manifold The engine
time span between printings of WESTERBEKE product soft serial number can also be found stamped into the engine
ware and the unavoidable existence of earlier WESTER block just above the injection pump and on generators on
BEKE manuals Product software provided with the decal located on the side of the generator You must products whether from
WESTERBEKE or vide us with this information so we may properly suppliers must not and cannot be relied upon exclu
your engine In addition include a complete part as the definitive authority on the respective product It and part number for each part needed
see the separately fur
not only makes good sense but is imperative that appropriate nished Parts List Also insist upon WESTERBEKE of WESTERBEKE or the supplier in
question aged parts because will fit or generic parts are frequently not
be consulted to determine the accuracy and currentness of the made to the same as original software being consulted by the customer
NOTE Component locations in this manual are CAUTION AND WARNINGS from the front of the engine
which is the pulleydrive belt end
Left and right sides are determined as follows imagine
As this manual takes you through the service procedures and straddling the engine facing in the same direction as of your marine engine
critical information front of the engine the left side is at your left the right side
will be highlighted by NOTES CAUTIONS and WARNINGS is at your right An operating procedure essential to note
A CAUTION Procedures which if not strictly
observed can result in the damage or destruction of
your engine
AWARNING Procedures which if not properly fol
lowed can result in personal injury or loss of life
Engines Generators
INTRODUCTION
Owners may find it convenient to fill in the data on the decal or shown below to provide a quick reference when using this service manual
SPECIFICATION 50 HZ 60 HZ
MODEL
RPM
KW
KVA
VOLTS
AMPS
ENG HP
ENG SER NO
GEN SER NO
PFPHASE I
WIRES
RATING
INSUL CLASS
TEMP RISE
BAITERY
CID
GENERATOR DECAL
ENGINE Engines Generators
gOA FOUR PROPULSION ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh water General Closed system with bleed points
cooled vertical inline overhead valve
mechanism 90 hp at 3600 rpm maximum Fuel No2 diesel oil cetane rating of 45 or Naturally
aspirated Fuel Injection Pump ZEXEL Model PE Integral with the injection pump mechanical
Fuel Injection Timing 12 BTDC
flyweight type Nozzle Orifice type
Bore Stroke 394 x 433 inches 1000 x 1100 mm Fuel filter on engine Full flow replaceable spinon Displacement
2108 cubic inches 35 liters Air Intake Silencer Metal screen type cleanable Tuned intake
1342 no of Rotation Clockwise when viewed from the front
AirFlow 220 cfm 62 cmm
engine Torque 168 Ibft 23 kgm
at 3600 rpm Fuel consumption 20 US gph 75 Iph at 2500 Ratio
LUBRICATION Height 360 inches 914 em General Pressure fed system
Width 230 inches 584 cm
Length 393 inches 998 cm Oil pump Trochoid type
Oil filter Full flow paper element spinon type
Weight 790 Ibs 3583 kgs Water cooled
Oil cooler
Sump Capacity 63 US qts 60 liters
TUNEUP not including filter plus filtercooler Pressure 427 psi 30 kgcm at 200 rpm
Operating Oil Pressure 50 55 psi 35 39 of difference engine hot
between cylinders 476 psi 30 kgcm Oil Grade API Specification CF or CG4
SAE 30 10W30 15W40
Valve Timing Intake Opens 19 BTDC
Intake Closes 47 ABDC ELECTRICAL SYSTEM
Exhaust Opens 52 BBDC Starting Battery 12 Volt negative ground
Exhaust Closes 14 ATDC
Battery Capacity 800 900 Cold Cranking Amps CCA
Engine Timing Static timed drop valve method
0180 t 0005 inches BTDC DC Charging Alternator 51 amp rated Pressure 2450t 35 psi 1722t 25 kgcm
Starting Aid Air intake heater
Valve Seat Angle Intake 45 Starter 12 Volt 3 KW
Exhaust 30 DC NoLoad Current t 2 of rated amps
Valve Clearance Intake 0012 inches 03 mm DC Cranking Current 250 300 amps engine cold
engine cold Exhaust 0014 inches 035 mm
Engine Speed Idle 700 900 rpm ENGINE AIR REQUIREMENTS
Cruise 2500 3000 rpm
Max 3500 3600 rpm Combustion Air 220 cfm 62 cmm
Engine Cooling 100 cfm 28 cmm
COOLING SYSTEM Note The pressure differential between the outside of the engine Fresh
watercooled block ment versus the inside ofthe engine compartment should not exceed 2inches
controlled with heat exchanger of water 51 mm at full open throttle measured with a Temperature 170 190 F77 88 C
Pump Centrifugal type metal impeller Water Pump Positive displacement rubber impeller General
Hurth Standard Transmission Case
hardened helical gears with a beltdriven multiple
disc clutch
Raw Water Flow 200 US gpm 755 Ipm measured Gear ratio standard 274 1 HBW250 3R
at 3600 rpm before discharging into exhaust elbow
Propeller Shaft Right handed standard fresh water 85 US qts 804 liters
Propeller 24 D x 12 P2 blade or 22 D x 14 P3
System Capacity blade propeller should allow the engine
using standard to reach its full rated rpm 3600 000
EXHAUST SYSTEM transmission 100 atflill open throttle while under
274 1 reduction way
in forward gear
Exhaust Elbow 70 elbow
Lubricating Fluid ATF type A or Dextran I or 11
Exhaust Hose Size 3ID hose Transmission Sump
Capacity 079 US qts 075 liters Engines Generators
gOA FOUR PROPULSION ENGINE PARTS TOP ENGINE
OIL FLANGE
STARTER
WITH SOLENOID
REAR RIGHT SIDE FRONT
COOLANT
TEMPERATURE
SWITCH
OIL OIL PRElSUFlIEI ENGINE OIL
SENDER SWITCH FILTER
FRONT LEFT SIDE REAR
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE WHEN Measuring Compression Pressure
TO OVERHAUL THE ENGINE To check the compression pressure see ENGINE of Low Compression
SION TEST under ENGINE the time at which an engine should be overhauled NOTE Do not guess the conditions
of other cylinders from a
is determined by various conditions such as lowered engine result of testing one cylinder Be sure to measure the com
power output decreased compression pressure and increased pression pressure for each cylinder Lookfor cylinders with
fuel and oil consumption The lowered engine power output dramatically at least 20 lower compression than the aver
in the case of diesel engines is not necessarily due to trouble age of the other cylinders If the weak cylinder is flanked by
with the engine itself but is sometimes caused by injector healthy cylinders the problem is either valve or wear or injection pump wear
It is most reasonable to related Very low compression in an adjacent cylinder indi
judge by a decrease in compression pressure The decrease in cates gasket failure Abnormally high readings on all pressure is caused by
many factors It is there ders indicate heavy carbon a condition that
fore necessary to determine a cause or causes on the basis of might be accompanied by high pressures and noise
data produced by periodic inspection and maintenance Oil NOTE In case of severe vibrations and detonation on a seasonal basis is a good
means of monitoring have the injectors overhauled by an authorized fuel internal wear When caused by worn cylinders or pis
service center Poor fuel quality contaminants and loss of
ton rings the following symptoms will occur positive fuel pressure to the injection pump will result in
Low engine power output injector faults
Increased fuel consumption OVERHAUL CONDITIONS
Increased oil consumption Compression pressure tends to increase a little in a new
Hard engine starting engine until the piston rings and valve seats have been bro
ken in Thereafter it decreases gradually with the progressive
Noisy engine operation
wear of these parts
These symptoms often appear together Increased fuel con
When the decrease of compression pressure reaches its and hard engine starting can also result from exces
see SERVICE STANDARDS the engine must be over
sive fuel injection improper injection timing and wear of the
hauled The engine also requires an overhaul when oil pump and nozzles They are also caused by defec
sumption is high when blowby is evident and when
tive electrical components such as the battery alternator
compression values are at a minimum or and air intake heater Therefore it is desirable to judge
the optimum engine overhaul time by the lowered compres NOTE Refer to the SERVICE STANDARDS chart during an
sion pressure caused by worn cylinders and pistons plus engine overhaul It gives the measurements and values for
increased oil consumption In diesel engines satisfactory the repair or replacement of the engine is obtained only under sufficient
compression NOTE The ENGINE section may be
pressure If an engine lacks compression pressure incomplete helpful in determining the need for an engine of fuel will take place even if
other parts of the
engine are operating properly To determine the period of
engine overhaul it is important to measure the engine com
pression pressure regularly At the same time the engine
speed at which the measurement of compression pressure is
made should be checked because the compression with engine rpm The engine rpm can be measured at
the front end of the Engines Generators
ENGINE following table describes certain problems NOTE The engineS electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a and the to overcome these
problems The preheat solenoid is mounted on the same bracket
PROBLEM PROBABLE CAUSE HARD STARTING LOW CRANKING SPEED
1 Engine oil viscosity too high 1 Replace engine oil wfth less viscous oil
2 Rundown battery 2 Recharge battery
3 Worn battery 3 Replace battery
4 Battery terminals loosely connected 4 Clean terminals and tighten cables
5 Defective starter 5 Repair or replace starter
DEFECTIVE FUEL INJECTION SYSTEM
1 No fuel at injectors 1 Check a through e
a No fuel in fuel tank andor fuel shutoff a Fill fuel tank Open shutoff and bleed system
b Fuel filterWater separator clogged b Replace filter and bleed
c Injection pump fuel filter clogged c Bleed injection pump Check fittings for
suction leak on fuel supply
d Fuel shutoff solenoid not working d Check solenoid
e Injection pump faulty e Inspect pump Repair or replace pump as
needed
2 Fuel injectors faulty inadequate spray 2 Remove and test nozzles Repair nozzles as
needed
3 Low injection pressure 3 Adjust injection pressure
4 Injection timing incorrect 4 Check and adjust timing
5 Poor quality fuel 5 Drain and replace with proper fuel
6 Water andor air in fuel system 6 Remove water andor bleed air from fuel system
Check fuel system for leaks and fuel tank for
water MAIN ENGINE TROUBLES
1 Low compression 1 Check a through k
a Leaking compression from fuel injector gasket a Tighten fuel injector or replace gasket
b Incorrect valve clearance b Adjust valve clearance
c Inadequate contact of valve seat c Lap valve
d Valve stem seized d Replace valve and valve guide
e Weak or broken valve spring e Replace valve spring
I Bent push rod I Replace push rod
g Compression leaks through cylinder head gasket g Replace gasket
h Cracked or worn piston h Replace piston
i Piston ring seized i Replace piston and piston ring
j Worn piston ring or cylinder liner j Replace piston ring or cylinder liner
Ie Cracked or distorted cylinder head Ie Replace cylinder head
2 Carbon accumulation in combustion chamber 2 Clean
3 Faulty air intake heater 3 Check terminal connections replace heater
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE IDLING 1 Idle speed too low
1 Adjust idle stop as needed
TOO LOW
2 Fuel filter clogged 2 Replace filter and bleed fuel system
3 Incorrect injection pump timing 3 Check timing and adjust as needed
4 High pressure injection line leaking 4 Slacken attaching nut and retighten
5 Fuel injector leaking at sealing gasket in head 5 Retighten injector andor replace sealing washer
6 Injection nozzle not operating properly 6 Check nozzle and adjust as needed
7 Engine air intake obstructed 7 Check air intake silencer and air flow into
engine IDLING MALFUNCTION OF COMPONENTS
1 Improper valve clearance 1 Adjust clearance
2 Poor valve to valve seat contact 2 Repair or replace valve
3 Failure of cylinder head gasket 3 Replace gasket
FUEL INJECTION SYSTEM PROBLEM
1 Faulty idling speed 1 Adjust idling speed
2 Faulty injection timing 2 Adjust injection timing
3 Clogged fuel line or fuel filter 3 Clean fuel line or replace fuel filter
4 Leak in fuel line or fuel filter 4 Repair fuel line or replace fuel filter
5 Air in injector fuel line injection pump fuel filter 5 Bleed air
or fuel filterwater separator
6 Seized or leaky delivery valve 6 Clean or replace delivery valve
7 Faulty injection starting pressure 7 Adjust starting pressure
8 Injection nozzle malfunction 8 Clean or replace injection nozzle
9 Feed pump malfunction 9 Clean or replace feed pump
10 Injection pump timer malfunction 10 Replace timer
11 Injection pump malfunction 11 Take to a fuel injection pump service facility
or replace the SLOWS 1 Fuel lift pump failure 1 Check fuel pump STOPS
2 Switches andor wiring loose or disconnected 2 Inspect wiring for short circuits and loose
connections Inspect switches for proper
operation
3 Fuel starvation 3 Check fuel supply fuel valves fuel lift pump
4 20 amp circuit breaker tripping 4 Check for high DC amperage draw during
operation Ensure breaker is not overly sensi
tive to heat which would cause tripping
5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon
buildup at exhaust elbow
6 Water in fuel 6 Pump water from fuel tanks change filters
and bleed fuel system
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT LOW COMPRESSION
See Low Compression under 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 Bleed and check for source
2 Clogged filter 2 Clean or replace filter element
3 Contaminated or inferior fuel 3 Purge fuel system and replace with quality
fuel
4 Contaminated fuel tank 4 Clean fuel tank
OVERHEATING
1 Low coolant level 1 Add coolant
2 Loose Vbelt 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low engine oil level 4 Add engine oil
OTHER
1 Insufficient intake air 1 Increase engine compartment air ENGINE KNOCKS WITHOUT MUCH SMOKE
1 Main engine troubles 1 Check a and b
a Overheated cylinder a See ENGINE DOWN
LOW OUTPUT
b Carbon depOSits in cylinder b Clean
2 Injection timing too early 2 Correct the timing
3 Injection pressure too high 3 Correct the pressure
4 Improper fuel 4 Replace with proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See Low Compression under HARD
STARTING
2 Injection pump 2 3 Nozzle 3 Check a through d
a Poor spray a Clean or replace nozzle
b Chattering b Repair or replace nozzle
c drip c Repair or replace nozzle
d Nozzle needle valve seized d Replace needle SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE
1 Badly worn main bearing 1 Replace bearing and grind crankshaft
2 Badly worn crankshaft 2 Grind crankshaft
3 Melted bearing 3 Replace bearing and check lubrication system
4 Excessive crankshaft end play 4 Repair or replace crankshaft
continued
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE SOUND CONNECTING ROD AND CONNECTING ROD BEARING
OR NOISE Contd 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
4 Excessive connecting rod bearing oil clearance 4 Repair or replace bearing
5 Connecting rod bearing seized or heatdamaged 5 Replace bearing
PISTON PISTON PIN PISTON RING CYLINDER LINER
1 Worn cylinder liner 1 Repair or replace liner
2 Worn piston or 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
VALVES OR PARTS
1 Worn camshaft 1 Replace camshaft
2 Excessive valve clearance 2 Adjust valve clearance
3 Worn timing gear 3 Replace timing gear
4 Broken valve spring 4 Replace valve spring
5 Excessive clearance between rocker arm and 5 Replace bushing
bushing
6 Excessive clearance between idler gear bushing and 6 Replace bushing
spindle
FUEL SYSTEM
1 Poor quality andor incorrect fuel 1 Use No2 diesel fuel
2 Incorrect injection timing Timing too advanced 2 Check and correct injection timing
3 Fuel injector stuck open 3 Locate and remove faulty injector Rebuild or
replace
OTHER
1 Coolant pump bearing worn or seized 1 See Coolant Pump under COOLING SYSTEM
2 Improper drivebelt tension 2 Adjust
3 Malfunction of alternator bearing 3 See Alternator under
DC ELECTRICAL SYSTEM
4 Exhaust gas leakage 4 OPERATION INJECTION 1 Uneven injection 1
Adjust injection or replace parts
2 Inadequate injection nozzle spray 2 Replace injection nozzle
GOVERNING SYSTEM
1 Governor lever 1 Check governor shaft and adjust
2 Fatigued governor spring 2 Replace spring
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST WHITISH OR PURPLISH
1 Engine is running cold 1 Warmup engine
2 Excessive engine oil 2 Correct oil level
3 Excessive rise of oil into combustion chamber 3 Check a through f
a Poor piston contact a Check
b Seized piston ring b Clean or replace
c Excessive clearance c Correct or replace
d Worn valve stem and valve guide d Replace valve stem and guide
e Low engine oil viscosity e Replace engine oil
f Excessive oil pressure f Inspect the lubrication system See
LUBRICATION SYSTEM
4 Injection timing is too late 4 Adjust timing
5 Insufficient compression 5 See Low Compression under HARD STARTING
BLUE
1 Incorrect grade of engine oil 1 Use the correct grade of oil see LUBRICATION
SYSTEM under 90A FOUR ENGINE
2 Crankcase is overfilled with engine oil oil is blow 2 Decrease oil level
ing out through the exhaust
BLACKISH OR DARK GRAYISH
1 Poor compression 1 See Low Compression under HARD STARTING
2 Improper valve clearance 2 Adjust valve clearance
3 Improper injection timing 3 Adjust injection timing
4 Improper fuel 4 Replace with proper fuel
5 High backpressure in exhaust 5 Check for restrictions in exhaust system
6 Insufficient intake air 6 Increae engine compartment air supply
7 Overload 7 Reduce load
BLACK LARGE AMOUNT
1 Clogged fuel filter 1 Replace fuel filter and bleed system
2 Restricted air intake 2 Remove air obstruction
3 Engine overloaded 3 Check engine propeller size and engine
performance noload 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 SMOKE
1 Faulty injection timing 1 Adjust timing
2 Water in injection pump fuel filter or fuel filterwater 2 Drain fuel system
separator
3 Faulty injection starting pressure 3 Adjust starting pressure
4 Injection pump 4 Replace injection pump
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE SOUND
1 Fuel filter clogged 1 Clean or replace filter
2 Fuel line sucks air 2 Retighten fuel line joints or replace fuel line
3 Water mixed in fuel 3 Replace FUEL ENGINE 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 under HARD STARTING
5 Improper valve timing 5 Adjust timing
6 Improper valve clearance 6 Adjust clearance
INSUFFICIENT INTAKE AIR
1 Air intake obstructed 1 Remove FUEL INJECTION PROBLEMS
1 Injection timing incorrect 1 Adjust timing
2 Faulty injection starting pressure 2 Adjust starting pressure
3 Seized nozzle 3 Replace nozzle
4 Worn nozzle 4 Replace nozzle
5 Nozzle leaking 5 Tighten nozzle or replace sealing gasket
6 Injector not operating properly 6 Adjust nozzle spray pressure
7 Clogged fuel filter 7 Replace filter
8 High idling speed 8 Adjust idling speed
FUEL PROBLEMS
1 Improper fuel 1 Replace with proper fuel
2 Fuel leaks 2 Find fuel leaks
ENGINE OVERLOADED
1 Propeller size 1 Check propeller size and engine performance
at rated OIL OIL 1 Defective oil seals 1 Replace oil seals
2 Broken gear case gasket 2 Replace gasket
3 Loose gear case attaching bolts 3 Retighten bolts
4 Loose drain plug 4 Retighten plug
5 Loose oil line connector 5 Retighten oil line connections
6 Broken rocker cover gasket 6 Replace gasket
7 Loose rocker cover attaching bolts 7 Retighten attaching bolts
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OIL OIL LEVEL 1 Incorrectly
positioned piston ring gaps 1 Correct ring gap positions
2 Displaced or twisted connecting rod 2 Replace connecting rod
3 Worn piston ring or piston ring groove 3 Replace ring or piston
4 Worn piston or cylinder liner 4 Repair or replace
OIL LEVEL FALLING
1 Defective stem seal 1 Replace stem seal
2 Worn valve and valve guide 2 Replace valve and valve guide
LOW OIL PRESSURE 1 Worn main or connecting rod bearings 1 Replace bearings
2 Relief valve malfunction 2 Overhaul oil pump
3 Clogged oil cooler 3 Clean
4 Diesel fuel is diluting the oil 4 Injection pump OVERHEATS 1 Vbelt slackening or slippery with oil 1 Adjust
replace or clean belt
SHUTS DOWN 2 Add or change oil
2 Low oil level or poor oil quality
3 Knocking 3 See KNOCKING
4 Moving parts seized or damaged 4 Replace
5 Lack of coolant 5 Add coolant
6 Raw water not circulating 6 Check a and b
a Raw water pump failure Check impeller
replace if necessary
b Obstruction at raw water intake or raw water
filter
7 Coolant not circulating 7 Check a through d
a Thermostat remove and test in hot water
Replace thermostat
b Loss of coolant check hoses hose clamps
drain plug etc for leaks
c Broken or loose belts d Air leak in system run engine and open the
pressure cap to bleed air Add coolant as
needed
Engines Generators
ENGINE DISASSEMBLY PROCEDURE 5 Drain the engine oil and the coolant from the engine
NOTE Before disassembly and cleaning carefully check 6 Carefully support and then unbolt the generator back
for defects which cannot be found after disassembly and end from the engine See SPECIAL
GENERATOR in this manual
All disassembled parts should be carefully arranged in For generator maintenance and service refer to the
the order of reassembly Mark or label the parts as GENERATOR section of this manual
needed to insure proper mating and reassembly in the
proper directions and positions
If the disassembly procedure is complex requiring many
parts to be disassembled the parts should be disassem STARTER MOTOR
bled in a way that will allow them to be efficiently SOLENOID
reassembled without any change in the engines external
appearance or its Do not remove or disassemble parts that require no
Carefully inspect each part after removal for damage
deformation and other problems
Carefully check gaskets packings and oil seals even if
checking is not specified Replace with new ones if
defective
Be careful not to damage the disassembled parts Keep
the parts clean
Use the proper tools Apply oil when necessary Take
special care to keep the fuel system parts free from the
intrusion of dust and REMOVAL
1 Unplug the instrument panel wiring harness
2 Drain the transmission fluid and the transmission oil
cooler hoses
3 Detach the oil cooler hoses
4 Unbolt the transmission from the engine
NOTE For transmission service and maintenance refer to
your transmission owners manual To rebuild a contact your WESTERBEKE dealer or a transmission service facility
If the transmission is not being rebuilt it should be Flush out and pressuretest the oil cooler and
replace the coolant hoses Inspect and lubricate the gear shift GENERATOR and the propeller shaft coupling Clean and
repaint
the transmission and change the transmission fluid Refer to
the TRANSMISSIONS section in this manual ENGINE REMOVAL With the
transmission or generator separated from the
engine begin the following stepbystep procedure of the
1 Disconnect the AC wiring and unplug the engines DC
engine disassembly
wiring harness at the generator control panel
1 Clean the exterior of the engine of any deposits of dirt
2 Disconnect the battery cable connections and the
and oil
engine ground cables
2 Mount the engine on a suitable engine stand for
3 Separate the exhaust hose at the water injected elbow
Disconnect the fuel supply and return lines
NOTE Label any lines hoses or cables as you separ
ate them
Engines Generators
ENGINE DISASSEMBLY
8 Remove the transmission damper plate propulsion
engines only
DAMPER PLATE
BOLTS
TRANSMISSION
DAMPER PLATE
PROPULSION
NGINES ONLY
9 Remove the flywheel and flywheel washer
3 Drain the coolant from the engine and engine hoses and
from the heat exchanger Drain the fuel and drain or
pump out the engine oil ONE BOLT DEVIATES 5
FROM THE 60 SET UP
4 Remove the engine wiring hamess in its entirety Label
the terminal connections to insure proper
FLYWHEEL
WASHER
LABEL THE TERMINAL
Remove the engine heat exchanger and the engine oil
cooleroil fllter assembly If possible leave one end of WHEN REMOVING
each hose connection attached to the part being removed THE MOUNTING BOLTS
LOCK THE FLYWHEEL
WITH A RING GEAR
6 Remove the starter motor BREAK TOOL
7 Remove the engine bellhousing propulsion engines only REMOVING THE FLYWHEEL
10 Remove the engine back plate
11 Remove the exhaust manifold
12 Remove the alternator and alternator adjusting strap
13 Remove the raw water pump
14 Remove all the high pressure injector lines from the
injection pump to the injectors Leave the upper line
clamps in place
NOTE Cap the ends of the lines and the connections at
the injection pump and at the injectors to prevent entry
offoreign material
15 Remove the oil level dipstick
16 Remove the injection pump oil line
17 Remove the fuel line to the injection pump Note the
arrangement of the sealing washers on the banjo bolts
TRANSMISSION
DAMPER PLATE at the fuel fllter and the injection pump
PROPULSION
NGINES ONLY 18 Remove the fuel return lines from the top of the injectors
and from the fuel injection pump Note the washer ar
rangement on the fuel return line banjo bolts Cap all
openings on the fuel return line injectors and injection
pump
19 Remove the fuel fllter and fuel fllter
ENGINE DISASSEMBLY bracket
Engines Generators
ENGINE Remove the thermostat housing gasket and the thermo 28 Loosen the cylinder head bolts gradually in the numbered
stat Leave the temperature sending unit in place sequence shown in the
3 7 11 15 18 14 10 6
4 8 12 16 17 13 9 5 1
LOOSENING THE CYLINDER HEAD BOLTS
THERMOSTAT
ASSEMBLY 29 Remove the rocker arm and shaft assembly
21 Remove the air intake silencer 30 Remove the push rods Label each rod as to which valve
it belongs
22 Remove the two front lifting eyes and the rear lifting eye
23 Remove the intake manifold
24 Remove the alternator bracket
25 Remove the crankcase breather hose
26 Remove the rocker covers and gaskets
27 Remove the fuel injectors Orings and gaskets from the
cylinder head
ROCKER
COVER
COVER
ROCKER
COVER
INNER
SPRING
puODi LOWER
SEAT
31 Remove the cylinder head by tapping it from below
with a plastic hammer
32 Remove the cylinder head gasket
Engines Generators
ENGINE Valves Disassembly b Remove the valve oil seals intake only by grasping
a Mark the valves with their cylinder numbers then them with pliers and working them out
remove the valves stem caps cotters spring seats and
springs from the cylinder head using the valve spring
lifter Mazda 49 0636 100A and pivot Mazda 49
0107 222A or an appropriate valve spring compres
sion tool
c When removing the valves make sure each valve is
marked so it can be returned to its original position
if reused
NOTE Valve guides are only to be removed if neces
sary after completing the procedure described under
Valves and Valve Guides in the ENGINE INSPECTION
AND REPAIR Timing Mechanism Disassembly
Remove the following components that
are related to the timing mechanism
a Coolant pump
b Crankshaft pulley
c Timing gear cover and gasket
d Fuel injection pump
NOTE See Fuel Injection Pump Removal
under FUEL SYSTEM for detailed instructions
on removing the fuel injection pump
e Camshaft gear lock plate
f Camshaft friction gear
g Camshaft gear
h Idler gear plate
i Idler gear
j Idler gear hub
k Crankshaft slinger
l Crankshaft friction gear spring
m Crankshaft friction gear
D Crankshaft gear and key
o Timing gear case and gasket
TIMING MECHANISM
Engines Generators
ENGINE Lubrication System Disassembly
Remove the following lubrication system components
a Oil filter housing g Lower block
b Lube oil cooler and gasket h Block to lower block left and right gaskets
c Oil filter housing gasket i Block to lower block front and rear gaskets
d Sump stiffeners j Oil jets
e Lube oil sump and gasket k Oil pressure sender
f Lube oil pump assembly I Oil pressure switch
h FT
LUBRICATION SYSTEM
Engines Generators
ENGINE Camshaft Crankshaft and Pistons Disassembly
Remove the following components that are related to
the camshaft crankshaft and pistons When removing
the parts connected to the crankshaft secure the crank
shaft using the two holes in the end of the crankshaft
a Back plate
b Crankshaft rear oil seal flange gasket and oil seal
c Camshaft retaining plate
d Camshaft
e Tappets
f Connecting rod bearing caps
g Connecting rod bearings
h Connecting rods and pistons
i Piston rings
j Snap rings
k Piston Pins
Use the following method to remove
a piston pin
1 Remove the snap rings
2 Heat the piston and connecting rod
assembly to 1220 1580 F 500 700 C
3 Remove the piston pin
I Connecting rods
m Main bearing caps
D Main bearings CAMSHAFT CRANKSHAFT
8 PISTONS DISASSEMBLY
o Thrust washers
p Crankshaft
q Cylinder Liners
Cylinder liners should be removable by hand
However if difficulty is encountered use a cylinder
liner replacer Mazda 49 W065 015 or equivalent
and press the liner out
A CAUTION 00 not directly hit the cylinder
liner with a hammer If the cylinder liner is
difficult to remove make sure the special tool
is used otherwise it will be damaged
Engines Generators
ENGINE INSPECTION AND REPAIR
GENERAL INSPECTION PROCEDURE
1 Before inspection clean each part taking care to remove
any gasket fragments dirt oil or grease carbon moisture
residue or other foreign materials MANIFOLD CONTACT SURFACE DISTORTION
2 Be careful not to damage the joints or sliding parts of
aluminum alloy components such as the cylinder head Valve Seats
and the pistons 1 Measure the protruding length Dimension L of each valve
3 Inspection and repair should be done in the order indi stem above the cylinder head If the measured length is
cated more than the specified value take the following steps
Dimension L Head Intake 1892 in 4805 mm
1 Inspect the cylinder head for water leakage fuel leakage Exhaust 1888 in 4795 mm
damage and cracks Replace it if necessary
2 Measure the cylinder head for distortion in six directions
using a thickness gauge and a straightedge as shown in f
DIMENSION L
the Distortion limit 0004 in 010 mm C
a When Dimension L is up to 0 0020 in 0 05 mm
longer the valve can be used as it is
b When Dimension L is 0020 0059 in 05
15 mm longer set a washer inner dia 0504 in
128 mm outer dia 1535 in 39 mm under the
lower spring seat to adjust Dimension L to within the
standard value
THICKNESS
GAUGE
WASHER
MEASURING THE CYLINDER HEAD If the cylinder head distortion exceeds the limit replace
A CAUTION Do not attempt to repair the cylin c When Dimension Lis 0059 in 15 mm longer or
der head by milling or grinding more replace the old valve with a new valve and
measure Dimension L again If the protruding length
Clearance between the bottom of the cylinder head is still outside the acceptable limit then replace the
and the top of the piston at TDC 00303 00374 in cylinder head
0770 0950 mm 2 Check the valve seat for roughness or damage If neces
4 Measure the manifold contact surface distortion in six sary use a valve seat cutter or valve seat grinder to re
directions as shown in the illustration If the distortion store the valve seat to the specified shape
exceeds the limit grind the surface or replace the cylind
erhead
Distortion limit 0004 in 010 mm
Engines Generators
ENGINE INSPECTION AND REPAIR
NOTE To check the contact width apply a thin coating b Inspect each valve for roughness or damage on its
of red lead to the valve seat and press the valve against face If a problem is slight repair the valve with a
the valve seat Be sure not to tum the valve when doing valve refacer
so 2 Measure the valve length and the valve margin Replace
When grinding a valve seat use a 15 45 or 80 valve the valve if necessary
seat cutter for the intake side and a 12 or 60 valve seat Valve length
cutter for the exhaust side or alternately use a valve seat Intake standard 4512 in 1146 rom
grinder to grind away the roughness andor scars to the Exhaust standard 4508 in 1145 rom
minimum limit of the seat surface always checking the
contact width and the contact position while grinding Valve margin
Intake limit 0039 in 10 rom
Standard valve seat contact width Exhaust limit 0047 in 12 mm
00669 in 17 mm
ItLVE MARGIN
VALVE LENGTH
3 Check the valve stem oil clearance
a Measure the outer diameters of each valve stem
INTAKE EXHAUST
GRINDING THE VALVE SEAT Standard valve stem diameter
Intake 0353 0354 in 8955 8980 mm
3 To seat the valves apply a thin coating of engine oil Exhaust 0352 0353 in 8935 8960 mm
mixed with a small amount of compound to the seat sur
face then lightly tap while turning the valve
RED LEAD
SEATING THE VALVES
A CAUTION When seating the valve be careful
not to let compound adhere to the valve stem
Valve contact position in relation to the valve seat
must be at the center of the and
the contact width must be the standard value
Check that the protruding length of the valve is
within the specified limits
CHECKING VALVE STEM OIL and Valve Guides b Measure the inner diameters of each valve guide
1 Inspection and repair of the valves Standard valve guide diameter
a Inspect each valve and replace any that show damage 0355 0356 in 9018 9040 mm
bending or dents
Engines Generators
ENGINE INSPECTION AND REPAIR
c Calculate the oil clearance by subtracting the outer
diameter of the valve stem from the inner diameter of
the valve guide Replace the valve or valve guide if
the oil clearance is outside the specified limits
Oil clearance
Intake standard
00015 00033 in 0038 0085 mm
Intake limit 00050 in 0127 mm
Exhaust standard
00023 00041 in 0058 0105 mm
Exhaust limit 00050 in 0127 mm
INDICATED
SCALE
MEASURING INNER DIAMETER OF VALVE GUIDE
4 Replacement of valve guides INSTALLING VALVE GUIDE
a Removal
Remove the valve guide at the side opposite the com
bustion chamber using the valve guide replacer
A CAUTION When the valve guide is replac
ed recheck the clearance between the valve
Mazda 490107 45lA or equivalent and the valve guide
The valve seal should be installed after inspec
A CAUTION Do not remove a valve guide tion and repair of the valve seat
unless it is to be replaced The intake and exhaust valve guides have the
same shape
Valve Springs
1 Inspect each valve spring for cracking or any other dam
age Replace if necessary
2 Measure each springs free length and angle limit Re
place if necessary
Free length
Inner spring
Standard 183 in 466 mm
Limit 176 in 447 mm
Outer spring
REMOVING VALVE GUIDE Standard 209 in 531 mm
b Instalkltion Limit 201 in 510 mm
Fit the clip onto the valve guide Use the valve
guide replacer Mazda 490107 45lA to tap the
valve guide in from the side opposite the combustion
chamber until the valve guide height reaches the in
dicated scale 065 in 165 mm height on the
valve guide replacer v WESTERBEKE
Engines Generators
ENGINE INSPECTION AND REPAIR
3 Check the camshaft bearing oil clearance
a Measure the outer diameter of each camshaft journal
Standard journal diameter
No1 2044 2045 in 51910 51940 mm
No2 2034 2035 in 51660 51690 mm
No3 2024 2025 in 51410 51440 mm
No4 2014 2015 in 51160 51190 mm
MEASURING SPRINGS FREE LENGTH
Angle limit
Inner spring 0064 in 163 mm
Outer spring 0073 in 185 mm
ANGLE VARIATION
FROM MEASURING CAMSHAFT JOURNAL
VALVE SPRING
b Measure the inner diameter of the camshaft bearing on
the cylinder block
Standard camshaft bearing diameter
No1 2047 2048 in 52000 52030 nun
No2 2037 2038 in 51750 51780 nun
SPRING ANGLE LIMIT No3 2028 2029 in 51500 51530 mm
Camshaft No4 2018 2019 in 51250 51280 mm
1 Check the camshaft for wear and damage Measure the c Calculate the oil clearance by subtracting the outer
cam height and replace if the height is less than the limit diameter of the camshaft journal from the inner dia
meter of the camshaft bearing If the oil clearance is
Cam height
outside the specified limits replace the camshaft or
Standard 1737 in 44116 mm
the cylinder block
Limit 1717 in 43616 mm
Standard oil clearance 00024 00047 in
0060 0120 mm
MEASURING INNER
DIAMETER OF
MEASURING THE CAM HEIGHT CAMSHAFT BEARING
Tappets
1 Check the condition of the tappets
2 Check the camshaft deflection
Limit 0003 in 008 mm at A and B a Check each tappet for cracking or any other damage
Replace if necessary
b Check the extent of the wear on the surface that is in
contact with the cam and replace any tappet showing
abnormal wear
2 Check the oil clearance between the tappets and the tap
pet guides
a Measure the outer diameter of each tappet
Standard tappet outer diameter
CHECKING CAMSHAFT DEFLECTION 0559 0560 in 14218 14233 mm
y WESTERBEKE
Engnes Generators
ENGINE INSPECTION AND REPAIR
MEASURING OUTER
DIAMETER OF TAPPET
CHECKING DEFLECTION OF PUSH ROD
b Measure the inner diameter of each tappet guide
Standard inner diameter of tappet guide Rocker Arms and Shafts
0563 0564 in 14288 14319 mm
1 Check the condition of the rocker arms and shafts
a Check each part of the rocker arm assembly for
cracking wear or any other damage Replace if nec
essary
b Check to see if the oil holes of the rocker arm and
shaft are clogged Clean if MEASURING INNER DIAMETER OF TAPPET GUIDE
c Calculate the oil clearance by subtracting the outer
diameter of the tappet from the outer diameter of the
tappet guide
ROCKER ARM ASSEMBLY
Standard oil clearance
00022 to 00040 in 0055 0101 mm
2 Check the oil clearance between the rocker arms and
Oil clearance limit
00059 in 015 mm shafts
a Measure the outer diameter of each rocker shaft
Push Rods
Standard rocker shaft diameter
1 Check each push rod to see if either end is worn or dam
0746 0747 in 18959 18980 mm
aged Replace if necessary
CHECKING PUSH RODS
2 Check the deflection of each push rod using a dial gauge
as shown Rotate the push rod slowly and measure the MEASURING OUTER DIAMETER
maximum deflection If the measured value exceeds the OF ROCKER SHAFT
specified limit replace the push rod
Deflection limit 0016 in 040 mm
Engines Generators
ENGINE INSPECTION AND REPAIR
b Measure the inner diameter of each rocker arm
bushing
Standard rocker arm bushing diameter
0748 0749 in 19000 19021 mm
CORRECTING THE
ROCKER ARM
BUSHING DIAMETER
Pistons and Piston Rings
MEASURING INNER
DIAMETERDF 1 Check the condition of the pistons and the piston rings
ROCKER ARM BUSHING
a Check the sliding surface of the piston ring grooves
and other parts of the piston for cracking or any
c Calculate the oil clearance by subtracting the outer other damage Replace the piston if necessary
diameter of the rocker shaft from the inner diameter
b Check the piston rings for broken parts thermal
of the rocker arm bushing If the oil clearance is out
damage and wear Replace the rings if necessary
side the specified limits replace the rocker arm bush
ing or the rocker arm shaft
Standard oil clearance
00002 00024 in 0020 0062 mm
Oil clearance limit
00039 in 010 mm
3 Replace the rocker arm bushing
a Remove the bushing by pressing it out using a pipe
having an appropriate diameter
2 Check the clearance between the piston and the cylinder
liner
a Measure each pistons diameter at the skirt side of the
piston 106 in 27 mm above the bottom end of the
piston
Standard piston outer diameter
Z 39345 39350 in 99937 99950 mm
REPLACING ROCKER
ARM BUSHING Y 39350 39355 in 99950 99963 mm
b Align the oil holes of the rocker arm and a new bush
ing so that the oil hole of the bushing will be open to
the hole in the rocker arm when installedoil must be
able to flow through these openings
c When the pressfitting is complete correct the dia
meter of the bushing with a pin hole grinder or a spi
ral expansion reamer so that the clearance between
the bushing and the shaft meets the standard value
106 in
Standard clearance 27mm
00008 00024 in 0020 0062 mm
MEASURING PISTON DIAMETER
Engines Generators
ENGINE INSPECTION AND REPAIR
b Measure the inner diameter of the corresponding Cylinder Liners
cylinder liner See Cylinder Liners in this section
1 Check the interior of each cylinder liner for scratches
c Calculate the piston clearance If the clearance wear or any other damage Replace if necessary
exceeds the limit replace the piston or the cylinder
2 Measure the inner diameter of each cylinder liner at
liner
three positions top middle and bottom At each
Piston clearance position measure the inner diameter in XX and YY
Standard directions see illustration for a total of six 00020 00030 in 0050 0076
a Extent of wear
Limit
00017 and 00032 in 0044 and 0082 mm The extent of wear of a cylinder liner equals the max
imum measured value minus the maximum standard
NOTE Oversized pistons and cylinder liners are not value
available Z or Y marks are stamped on top of the
piston Standard cylinder liner inner diameter
Z 39370 39375 in 100000 100013 mm
3 Checking the piston ring end gap
Y 39375 39380 in 100013 100026 mm
Position the piston ring in the cylinder liner and meas
ure the piston ring end gap
a When reusing a piston ring measure the end gap
when the ring is set in the most worn part of the
cylinder liner
b When replacing a piston ring measure the end gap
when the ring is set in the least worn part of the
cylinder liner
Piston ring end gap limit 0059 in 15 mm
MEASURING CYLINDER LINER INNER DIAMETER
b Extent of uneven wear
The extent of uneven wear of a cylinder liner equals
the maximum measured value minus the minimum
measured value If the extent of unequal wear ex
ceeds 00079 in 020 mm replace the cylinder liner
CYLINDER BLOCK MEASURE THE
END GAP
NOTE Z or Y is painted on the outside of each
CHECKING PISTON RING END GAP cylinder liner
4 Check the clearance between the piston ring grooves and
the piston rings
a Fit the piston ring on the piston
b Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge If the
clearance exceeds the specified limit replace the pis
ton or the whole set of piston rings
Clearance limit 3 Check the clearance between the cylinder liners and the
Top ring 00098 in 025 mm cylinders
Second ring 00079 in 020 mm
a Measure the outer diameter of each cylinder liner
Oil ring 00079 in 020 mm
Standard outer diameter of cylinder liner
A type 40777 40782 in
103474 103487 mm
B type 40743 40748 in
103487 103500 mm
NOTE A or B is painted on the outside of each
cylinder liner
CHECKING PISTON RING AND GROOVE CLEARANCE Engines Generators
ENGINE INSPECTION AND REPAIR
b Measure the inner diameter of the cylinder
Standard cylinder bore Connecting rod torsion limit
0002 in 005 mm per 197 in 50 mm
A type 40748 40753 in
103500 103513 mm
B type 40753 40758 in
103513 103525 mm
NOTE A or B is stamped on the cylinder block above
each cylinde xEB x
3 Check the clearance between the connecting rod bushings
and the piston pins
a Measure the inner diameter of the bushings
Standard connecting rod bushing diameter
13391 13399 in 34012 34033 mm
MEASURING CYLINDER INNER DIAMETER
c Calqllate the oil clearance by subtracting the outer
diameter of the cylinder liner from the inner diameter
of the cylinder If the oil clearance exceeds the limit
replace the cylinder liner or the cylinder block
Clearance limit
A type 000051 in 0013 mm
B type 000154 in 0039 mm
MEASURING CDNNECTING Rods BUSHING INNER DIAMETER
1 Check the side surfaces of the big end and the small end b Measure the outer diameter of the piston pins
of each connecting rod for cracking or any other damage Standard piston pin diameter
Replace if necessary 13383 13386 in 33993 34000 mm
2 Check the connecting rod for bending and torsion using a
connecting rod aligner If bending or torsion exceeds the
specified limit correct with a press or replace
Connecting rod bending limit MEASURING PISTON
PIN OUTER DIAMETER
0002 in 005 mm per 197 in 50 mm
Engines Generators
ENGINE INSPECTION AND REPAIR
c Calculate the oil clearance by subtracting the outer 2 Check the crankshaft for deflection
diameter of the bushings from the inner diameter of a Support both ends of the crankshaft on Vblocks
the piston pins If the oil clearance is outside the
specified limits replace the bushing or the piston pin b Set a dial gauge on the middle main journal and
measure the deflection by slowly turning the crank
Standard clearance shaft Read the maximum value and if the deflection
00005 00016 in 0012 0040 mm exceeds the specified limit replace the crankshaft
Clearance limit Deflection limit 00020 in 005 mm
00024 in 006 mm
4 Replacement of the connecting rod bushing
a Use a press and a suitable pipe having a diameter of
122 126 in 31 32 mm
A CAUTION Before installing apply a
coating of clean engine oil to the connecting
rod bushing and the connecting rod
Align the connecting rod bushing oil hole with
the connecting rod oil hole CHECKING CRANKSHAFT DEFLECTION
3 Check the crankshaft for wear
a Measure wear on the crankpin see If
wear exceeds the limit replace or grind the crank
shaft until it agrees with the undersize bearing
Standard journal diameters
1 Main journal diameter
REPLACING 2984 2985 in 75805 75825 mm
THE CONNECTING
ROD BUSHING 2 Crankpin diameter
24060 24065 in 61112 61125 mm
3 Rear flange oil seal sliding surface
5 After pressing the bushing in correct its inner diameter
39985 39995 in 101562 101587 mm
with a spiral expansion reamer so that the clearance will
be within the standard value
STANDARD JOURNAL DIAMETERS
Journal wear limit 00012 in 003 mm
Journal grinding limit 00295 in 075 mm
Undersize 0010 in 025 mm 0020 in 050 mm
1 Check the condition of the crankshaft 00295 in 075 mm
a Check each part of the crankshaft for cracking cuts
or any other damage Replace if necessary
b Check to see if the oil holes are clogged Clean if
A CAUTION When grinding a journal or pin
pay attention to each fillet R dimension
necessary
Fillet R dimension
Journal 0146 0157 in 37 40 mm
Pin 0126 0138 in 32 35 mm
Engines Generators
ENGINE INSPECTION AND REPAIR
MAIN JOURNAL CRANKPIN
Cylinder Block
1 Cylinder block inspection and repair
a Check each cylinder for dampness damage and
cracks Replace the cylinder block if necessary
b Measure the distortion of the top surface of the cylin
der block in six directions using a thickness gauge
and a straightedge see If the distortion
exceeds the limit replace the cylinder block
FILLET R DIMENSION Distortion limit 00039 in 010 mm
4 Check the inside surfaces of the main and connecting rod
bearings for streaking flaking pin holes etc Replace all
bearings as a set if necessary
A CAUTION Do not grind the surface of the
cylinder block If ground the pistons will hit
UPPER the valves
J1 rn rn ffi
jJmm
MAIN BEARINGS THRUST WASHERS
Rear Oil Seal Crankshaft
1 Inspecting the oil seal
a Check the oil seal lip for wear fraying or other dam
age and if necessary replace it
2 Oil seal replacement
a Strike out the old rear oil seal with a suitable mandrel
b Apply engine oil onto the outside of a new seal and
pressfit the seal in the rear oil seal flange eqUally
NOTE In case the crankshaft is worn the oil seal must
be fitted on the oil seal flange with its fitting position
moved by approximately 01181 in 3mm so that the seal MEASURING CYLINDER BLOCK DISTORTION
does not touch the worn down portion of the crankshaft
Flywheel
An alternative is to install a metal seal saver on the crank 1 Check the outerfacing side of the flywheel for scratches
shaft to restore it This will make the surface of the crank dirt wear of the ring teeth or any other damage Replace
shaft smooth again
if necessary
2 Measure the distortion of the outerfacing side of the fly
wheel with a thickness gauge and a straightedge If
distortion exceeds the limit replace the flywheel
Limit 0008 in 020 mm
MEASURING
FLYWHEEL
INSTALLATION
DISTORTION
REMOVAL
REAR OIL SEAL CRANKSHAFT
Engines Generators
ENGINE INSPECTION AND REPAIR
Timing Gears 4 Check the oil clearance between the idler gear and the
idler gear hub
1 Check the timing gears for cracking damage to the teeth
or any other damage Replace if necessary a Measure the inner diameter of the idler gear
Standard idler gear diameter
1732 1734 in 44009 44034 mm
TIMING GEARS
2 Measure the backlash of the idle gear and the other gears
with a dial gauge Gears not being measured should be
kept disengaged MEASURING
Backlash IDLER GEAR
INNER DIAMETER
Standard 00039 00079 in 010 020 mm
Limit 00118 in 030 mm
b Measure the outer diameter of the idler gear hub
Standard idler gear hub diameter
1730 1731 in 43950 43975 mm
MEASURING TIMING GEAR BACKLASH MEASURING
3 Measure the end play of the idler gear with a dial guage IDLER GEAR HUB
OUTER DIAMETER
Standard end play
00020 00071 in 005 018 mm c Calculate the oil clearance by subtracting the outer
End play limit 00098 in 025 mm diameter of the idler gear hub from the inner diame
ter of the idler gear If the clearance exceeds the
specified limit replace the idler gear bushing and the
idler gear hub
Oil clearance
Standard 00013 00033 in
0034 0084 mm
Limit 00059 in 015 mm
Oil Jets
1 Inspect each oil jet for cracking or any other damage
2 Check that the valve in the oil jet moves MEASURING IDLER GEAR END PLAY
Engines Generators
ENGINE REASSEMBLY PROCEDURE
Clean or wash the parts to be reassembled Apply lubri A CAUTION Be sure to use the special tool for
cating oil when specified or as needed to the surfaces of the installation of the valve seals If a valve seal is
moving parts during reassembly Heavily oil sliding not installed correctly oil might leak down into the
turning rotating and reciprocating parts lightly oil head cylinders during operation
bolts and other fasteners except those that penetrate into
the water jacket These fasteners should be sealed with
Permatex No2 or a hightack equivalent Make sure that
moving parts after assembly onto the engine are not sub
ject to binding or excessive tension
Carefully check gaskets packings and oil seals even if
checking is not specified Use new gaskets lockwashers
and Orings
Be careful not to mix bolts and nuts Both metric and
SAE bolts are used on various engine assemblies
INSTALLING
Replace plain bearings if they are peeling burned or VALVE SEALS
otherwise damaged
Reassemble parts eg pistons piston rings bearings
bearing caps in their proper order positions and direc Valves
tions relative to the engine block Avoid reversed orienta 1 Insert the valve after applying molybdenum disulphide
tion note that the cylinder head gasket head bolt wash grease to the valve stem
ers and thermostat are assymetrical Any mating marks 2 Install the valve springs and the upper spring seats
that were drawn or scribed during disassembly should be
positioned correctly for reassembly Position gaskets 3 Using the valve spring lifter Mazda 49 0636 100A
carefully especially the head gasket so they will not be and pivot Mazda 49 0107 222A or an appropriate
damaged during assembly valve spring compression tool press each valve spring
then install the valve cotters securely and the stem caps
Inspect all critical clearances end plays oil clearances
and bends
Use liquid sealants when specified or needed on nuts
bolts and gaskets Use Permatex No2 or equivalent
Dont use tape sealants Refer to SEAlANTS
LUBRICANTS in this manual
Tighten the bolts and nuts on the important parts of the
engine to the specified torques using a reliable torque
wrench Tighten fasteners in the specified torque
sequences and in three steps 112 23 and 111 torque
Exceptions are head bolts and rocker arm INSTAWNG
VALVE COTTERS
shaft fasteners The former are torqued as indicated The
latter rocker shaft fasteners should be brought down in
very small increments working from the center bolts out
Where a tightening torque is not specified tighten evenly Oil Jets
to an ordinary torque Install the oil jets to the cylinder block
After completion of reassembly recheck for any abnor NOTE Make sure the protrusion on the oil jet is in its hole in
malities Prepare for starting the engine and idle the the cylinder block
engine sufficiently for a test run Oil jet tightening REASSEMBLY
81 130 ftIb 12 18 mkg
Valve Seals
NOTE Always replace the valve seals during an engine
Apply engine oil to the valve guides
2 Install the lower spring seats
3 Using the valve seal pusher Mazda 49 SE01 160
install the valve seals to the intake valve guides
INSTALLING OIL JETS
Engines Generators
ENGINE engine oil to the tappets and insert them into
INSTALLING MAIN BEARINGS
2 Check the oil clearance of the crankshaft and main bear
ings with a plastigauge
INSTAUING TAPPETS a Remove any foreign material from the main journal
or b Position the plastigauge on top of the main journal
1 Apply engine oil to the camshaft and insert it into the
in the journals axial direction
cylinder block
c Set the main bearing caps in position then tighten
the bolts to the specified torque in the sequence
shown in the Main bearing cap tightening torque
72 77 ftIb 100 107 mkg
INSTAUING CAMSHAFT
2 Install the camshaft retaining plate with the flush side
facing the cylinder block
Camshaft retaining plate tightening torque
14 19 ftIb 19 26 mkg
MAIN BEARING CAP TIGHTENING SEQUENCE
d Remove the main bearing cap and measure the oil
clearance
Standard main bearing cap oil clearance
00023 00035 in 0059 0090 mm
Oil clearance limit 00047 in 012 mm
INSTALLING CAMSHAFT
RETAINING PLATE
Install the main bearings
A CAUTION Make sure no oil or dirt is on the
back surface of the main bearings
MEASURING THE OIL CLEARANCE
Engines Generators
ENGINE REASSEMBLY
e If the oil clearance exceeds the limit replace the 5 With the main bearing caps set move the crankshaft
entire set of main bearings then measure the oil backward and forward to improve the setting Then
clearance again tighten the bolts to the specified torque
If the entire set of main bearings is replaced and the 6 Measure the end play of the crankshaft and confirm that
oil clearance still exceeds the oil clearance limit it is within the standard range Also check that the crank
grind the crankshaft and use undersize bearings shaft turns lightly
Standard crankshaft end play
A CAUTION 00055 00150 in 014 039 mm
End play limit 0015 in 040 mm
a Position the plastigauge horizontally on
the crankshaft away from the oil hole
b Do not rotate the crankshaft when mea
suring the oil clearance
c Install the main bearing cap referring to
the cap number and arrow
MEASURING
CRANKSHAFT
END PLAY
7 If the end play is not within the standard range select a
suitable thrust washer
Standard thrust washer width
00896 00915 in 2275 2325 mm
MAIN BEARING CAP NUMBER ARROW
Oversize thrust washer width
00966 00985 in 2453 2503 mm
3 After checking and correcting the oil clearance apply A CAUTION When replacing the thrust washers
engine oil to the main bearings and main journals then on one side only always install them at the rear
install the crankshaft
side
Cylinder Liners
1 If a new cylinder liner is to be installed select a cylinder
OILING THE MAIN BEARINGS liner with the same letter A or B as is printed on top of
4 Apply engine oil to the thrust washers then install them the CCk 1J
to the center part of the main journal G J
s 0 A OA
A CAUTION Install the thrust washers so that
the inner surface of the oil groove faces the cylin
der block
Engines Generators
ENGINE REASSEMBLY
2 Apply engine oil thoroughly to the cylinder liners d Position the piston and connecting rod assembly so
that the matching number on the big end of the con
necting rod faces the same side as the combustion
chamber cutout
t1 COMBUSTION
CHAMBER
CUTOUT
OILING THE CYLINDER LINERS
3 Check to see that the cylinder walls are free of carbon
and dirt Then install the cylinder liners to their original
locations making sure the letters on the cylinder liners POSITIONING PISTON
match the letters on the cylinder block CONNECTING ROD
MATCHING
NUMBER
e Assemble the piston and connecting rod with the
piston pin and lock the snap rings so the pin wont
come out
INSTALLING CYLINDER and Connecting Rods
1 Assemble the pistons and connecting rods
ASSEMBLING PISTON
a Heat the piston to 1220 1580 F 500 700 C CONNECTING ROD
f Check to make sure the connecting rod can be easily
moved
b Apply engine oil to the small end of the connecting
rod and around the piston
c Insert a snap ring into one of the piston pin holes
CHECKING CONNECTING
ROD MOVEMENT
2 Assemble the piston rings
a Assemble the piston rings to the piston using the pis
ton ring inserting tool commercially available The
order of assembly is oil ring expander oil ring sec
ond ring and top ring
Engines Generators
ENGINE REASSEMBLY
A CAUTION
a Pistons must be inserted so that the front
marks F face front
b Apply engine oil liberally to the cylinder
liner walls piston circumference and
rings
c Check to be sure that each oil jet aligns
PISTON to the oil path in the piston at SOC If not
RINGS
replace the oil jet with a new one
A CAUTION
a Apply engine oil liberally during b The rings must be mounted so the Nil
mark faces upward
b Align the piston ring openings as shown in the illustra
tion FRONT
ALIGNING THE OIL JETS
4 Install each connecting rod bearing cap as follows
a Measure and adjust the connecting rod bearing and
crankshaft pin journal oil clearance by the same pro
cedure used to measure and adjust the crankshaft and
main bearing oil clearance
Connecting rod bearing cap tightening torque
REAR
59 65 ftIb 82 90 mkg
PISTON RING OPENINGS
Standard oil clearance
3 Install the pistons and connecting rods 00014 00030 in 0036 0076 mm
a Fit the connecting rod bearing to the connecting rod Oil clearance limit 00020 in 005 mm
and apply engine oil Undersize connecting rod bearings
b After cleaning the inner surface of the cylinder liner 0010 in 0254 mm 0020 in 0508 mm
apply engine oil 0030 in 0762 mm
c Insert each piston and connecting rod assembly into
the cylinder block using a piston insertion tool com
INSERTING PISTON
AND CONNECTING
ROD ASSEMBLY
MEASURING CONNECTING ROD BEARING
CRANKSHAFT PIN JOURNAL DlL CLEARANCE
Engines Generators
ENGINE REASSEMBLY
b Check the connecting rod end play Back Plate
Standard connecting rod end play Install the back plate
00094 00130 in 0239 0379 mm
Back plate tightening torque
End play limit 00157 in 040 mm
28 38 ftIb 38 53 mkg
NOTE Measure each connecting rods end play be
fore installing the connecting rod bearing cap
CHECKING CONNECTING ROD END PLAY
c Install the connecting rod bearing cap and tighten it
Flywheel and Flywheel Washer
to the specified torque When doing so apply engine
oil to the threaded part of the bolts and nuts and to the 1 Install the flywheel and flywheel washer Temporarily
bearing surfaces tighten the bolts by hand
Connecting rod bearing cap tightening torque
59 65 ftIb 82 90 mkg
A CAUTION Install the connecting rod
bearing cap after aligning the cap and con
necting rod mating marks
2 Turn the flywheel until the first cylinder is at TDC
MATING
MARKS 3 Secure the flywheel with the ring gear brake Mazda
49 VIOl 060A and collar Mazda 49 W065 062
4 Tighten the bolts on the flywheel
INSTALLING CONNECTING ROD BEARING CAP Flywheel tightening torque
130 145 ftIb 18 20 Rear Oil Seal the crankshaft rear oil seal flange with its gasket and
oil seal
NOTE Apply engine oil to the oil seal before
SECURING THE FLYWHEEL
Engines Generators
ENGINE Gear Case 4 Trim off the protruding parts of the gasket between the
cylinder block and the timing gear case
1 Attach the idler gear hub making sure that the oil holes
are aligned Temporarily tighten the bolts
TRIMMING THE BLOCK TO TIMING GEAR CASE GASKET
ATTACHING IDLER GEAR HUB 5 Apply a siliconbased sealant to the areas where the
gasket was trimmed off
APPLYING SEALAN
Lower Block
INSTAUING TIMING 1 Apply a siliconbased sealant to the ends of the blockto
GEAR CASE GASKET
lowerblock front and rear gaskets and install them
Apply the sealant to both ends of each gasket
3 Install the timing gear case
Timing gear case tightening torque
REAR GASKET
14 19 ftlb 19 26 mkg
EALANT AREA
AP in 3 mm
SEALANT
BOTH ENDS
INSTAWNG TIMING GEAR CASE
INSTALLING GASKET
REAR GASKET SHOWN
Engines Generators
ENGINE REASSEMBLY
2 Install the right and left gaskets onto Oil Cooler
the cylinder block and then install the lower block
Install the lube oil cooler housing and gasket
Lower block tightening torque
14 19 ftIb 19 26 mkg Oil Filter Housing
Install the oil filter housing gasket and oil filter
Oil filter housing tightening torque
14 19 ftIb 19 26 mkg
FILTER
Pump
Remove the oil pipe from the oil pump and install the
oil pump Reinstall the oil pipe
NOTE Install the oil pipe after coating the Oring with
engine oil
Oil pump tightening torque INSTALLING OIL FILTER HOUSING
Large bolts 14 19 ftIb 19 26 mkg
Oil pipe tightening torque Timing Gears
Small bolts 58 80 ftIb 08 11 mkg 1
CRANKSHAFT
GEAR
Set the rubber gasket between the lower block and the oil INSTALLING CRANKSHAFT GEAR
sump then set the sump stiffeners and install the sump
2 Remove the bolts on the idler gear hub and install the idler
Oil sump tightening torque
gear and idler gear plate making sure that the A marks
14 19 ftIb 19 26 mkg are aligned Tighten the bolts
A CAUTION Be sure the oil sump attaching bolts
do not twist the gasket
INSTALLING IDLER GEAR
INSTALLING OIL SUMP
Engines Generators
ENGINE REASSEMBLY
3 Install the camshaft gear and key making sure that the b Tighten the fuel injection pump bolts to the specified
B marks are aligned torques see
Tightening torques
A 14 19 ftIb 19 26 mkg
B 27 38 ftIb 38 53 mkg
H MARKS
INSTAWNG CAMSHAFT GEAR
TIGHTENING FUEL
4 Install the camshaft friction gear and lock plate to the INJECTION PUMP BOLTS
camshaft gear and tighten the bolt
INSTALLING FRICTION GEAR AND SLINGER
INSTAUING FRICTION GEAR
Timing Gear Cover
5 Fuel injection pump installation
Install the timing gear cover and gasket
a Install the fuel injection pump by first aligning the
Timing gear cover tightening torque
notch on the injection pump gear with the mark on
14 19 ftIb 19 26 mkg
the casing Carefully insert the injection pump
making sure the gear has not turned Check that the NOTE Apply engine oil to the lip of the oil seal before installa
C marks are aligned If not remove the pump tion
and try again
INSTAUING TIMING
GEAR COVER
INSTAUING FUEL INJECTION PUMP
Engines Generators
ENGINE Pulley Cylinder Head
Install the crankshaft pulley and tighten the bolts Install the cylinder head and gasket onto the cylinder block
Crankshaft pulley tightening torque NOTE Remove any dirt or grease from the top of the cylinder
253 289 ftlb 35 40 mkg block and the bottom of the cylinder head
A CAUTION Use a new cylinder head gasket
INSTALLING CRANKSHAFT PULLEY
CYLINDER HEAD Pump
Install the coolant pump and gasket Push Rods
Coolant pump tightening torque Insert the push rods
14 19 ftlb 19 26 mkg
A CAUTION Make sure the ends of the push rods
are set in the hollowed portion of the tappets
INSTALLING COOLANT the alternator bracket
INSERTING PUSH RODS
Alternator bracket tightening torque
27 38 ftIb 38 53 mkg
INSTALLING ALTERNATOR BRACKET
II 111111
INCORRECT CORRECT
INSERTING PUSH RODS
Engines Generators
ENGINE REASSEMBLY
Valve Stem Caps Cylinder Head Bolts
Apply engine oil to the valve stem caps and install them 1 Measure the length of each cylinder head bolt from
below the head If the measured value is within the
specified limit apply engine oil to the threads and insert
the bolt into its original location
Length of the cylinder head bolt measured from
below the head
Standard
Long size 593 596 in 1507 1513 mm
Short size 479 482 in 1217 1223 mm
Limit
Long size 598 in 1520 mm
Short size 484 in 1230 mm
INSTALLING VALVE CAPS
A CAUTION If the length of the bolt below the
head exceeds the specified limit it must be
Rocker Arm and Shaft Assembly replaced
Reassemble the rocker arm and shaft assembly if it was dis
assembled and install it on the cylinder head Tighten the
two nuts to the specified torque
Rocker arm tightening torque
14 19 ftIb 19 26 mkg
Note that the front end of the rocker shaft is identified by a
pin protruding from the top and a larger oil hole between the
supply holes serving 1 and 2 rocker arms This pin fits a
slot in the 1 rocker shaft support which prevents the shaft
from turning and cutting off the lube oil to the rocker arms
and valves CYLINDER HEAD BOLT
LENGTH BELOW HEAD
Use the following order of assembly
1 Spring CYLINDER HEAD BOLTS
2 Rocker
3 Rocker shaft support 2 Tighten the cylinder head bolts to a tightening torque of
43 ftIb 60 mkg iIi the sequence shown in the
4 Rocker
5 Wave washer 16 12 8 1 5 9 13 17
6 Snap ring
VJAMNUT
I BUSHING
Cl IllIrt
SPRING TAPER PIN
1nRECESS
1 ROCKER
WAVE WASHER i
SHAFT SAOP
SNAP
ROCKER
SUPPORT
TAPER PIN
RING HOLE 15 11 7 3 2 6 10 14
INSTALLING ROCKER ARM ASSEMBLY
CYLINDER HEAD BOLTS TIGHTENING SEQUENCE
Engines Generators
ENGINE INSTALLING INTAKE MANIFOLD
MARKING THE CYLINDER HEAD BOLTS Air Intake Silencer
4 Using these marks as reference points tighten the cylin
der head bolts 90 90 105 in the same sequence
5 Once again tighten them 90 90 105 in the same
sequence
A CAUTION
a Be absolutely sure to tighten in the sequence
shown in the b Make sure the rocker arms and push rods are
squarely engaged while tightening
Lifting Eyes Fuel Filter
Fuel Injectors 1 Install both front lifting eyes
Install the fuel injectors Orings gaskets injector brackets Front lifting eye tightening torque
and fuel return line Water pump side
NOTE Be sure the notch on the injector bracket is engaged Small bolt 14 19 ftIb 19 26 mkg
in the hole in the cylinder head Large bolt 47 66 ftIb 65 91 mkg
Fuel injector tightening torque Alternator side
34 40 ftIb 47 55 mkg 27 38 ftIb 38 53 mkg
INSTALLING FUEL Return Lines LEFT SIDE RIGHT SIDE
Install the fuel injectors return lines INSTALLING FRONT LIFTING EYES
Intake the intake manifold and gasket
Intake manifold tightening torque
14 19 ftIb 19 26 mkg
Engines Generators
ENGINE REASSEMBLY
2 Install the rear lifting eye and the fuel filter assembly 5 Install the fuel injection pump oil line
Rear lifting eye tightening torque Injection pump oil line tightening torque
Lifting eye bolt 14 19 ftlb 19 26 mkg Joining bolts
Fuel filter bolts 27 38 ftIb 38 53 mkg A 17 26 ftlb 24 36 mkg
B 9 13 ftlb 12 18 mkg
PII Bracket bolts
C 14 19 ftlb 19 26 mkg
D 59 80 ftlb 08 11 mkg
REAR
LIFTING
INSTALLING REAR LIFTING EYE FUEL FILTER Feed Line
1 Install the fuel feed line from the fuel lift pump to the NSTALLING INJECTION
PUMP OIL LINE
fuel filter
Fuel feed line tightening torque 6 Install the fuel injection lines and their clamps from
Joining bolts 22 25 ftlb 30 35 mkg the injection pump to the injectors
Bracket bolts
Small 58 80 ftlb 08 11 mkg
Large 14 19 ftlb 19 26 mkg A CAUTION Be careful not to damage the fuel
injection lines when installing them
Injection line tightening torque
Joining nuts 18 22 ftlb 25 30 mkg
FEED LINE
INSTALLING FUEL FEED LINE
2 Install the fuel line from the fuel filter to the injection
pump
INSTALLING FUEL INJECTION LINES
3 Install the injection pump return line
4 Install the fuel supply line to the fuel lift pump Oil Level Dipstick
Fuel line tightening torque 1 Install the oil level dipstick
Joining bolt 217 253 ftlb 30 35 mkg Oil level dipstick tightening torque
Bracket bolt 58 80 ftlb 08 to 11 mkg 14 19 ftlb 19 26 mkg
NOTE Apply engine oil to the Oring before
INSTALLING OIL
LEVEL DIPSTICK
INSTALLING FUEL SUPPLY
LINE TO FUEL LIFT PUMP Engines Generators
ENGINE Water Pump 1 Install the alternator cap screw through the alternator leg
underside and spacer into the alternator the raw water pump and drive belt Make sure the raw
water pumps pulley is in proper alignment with the crank 2 Swing the alternator into position on the adjusting strap
shaft pulley Check the belt tension See the RAW WATER and fasten Lightly tighten
PUMP page for pump servicing information 3 Install the drive belt and adjust the belt tension
4 Tighten both bolts and recheck the belt tension
NOTE Make certain the belts are perfectly aligned with the
alternator and engine pulleys If not insert or remove spacers
as needed to align the alternator
See ALTERNATOR for testing
information
Alternato strap tightening torque
14 19 ftIb 19 26 mkg
Alternator tightening torque
Strap bolt 14 19 ftIb 19 26 mkg
Long bolt and nut
27 38 ftIb 38 53 mkg
RAW WATER Pump Connector and Hose
INSTALLING ALTERNATOR
Thermostat
If the thermostat was removed reinstall the thermostat gas
ket and housing
Thermostat tightening torque
58 80 ftIb 08 11 mkg
COOLANT PUMP
CONNECTOR 11 the alternator alternator adjusting strap and drive belt
as follows THERMOSTAT
HOUSING
A CAUTION Connect the alternator properly
Should the polarity be reversed a powerful current
would flow from the battery into the alternator dam
aging the diodes and wiring harness
INSTALLING
Engines Generators
ENGINE Cover and Crankcase Breather Hose Bellhousing propulsion engines only
1 Apply Three Bond 1382 to the rocker cover gasket at Install the bellhousing
the locations shown in the Heat Exchanger
2 Install the rocker cover and its gasket
Mount the engine heat exchanger The heat exchanger should
3 Install the crankcase breather hose be serviced when the engine is overhauled see HEAT EX
CHANGER under COOliNG SYSTEM for inspection and
servicing information Install the hose connector elbow and
the hose from the coolant pump
c t t
Starter Motor
Install the starter motor
Oil Pressure Switch and Oil Pressure Sender
Install the oil pressure switch and sender
INSTALLING ROCKER COVER
Oil pressure switch and sender tightening torque
4 Put the rocker cover outer gasket on the rocker covers 9 13 ftIb 12 18 mkg
cover and install
Engine Wiring Harness
Rocker covers cover tightening torque
14 25 ftIb 02 035 mkg Assemble the engine wiring harness and ground wires Re
connect all DC wiring harness terminals to their engine
A CAUTION Check all AC and DC wiring con
nections by referring to the WESTERBEKE wiring
diagrams and schematics
ROCKER COVER
OUTER GASKET
PROPULSION ENGINES
1 Assemble the damper plate to the flywheel
Damper plate tightening torque
INSTALLING ROCKER COVERS COVER 14 20 ftIb 17 27 mkg
2 Reinstall the marine transmission and fill with the
Exhaust Manifold proper the exhaust manifold see EXHAUST MANIFOW
NOTE Some such as the Borg Warner
page Velvet Drive require oil coolers Oil coolers should be
Exhaust manifold tightening torque cleaned pressure tested and repainted at engine over
17 20 ftIb 23 27 mkg haul The transmission oil cooler hoses should also be
inspected Refer to the text on Heat Exchangers
A CAUTION Retighten the exhaust manifold using
the same torque after idling for twenty minutes
TRANSMISSION COOLER
Back Plate
Attach the back plate 3 Fill the engine cooling system with premixed coolant
Back plate tightening torque 916 socket 5050 good quality antifreeze and distilled water Fill
27 38 ftIb 38 53 mkg the engine oil sump to the mark on the dipstick with
lube oil AP1 spec CF or CG4
Fuel filter Assembly The engine should be test run under load prior to rein
Mount the fuel filter assembly installing At this time readjust the valve clearances on
Fuel rJter tightening torque the hot engine
33 49 ftIb 46 68mkg Allow the engine to cool to room temperature and re
torque the cylinder head bolts and recheck the Damper Plate propulsion engines only clearances see ENGINE the transmission
darnper plate
Damper plate tightening torque
14 20 ftIb 17 27 mkg Engines Generators
ENGINE Mount the generator back end assembly with its control
panel Reconnect all DC wiring and reconnect all AC
A CAUTION Check all AC and DC wiring con
nections by referring to the WESTERBEKE wiring
diagrams and Fill the engine cooling system with premixed coolant
5050 good quality antifreeze and distilled water Fill
the engine oil sump to the mark on the dipstick with lube
oil API spec CF or CG4
The engine should be test run under load prior to rein
stalling At this time readjust the valve clearances on the
hot engine
Allow the engine to cool to room temperature then re
torque the cylinder head bolts and recheck the valve
clearances see ENGINE MANIFOLD
See the EXHAUST MANIFOW page for inspection and
assembly Engines Generators
EXHAUST ASSEMBLY
The exhaust manifold which was disassembled from the 1 If the manifold was removed as an assembly and left
cylinder head should be inspected before reassembly intact it can be replaced on the cylinder head in the
1 Remove the exhaust nipples elbows and plugs from the reverse order of removal
manifold Do not reuse the gaskets install new ones
2 Examine all parts for defects corrosion and wear and a Loosely attach the manifold elbows to the cylinder
replace as needed head using new gaskets Do not use any gasket seal
3 Flush out the manifolds interior with a liquid cleaner and ant on these gaskets
rinse thoroughly with fresh water b Gradually tighten each fitting to ensure proper
4 Use a pipe cleaner to clear the passage that connects the alignment of all the parts This should be done in
filler neck to the coolant recovery tank tubing three steps
S Flush out the coolant recovery tank and its connecting Manifold mounting bolts torque
tube 12 17 ftlb 16 24 mkg
2 Reinstall the exhaust connections Use new gaskets and
check the exhaust clamps condition
CLEAR THIS Replace it if necessary
PASSAGE
3 Check the manifold pressure cap Open the valve by
pulling it and make sure it closes when released Make
certain the upper and lower seals are in good condition
If any doubt replace the cap
COOLANT
RECOVERY
TANK
REPLACE
GASKETS
CHECKINQJH PRESSURE CAP
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be peiformed by a competent engine mechanic The information
below is provided to assist the CLEARANCE ADJUSTMENT DRIVE BELT ADJUSTMENT
1 Remove the cylinder head cover Proper inspection service and maintenance of the drive belts
2 Set the piston of No 1 cylinder to the Top Dead Center is important for the efficient operation of your engine see
TDC of its compression stroke Drive Belts under MAINTENANCE SCHEDULE
3 Check the valve clearances only for the valves shown Drive belts must be properly tensioned Loose drive belts will
below Adjust these valves if their clearances deviate not provide proper alternator charging and will eventually
from the specified values damage the alternator Drive belts that are too tight will pull
the alternator out of alignment andor cause the alternator to
Intake No1 and No2 cylinders
wear out prematurely Excessive drive belt tension can also
Exhaust No1 and No3 cylinders
cause rapid wear of the belt and reduce the service life of the
Valve clearance engine cold
coolant pumps bearing A slack belt or the presence of oil on
Intake 0012 in 030 mm the belt can cause belt slipping resulting in high operating
Exhaust 0014 in 03S mm
temperatures and tachometer variations
The drive belt is properly adjusted if the belt can be deflected
no less than 38 inch IOmm and no more than 112 inch
12mm as the belt is depressed with the thumb at the mid
point between the two pulleys on the longest span of the belt
A spare belt or belts should always be carried on board
A WARNING Never attempt to check or adjust the
drive belts tension while the engine is in operation
Adjusting Belt Tension
1 Loosen the alternator adjusting strap bolt and the base
mounting bolt
CHECKING THE VALVE CLEARANCE 2 With the belt loose inspect for wear cracks and frayed
edges
3 Pivot the alternator on the base mounting bolt to the left
A CAUTION Do NOT retorque the cylinder head or right as required to loosen or tighten
bolts They are stretch bolts and do not require 4 Tighten the base mounting bolt and the adjusting strap
retorquing bolt
S Run the engine for about 5 minutes then shut down and
4 Turn the crankshaft one turn so that the piston of No4
recheck the belt tensions
cylinder is at the TDC of its compression stroke Check
the valve clearance of the remaining valves as illustrated
and adjust them if necessary
Intake No3 and No4 cylinders
Exhaust No2 and No4 cylinders
Check these valve clearances when the pistonof
No1 Cylinder is at the TOC of its compression stroke
I i I I
1 IN 1 EX 2 IN 3 EX
38 TO 12 ADJUSTING BELT TENSION
iFRONT
Install the cylinder head cover
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the THE CYLINDER HEAD BOLTS IDLE SPEED ADJUSTMENT
TACHOMETER CHECK New ACAUTION 00 NOT retorque the cylinder head bolts Checking the Idle Speed
They are stretch bolts and do not require retorquing Use a tachometer to check the idle speed
NOTE In a new installation having new instrument COMPRESSION TEST the tachometer may not always be
correctly calibrated to the
engines rpm This calibration should be checked in all new
To check the engines compression pressure warm up the shut off the raw water throughhull remove all the
fuel injectors disconnect the fuel shutoff solenoid wire and 1 Warm up the engine to normal operating a compression adapter in the injector
hole Connect a Remove any specks on the crankshaft pulley with a tester on the adapter and crank the engine with cloth
and place a piece of suitable reflecting tape on the
the starter motor until the pressure reaches a maximum value pulley to facilitate the use of the this process for each cylinder Look for
cylinders 2 Start and idle the engine
with dramatically at least 20 lower compression than the 3 Aim the light of the tachometer onto the reflecting tape to
average of the others confirm the engine speed Check the instrument panel
Compression pressure tachometer reading Adjust the tachometer in the panel
Standard 4261bin230 kglcm2 290 rpm by using the instrument calibration pod as needed to bring
Limit 384 Ibin227 kglcm2 290 rpm the instrument panel tachometer into the same rpm read
ing as the engine
4 Adjust the idle speed if the engine speed is not within the
specified value
Normal idle speed 700 900 rpm
If a weak cylinder is flanked by healthy cylinders the prob
lem is either valve or Check the valve clear
ances for the weak cylinder adjust as needed and test again CHECKING THE IDLE SPEED
If the cylinder is still low apply a small amount of oil into
the cylinder to seal the rings and repeat the test If the com
pression comes up the rings are high readings on all cylinders indicate heavy
carbon accumulation a condition that might be high pressures and noise
NOTE In case of severe vibrations and detonation noise have
the injectors checked and overhauled by an service center Poor fuel quality contaminants and
loss of positive fuel pressure to the injection pump will result
in injector faults
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the the Idle Speed
1 Loosen the locknut on the idle adjustment bolt on the
fuel injection pump
2 Turn the idle adjustment bolt until the idling speed is
within the standard range The idle speed will increase
when the adjusting bolt is turned clockwise and decrease
when turned Tighten the locknut
4 Race the engine several times to ensure the idle speed
remains as set
NOTE Should the engine rpm be in question verify readings as shown at the instrument panel
with a mechanical or strobetype tachometer at the
engine FUEL INJECTION
PUMP
IDLE SPEED Engines Generators
LUBRICATION
The lubricating system is a pressure feeding system using an
oil pump The engine oil is drawn from the oil sump by the DlL PRESSURE SWITCH
oil pump which drives the oil under pressure through the PROPULSION ENGINE
oil filter oil cooler and various lubricating points in the
engine The oil then returns to the oil sump to repeat the con
tinuous cycle When the oil pressure exceeds the the oil pushes open the relief valve in the oil pump
YOPEN
and returns to the oil sump keeping the oil pressure within
its specified range
FUEL SOLENOIO 1
TESTING THE OIL PRESSURE OIL PRESSURE SWITCH
JUL GENERATOR
To test the oil pressure remove the oil pressure sender then
install a mechanical oil pressure gauge in its place After
warming up the engine set the engine speed at 1800 rpm OIL or 3600 rpm propulsion engines and read the
oil pressure gauge If the pressure is not within the specified Removing the Oil Pump
range check each part and repair if necessary Remove the following components from the engine in the
Oil pressure numbered sequence see 30 35 Ibin2 21 25 kgcm at 1800 rpm
1 Stiffeners
50 55 lbin 35 39 kgcm at 3600 rpm 2 Oil pan
3 Oil pan gasket
4 Oil pipe attatching bolts
5 Oil pipe
6 Oil pump
TESTING THE
OIL Oil Pressure
The specified safe minimum oil pressure is 4314 psi
0301 kgcm A gradual loss of oil pressure usually indi
cates worn bearings For additional information on low oil pres
sure readings see the ENGINE section
OIL PRESSURE performing an engine overhaul replace the oil and the oil pressure sender
When installing the new parts apply teflon sealant to the thread
ed ends being careful not to close off the oil hole in the sender
Oil pressure switch and sender torque
9 13 ftIb 12 18 mkg
A CAUTION Oil Pressure Switch 00 not use 3
lock pliers vise grips or pipe wrenches on the oil
pressure switch Use the correct socket which is
available from SnapOn Proto New Britain and
others Damage to the switch will cause oil leaks
andor switch failure
REMOVING THE
OIL PUMP
Engines Generators
LUBRICATION b Check the relief valve for wear or the oil pump components in the
following c Check for a weak or broken relief valve sequence see Measure the springs free
length
1 Oil strainer Standard relief valve spring free length
2 Oil strainer gasket 169 176 in 428 448 mm
3 Pump cover RELIEF VALVE RELIEF VALVE
4 Outer rotor
5 Drive gear use a press and a suitable mandrel
6 Pumpbody
7 Innerrotor5
8 Screw SCREW
9 Relief valve spring FREE
LENGTH
10 Relief valve plunger 6
2 Inspect the clearance between the pump body and the
shaft Measure the clearance with a dial gauge and mag
net base If the clearance exceeds the limit replace the
pump drive shaft inner rotor pump body and drive gear
Standard clearance
00015 00030 in 004 008 mm
Clearance limit 00039 in 010 mm
OIL PUMP 4
1
3 Inspect the clearance between the inner rotor and
9 the outer rotor Check the clearance between the
lobes of the rotors with a feeler gauge If the clearance
8 exceeds the limit replace both rotors
Standard clearance
00016 00079 in 004 020 Clearance limit 00098 in 025 mm
1 VISually check the disassembled parts and replace
any faulty parts
a Check the pump body and pump cover for distortion
or damage Repair or replace if necessary Check
the sliding surface of the pump cover with special
care and replace the cover if the surface has steps or
excessive streaks Minor steps or streaks may be
repaired by rubbing them with compound on a sur
face plate
INNER ROTOR
17 TALLY MARKS
Engines Generators
LUBRICATION SYSTEM
4 Inspect the clearance between the outer rotor and STRAIGHTEDGE
the pump body Check the clearance between the
outer rotor and the pump body with a feeler gauge If
the clearance exceeds the limit replace the rotor or
pump body
Standard clearance
00039 00083 in 010 021 mm
Clearance limit 00098 in 025 mm
Reassembly
Reassemble the oil pump in the reverse of the order of disas
sembly
5 Check the clearance between the rotors and the NOTE When installing the rotors into the body be sure that
pump cover Inspect the end float of the rotors Place the tally marks on the rotors are positioned toward the cover
a straightedge across the pump body and measure the Pump cover tightening torque
clearance between the rotor and the straightedge with a 58 87 ftlb 08 12 mkg
feeler gauge If the clearance exceeds the limit replace
the drive gear drive shaft inner rotor outer rotor and Installing the Oil Pump
pump body Install the six components in the reverse of the order of
Standard clearance removal
00012 00039 in 003 010 mm NOTE When installing the oil pump set screw apply sealing
Clearance limit 00059 in 015 mm compound on the set screw SYSTEM Lubrication system type
Pressurefed
Type Trochoid
Oil pump
Relief valve opening pressure 924 Ibin2 65 kgcm2
Type Full flow paper element spinon type
Oil filter
Oil filter relief valve opening pressure 142 Ibin2 10 kgcm2
Oil cooler Type Water cooled
Oil filter body Relief valve opening pressure 569 Ibin2 40 kgcm2
Oil sump capacity not including oil filtercooler assembly 63 US Quarts 60 liters
Oil filter capacity 11 US Quarts 10 liters
Oil Grade API Specification CF or CG4 SAE 30 10W30 15W40
Engines Generators
COOLING The raw water pump is a selfpriming rotary pump with a
nonferrous housing and a neoprene impeller The marine diesel engines are designed and equipped
has flexible vanes which wipe against a curved cam plate
for fresh water cooling Heat produced in the engine by com
within the impeller housing producing the pumping and friction is transferred to fresh water coolant
This pump must not be run dry as water acts as a circulates throughout the engine This circulating fresh
for the coolant cools the engine block its internal moving
parts and the engine oil The coolant is in tum cooled by Heat Exchanger
raw water and the raw water carries the transferred heat over
The engine heat is transferred externally from the fresh water
board through the exhaust system The fresh water coolant
coolant to the raw water in the heat exchanger The raw
and raw water circuits are independent of each other Using water flows through tubes in the heat exchanger while the
only fresh water coolant within the engine allows the cooling
fresh water coolant flows around the tubes The engine heat
water passages to stay clean and free from harmful deposits is conducted from the fresh water coolant through the tube
Coolant Pump walls to the raw water
The fresh water coolant is pumped through the engine by a pump The coolant passes through the thermostat A thermostat located
near the manifold at the front of the
into the manifold to the heat exchanger where it is cooled
engine controls the coolant temperature as the coolant contin
and returned to the engine block via the suction side of the uously flows through the closed cooling circuit When pump
engine is first started the closed thermostat prevents coolant
Raw Water Pump from flowing some coolant is bypassed through a hole in
the thermostat to prevent the exhaust manifold from over
The raw water flow is created by a positive displacement heatingAs the engine warms up the thermostat pump This pump draws water
directly from the
opens
raw water source ocean lake or river through a hose to the
water strainer The raw water passes from the strainer When the engine is started cold external coolant flow is pre
through the raw water pump to the heat exchanger then to the vented by the closed thermostat although some coolant oil cooler propulsion
engines only The raw is bypassed around the thermostat to prevent the exhaust
water is then discharged into the exhaust el manifold from overheating As the engine warms up the
bow mixing with and cooling the exhaust gasses This mix thermostat gradually opens allowing the engines coolant to
ture of exhaust gas and raw water is discharged overboard by flow unrestricted to the external portion of the cooling system
the engines exhaust gas discharge pressure
COOLANT
TEMPERATURE
SWITCH
COOLANT
RAW WATER
NOTE Antislphon
valve is not shown
TO TRANSMISSION COOLING SYSTEM
OIL COOLER PROPULSION
ENGINES ONLY
WESTERBEKE COOLANT DRAIN
Located under
Engines Generators heat exchanger
near engines
back plate
COOLING SYSTEM
HEAT EXCHANGER Replacing The heat exchanger should be inspected and serviced during
Remove the cap screws and disassemble the thermostat
an engine overhaul housing as shown When installing the new thermostat and
1 Disconnect the hoses and remove the hose fittings gasket apply a thin coat of sealant on both sides of the gas
petcock drain plugs and zinc anode Also remove the ket before pressing it into place Do not overtighten the cap
covers and gaskets screws
2 Inspect the tube casing for wear and dents if necessary Run the engine and check for normal temperatures and that
replace the heat exchanger there are no leaks at the thermostat housing
3 Clean out any zinc debris and pressure test the coolant
and raw water passages
4 When reassembling install new gaskets and Orings
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them
S Install a new zinc anode
NOTE All of the above can be accomplished by sending the
heat exchanger to a heat service shop GASKET
They will also service the transmission and engine oil PUT A THIN COAT OF
SEALANT ON THERMOSTAT BEFORE ASSEMBLY
HOUSING
6 Repaint the assembled heat exchanger with Westerbeke
spray enamel
7 Reconnect all hoses replacing them as needed
8 Refill the system with coolant
9 Pressure test the system and check for leaks
DroZINC
ANODE
THERMOSTAT ASSEMBLY
COOLANT PUMP
The coolant fresh water pump is a pump
and is beltdriven
Removal
1 Drain the engine coolant into a suitable container
2 Remove the following components in sequence
a C00lant pump pulley
b Alternator drive belt
c Spacer
d Coolant pump
HEAT EXCHANGER e Coolant pump check the thermostat for damage Then put it in
water and raise the water temperature gradually to test its
valve opening temperature Replace if defective
A CAUTION The wax pellettype thermostat remains
closed if its heatsensing part is defective Leaving REMOVING COOLANT PUMP
this uncorrected would cause the engine to Engines Generators
COOLING 3 Tap out the seal using a pipe of the specified the coolant pump in the following
sequence NOTE The outer diameter of the pipe should be below
1 Pulley flange
11 in 28 mm and the inner diameter of the pipe
2 Shaftlbearing IMPELLER
should be above 055 in 14 mm
3 Housing and gasket
4 Impeller seal
5 Impeller
HOUSING Inspection
Inspect the coolant pump parts for the following conditions
and replace if necessary
1 Cracking of the water pump body
1 Press out the coolant pump pulley flange using a suitable
puller and a press 2 Wear in the areas that the impeller contacts the seal
3 Breakage of the seal spring
4 Check that the shaftlbearing rotates easily and check for
abnormal noise
Reassembly
2 Press out the water pump impeller and shaftlbearing using
1 Use a pipe of the specified diameter to press the shaft
the water pump impeller support block Mazda 49
bearing into the water pump body
0823 146 and a press
A CAUTION Use a pipe with an inner diameter
of 10 in 26 mm or more and press the end of the
pipe against the outer race of the shaft bearing
Make sure the shaft bearing is inserted straight
When the inserting force suddenly increases the
shaft bearing is pressed in
PRESS OUTER RACE
Engines Generators
COOLING SYSTEM
2 Apply gasket cement to the contact surface between the 7 Press in the water pump flange using a pipe of the speci
seal and the pump body fied size
3 Apply coolant to the seal
4 Press the seal into the pump body using a pipe of the
speci fied size A CAUTION
a Use a pipe with an inner diameter greater than
075 in 19 mm and an outer diameter of less
A CAUTION than 118 in 30 mm
a Check to be sure that there is no oil on the b Press in the flange until the length of the pro
seals sliding surface truding portion is about 0413 in 105 mm
b Using a pipe with an inner diameter of 11 in
27 mm or more press in the seal making
sure it goes in straight
5 Dry off both the seal and the impellers sliding surface
with compressed air
Installation
The coolant pump installation sequence is the reverse of the
removal Press the impeller onto the A CAUTION
a When preSSing make sure the lower edge of
the shaft rests on a block
b Press the water pump impeller until its edge is
flush with the shaft
c After installing check that the impeller can
be easily moved by hand
Engines Generators
COOLING SYSTEM
RAW WATER PUMP NOTE It may be necessary to use a drift and arbor press
to press the bearing and seal assembly from the shaft
NOTE Since completely rebuilding a damaged or worn pump
from individually purchased parts would almost match the 6 Inspect all parts and replace those showing wear or
price of a new pump Westerbeke recommends that a new erosion
pump be disassembling the raw water pump inspect the pump
by rotating the drive shaft If it is rough frozen or seems to
A CAUTION If any of the vanes have been bro
ken off the impeller they must be found to prevent
have excessive play a major overhaul may be needed
blockage in the cooling circuit They often can found in the heat pump as removed
from the engine will have nipples threaded into its inlet and outlet ports 7 Use the illustration to assist in reassembling the raw water
The nipples may be left in place or removed if they interfere pump
with the pump disassembly Note the port location and posi a Apply a small amount of petroleum jelly to the if removed
surface and to the impeller shaft at Loosen the set screw with an allen wrench and remove
b When positioning the cam in the housing use a small
the water pump pulley from the shaft taking care not to amount of Permatex 1 on the inner cam surface and
lose the key cam screw head remove any excess from the impeller
2 Remove the four impeller cover screws the impeller housing
cover and its gasket c Apply a light film of silicon or petroleum jelly to the
NOTE Replacement of the impeller cover gasket is inner surface of the housing for the impeller
recommended however if you are going to reuse it keep d Apply a thin coating of lubricant to the impeller cover
the gasket well lubricated until the pump is reassembled gasket
If it allowed to dry the gasket will shrink and not be
S When the pump is assembled reposition and tighten the
reusable
hose nipples into the pump housing use Teflon sealant on
3 Pull out the impeller with longnose pliers or a pair of the nipple thread Assemble the pump to the engine and
screwdrivers attach the hoses and the belt
4 Remove the cam screw and cam
5 Remove the bearing housing releasing the shaft bearing IMPELLER
COVER
and seal assembly This will allow the bearing and seal
assembly to be inspected
CAM SCREW RAW WATER PUMP
Engines Generators
FUEL The fuel system uses 5hole type injection nozzles and combustion chamber improving combustion and
an inline injection pump Bosch type The injection increasing power
pump generates a high injection pressure of 2417 lbin 2 The fuel which is drawn up through the fuel filterwater
170 kgcm and the fuel is injected from the injection separator from the fuel tank is filtered and then supplied
nozzles as a fine spray and at a wide angle into the to the injection pump
FUEL FILTER
FUEL
INJECTION
PUMP
FUEL THE FUEL FILTER
1 Shut off the fuel supply
2 Open the bleed screw on the top of the filter Place a con
tainer under the fuel filter and open the drain on the bot
tom of the bowl and drain the fuel
3 Close the drain and unscrew the bolt that secures the
bowl The bowl and the filter will drop down
4 Clean the base Install a new sealing ring in the base
making certain that it lies squarely on the base recess
5 Replace the upper sealing ring and the oring in the filter
head Install the new filter element and reinstall the
retaining bolt
NOTE Apply fuel to the seal rings and oring before
Bleed the air from the filter assembly
FUEL FILTER
Engines Generators
FUEL SYSTEM
FUEL FEED PUMP STRAINER Bleeding air from the fuel line between the
ed fuel filter and the injection pump
An additional fuel screen is located in the feed pump This
screen strainer is removed for cleaning by releasing the 1 Confirm that the plugs on the fuel filterwater bolt at the bottom This screen
should be cleaned every are closed and that the fuel lines are operating hours Use compressed air andor clean with 2 Tum
the fuel lift pump primer to re
kerosene lease it
3 Disconnect the fuel return hose
TO FUEL l
FUEL IN
FUEL FEED
PUMP STRAINER
4 Repeatedly depress and release the primer until only fuel
BLEEDING THE FUEL SYSTEM no air bubbles flows out of the air bleeding plug hole
If air is present in the fuel lines the engine may be difficult 5 Connect the fuel return hose
to start there may be insufficient power or hunting may oc 6 Depress the primer and tum it clockwise to lock it
cur when idling
Air bleeding must be performed after the injection pump
has been installed and after checking or adjusting the injec A CAUTION If hunting occurs when idling or
tion timing there is less engine power after air bleeding then
Bleeding air from the fuel line between the fuel tank and loosen the injector ends of all fuel lines and bleed
the fuel filter air by using the engine starter to crank the engine
until only fuel comes out
1 Confirm that the plugs on the fuel filterwater separator
are closed and that the fuel lines are connected After bleeding the air start the engine and check
for fuel leaks
2 Tum the primer on the fuel lift pump to release it
3 Loosen the air bleeding plug on the fuel filter
4 Repeatedly depress and release the primer until only
fuel no air bubbles flows out of the air bleeding plug
hole
5 Retighten the air bleeding plug
6 Depress the primer and tum it clockwise to lock it
LOOSEN THE INJECTOR ENDS OF AU FUEL LINES
Engines Generators
FUEL THE FUEL INJECTORS Fuel Injector The fuel injectors must be serviced in a clean room
The fuel injector consists of the following the Fuel Injectors
1 Disconnect the high pressure fuel lines from the injectors
then loosen the lines at their attachment to the injection
pump and move them out of the way of the injectors fi
NOZZLE BODY
GUmMl
Avoid bending the lines
2 Remove the fuel return line in its entirety from the top of
the injectors Take care not to lose the two sealing wash NEEDLE VAlVE
ers and banjo bolt that attaches the fuel return line to
each injector DISTANCE PIECE
3 Remove the fuel injector holder bracket mounting nuts
then remove the holder brackets PRESSURE PIN
4 Remove the fuel injectors PRESSURE SPRINGB
NOTE Clean the area around the base of the injector
prior to lifting it out of the cylinder head to help prevent
SHIM
any rust or debris from falling down into the injector
NOZZLE HOLDER
hole If the injector will not lift out easily and is held in
by carbon buildup or the like work the injector sideto FUEL INJECTOR
COMPONENTS
side with the aid of the socket wrench to free it and then
lift it out
The injector seats in the cylinder head on a copper seal
ing washer This washer should be removed with the
injector and replaced with a new washer when the injec
tor is reinstalled Checking the Injection Starting Pressure
5 Remove the gaskets 1 Set the nozzle tester in a clean place where there is no
dust or dirt
6 Remove the Orings HIGH PRESSURE
lINE 2 Mount the nozzle and the nozzle holder on the nozzle
tester
fJ
3 Use new fuel that has an approximate temperature of
FUEL 68F 20C
INJECTOR
4 Bleed the air in the nozzle line by pumping the nozzle
tester handle several times
5 Slowly lower the nozzle tester handle and check the read
ing on the pressure gauge when the injection starts
Injection starting pressure
2417 24891bin2 170 175 kglcm2
A CAUTION The spray nozzle velocity is such
that it may penetrate deeply into the skin of the
fingers and hands destroying tissue If it enters the
bloodstream it may cause blood REMOVING THE FUEL Engines Generators
FUEL SYSTEM
Inspecting the Spray Pattern
1 Mount the nozzle and nozzle holder on the nozzle tester
2 Bleed the air in the nozzle line by pumping the nozzle
tester handle several times
3 Keep the reading on the pressure gauge of the nozzle
tester just below the injection starting pressure while
pumping the handle of the nozzle tester as quickly as
possible so that a pulsating whistling sound is heard
Check the atomization of the fuel injected from the noz
zle see FUEL
INJECTOR
INJECTION PRESSURE TEST
6 If the injection starting pressure is not within the speci
fied range adjust it by replacing the shim with one of a
more appropriate thickness
The shims have 21 different thicknesses at intervals of
0002 in 005mm from 00197 in 050mm to 0059 in NORMAL FAULTY FAULTY
150 mm If the thickness of a shim is increased 0002 in PAmRN PATTERN PAmRN
005 mm the injection pressure increases FUEL INJECTOR
SPRAY PATIERNS
711lbin2 50 kgcm2
ADJUSTING SHIM
Normal Pattern The fuel is sprayed uniformly and
finely from all five injection nozzle holes
Faulty Pattern The number of fuel sprays and fineness
of the injected fuel is substandard
If the condition of the injected fuel is substandard disas
semble wash and recheck the injection nozzle or replace it
FUEL INJECTOR ADJUSTING SHIM Checking the Nozzle Body and Needle Valve
1 Check for damage to the valve seat of the needle of the Valve Seat and check for damage to other
parts
Apply a pressure of 2133 lbin2 150 kgcm2 and check if 2 Check for damage to the nozzle body Hold the nozzle
fuel leaks from the injection nozzle holes If fuel leaks disas body upright and insert fourfifths of the needle wash and recheck the
injector nozzle or replace it Then release the needle valve and check that it drops into
the valve seat under its own weight
NOZZLE
BODY
CHECKING THE TIGHTNESS CHECKING THE NOmE BODY AND NEEDLE VALVE
OF THE VALVE SEAT
Engines Generators
FUEL FUEL INJECTION PUMP
Be sure to do the following when reassembling the fuel injector NOTE The fuel injection pump is a very important compo
1 Tighten the nozzle body onto the nozzle holder to the nent of the diesel engine requiring the utmost care in
specified torque handling It has been thoroughly benchtested and the
Nozzle torque 29 36 ftlb 40 50 kgm is cautioned not to attempt to service it If
the fuel injection pump requires servicing remove it and
take it to an authorized Kiki fuel injection pump service
facility
The only adjustment the servicing mechanic should make to
the fuel injection pump are the adjustments for idle speed
see IDLE SPEED ADJUSTMENT under ENGINE
ADJUSTMENTS and injection timing see INJECTION
TIMING ADJUSTMENT below
TIGHTENING THE
NOZZLE BODY ONTO
THE NOZZLE HOLDER
2 After assembling the fuel injector check the injection
starting pressure and the spray fuel injector installation sequence is the reverse of the
removal sequence Make sure to include the following
1 Use new gaskets do not reuse the old gaskets
2 Replace the copper sealing washer for each injector
3 Tighten the fuel injector holder bracket mounting nuts to
the specified torque
Bracket mounting nuts torque
340 400 ftlb 47 55 kgm FUEL INJECTION PUMP
SCRIBE MARK
ALIGN THE SCRIBE MARK ON THE INJECTION PUMP FLANGE WITH THE
SCRIBE MARK ON THE GEAR CASE THIS WILL PLACE THE INJECTION
PUMP IN PROPER TIMING WITH THE ENGINE
TORQUING THE FUEL INJECTOR HOLDER BRACKET
Engines Generator REVISED 12002
STARTER MOTOR
START
SWITCH
BATIERY
CONTROL
SWITCH
FIGURE 1 STARTER WIRING Continuity Check
To independently test the starter it is necessary to remove Disconnect the field lead on the starter from the solenoid M
it from the engine However before doing this checks terminal and insulate it carefully to prevent accidental be made to ensure that
the problem is with the starter Set the transmission in neutral Use a voltmeter to check for
and not with the engine battery wiring or switches When voltage at the solenoid S terminal while the start switch is
the other possible problem sources have been eliminated held in the START position If voltage is not present at the S
then remove and test the starter Comparison of test results terminal use the voltmeter and the wiring diagram to trace
with the chart will aid in isolating the prob the control circuit and locate the point of voltage loss and cor
lem within the starter to specific components This will rect it as the repair or repairs needed to restore the starter to
Starter If the battery wiring and switches are in satisfactory Test
tion and the engine is known to be functioning testing as well as successful operation requires a
remove the starter for further charged battery capable of supplying the current needs Starter NoLoad Test
of the starting system Step one in the start
ing system is to test the battery Follow the battery manufac With the starter removed from the engine the noload test
turers instructions can reveal damage that can be corrected by repair or it may
indicate the need for component testing after the starter is dis
Wiring and Switches assembled Repair and component test procedures are
VISual Inspection described in the UNIT REPAIR section The noload test is
also used to test units for normal operation after repair or
Visually inspect all wiring and switches in the starting cir overhaul Comparison of test results with the Trouble
cuit for damage and loose or corroded connections This shooting chart will indicate what corrective action if any is
includes all ground connections Clean and tighten the con as required Replace damaged wiring or
Engines Generators
STARTER MOTOR
Test HookUp Figure 2 NOTE During the noload test close the switch and the starter for the noload test
as shown in the the starter for cycles of 30 seconds maximum using suitable instruments battery cables and con cycles allow the
starter to cool for at least two minutes oth
necting wiring Do the following erwise overheating and damage to the starter may result
1 Secure the starter in a suitable test stand to check its 1 Momentarily close the switch
operation a If there is a high current flow and the starter fails to
2 Use a momentary contact pushbutton switch in the test operate zero rpm release the switch immediately
circuit for a quick release if very high current surges Internal mechanical damage is indicated Discontinue
are encountered the test and refer to Make all connections or with the switch
h If there is no current flow and the starter fails to oper
open and the carbon pile load turned off ate zero rpm release the switch immediately An
open circuit is indicated Discontinue the test and
4 If sparking or current flow in the battery circuit is refer to noted when making the connections the starter sole
noid switch contacts may be frozen shut refer to c If there is a current flow and the starter operates
release the switch and proceed with the next step of
the noload test
5 As the last step in making the test connection ground
the negative battery cable securely to a clean metal 2 Close the switch and observe the voltmeter Adjust the
ground on the starter frame carbon pile load to obtain a 10 volt reading 20 volts on a
24volt starter Observe and record the ammeter and rpm
6 The carbon pile load is used to adjust the operating readings Release the switch
voltage for comparison with It may not
be necessary in all cases but should be used to elimi 3 Compare the ammeter and rpm readings to those listed
nate the need for interpolation of test data under at the end of this section If
the readings are outside the limits shown refer to
Test Procedure to determine the most likely
causes If the readings are within the limits the starter
is operating normally
A CAUTION Keep fingers and tools away from the
opening in the DE drive end housing while testing
The strong shifting action of the solenoid could cause
personal injury or damage as the drive pinion moves
into the cranking position and spins
VOLTMETER
CLAMP ON
AMMETER
SWITCH
CARBON
PILE
FIGURE 2 STARTER NOLOAD TEST HOOKUP
Engines Generators
STARTER ble cause and its remedy The problems listed in the chart
If the results of the noload test are outside the limits refer apply specifically to the noload test and do not the following chart
for the proba apply to operation under other PROBLEM PROBABLE
CAUSE Normal current and speed a Starter OK a
Recheck battery switches and wiring
including battery cable loss Check if
starter operation on engine is slow or
sluggish
Current flow with test circuit switch open a Solenoid switch contacts stuck closed a Test and if necessary replace solenoid
assembly
Failure to operate with very low or no a Open solenoid wiring a Inspect and test solenoid assembly
current b Inspect and test frame and field assembly
b Open field circuit
c Open armature coils or high insulation c Inspect armature
between commutator bars
d Broken brush springs or worn brushes d Inspect brushes and brush springs
Failure to operate with high current a Frozen bearing or other damage to drive a Inspect bearings armature drive shaft
train and related drive parts
b Direct ground in terminals or fields b Inspect and test frame and field assem
bly solenoid assembly armature and
brush installations for shorts
Low speed with high current a Excessive friction in bearings or gear a Inspect bearing armature drive shaft
reduction unit bent armature shaft or and gear reduction gears
loose pole shoe bent drive shaft
b Shorted armature b Inspect and test armature
c Grounded armature or fields c Inspect and test frame and field coil
assembly and armature
Low speed with normal or low current a High internal electrical resistance caused a Inspect internal wiring electrical connec
by poor connections defective leads or tions and armature commutator
dirty commutator
b Causes listed under Failure to operate b Remedies listed under Failure to operate
with very low or no current with very low or no current
High speed with high current a Shorted fields a Inspect and test field and frame assembly
Refer to the UNIT REPAIR section for required disassembly inspection test and if necessary repair or replacement REPAIR
This section provides instructions for complete disassembly
of the starter as would be the case for overhaul If the starter
NOTE Always install fasteners at their original locations is not due for an overhaul and repair affecting specific parts
If it is necessary to replace fasteners use only the correct only is required the starter may be disassembled only to the
part numbers or equivalent If the correct part number is not extent necessary to gain access to these parts Parts use only
afastener of equal size and strength Use from the starter as subassemblies or groups need not be dis
a torque wrench to tighten fasteners when a torque value is assembled for such limited repair unless they contain Torques
specified are for dry unlubricated fasten affected parts Total disassembly is recommended however
ers unless otherwise specified to ensure that all parts can be thoroughly cleaned
3 In this section the
starter is broken down by main 3 shows the starter broken down into its component These groups are then disassembled into
individual parts and
parts and assemblies Do not attempt to disassemble the fol assemblies Illustrations accompany the text to show components which
are serviced as assemblies operations To see the parts relationship of the complete
starter refer back to Figure 3
Solenoid assembly 1
To begin make a mark completely down one side of the
Clutch Drive assembly 2 starter to ensure proper alignment of all its components at
Brush Holder assembly 3 assembly Use a colored pencil or marker that will show on
Armature assembly 13 all parts
Frame and Field assembly 19
Engines Generators
STARTER MOTOR
30 31 32 15 12 I
2223
6l O
1 SOLENOID ASSEMBLY 10 7
2 CLUTCH DRIVE
ASSEMBLY 6
3 BRUSH HOLDER 2
ASSEMBLY 21
4 BRUSH GROUNDED
5 BRUSH INSULATED
6 DE HOUSING 18
BUSHING 21 SHIFT LEVER SCREW
7 BRUSH SPRING 22 SHIFT LEVER WASHER 34
8 DE ARMATURE 23 SHIFT LEVER NUT
BEARING 25 SOLENOID SCREW
9 CE ARMATURE 26 PLATE IF USED
BEARING 27 DRIVE HOUSING PLUG
10 CENTER SUPPORT 28 DOWEL PIN
BEARING 29 INSULATED BRUSH SCREW
11 SHIFT LEVER 30 WASHER FIBER
12 PINION STOP 31 WASHER THIN ONE OR
13 ARMATURE TWO MAY BE USED
14 CE FRAME 32 WASHER THICK
15 DRIVE SHAFT 33 FRAME SEAL
16 ARMATURE SUPPORT 34 BUSHING PLUG IF USED
BRACKET 35 STOP RING
17 DRIVE SHAFT 36 DRIVE HOUSING BOLT LONG
SUPPORT 37 DRIVE HOUSING BOLT
18 DRIVE HOUSING SHORTER ON SOME MODELS
19 FRAME FIELD 39 GROUNDED BRUSH SCREW
ASSEMBLY 41 THRU BOLT
20 CE FRAME ORING 42 BRUSH PLATE SCREW
FIGURE 3 STARTER ASSEMBLY
Engines Generators
STARTER MOTOR
General Disassembly 5 Frame field and brush holder group A dowel pin 28
Figure 4 and frame seal 33
Remove or Disconnect a The armature assembly 13 may come off with the
frame field and brush holder group A or may be
1 The motor lead on the frame field and brush holder
retained by the gear reduction and drive group B
group A from the solenoid assembly 1 Reinstall the
nut on the solenoid terminal 6 Armature assembly 13 with bearings 8 and 9
a Remove the nut on the solenoid slip off the motor a Do not remove the bearings from the armature
lead and reinstall the nut assembly unless replacement is required refer to
CLEANING INSPECTION AND REPAIR
2 Thru bolts 41
7 Solenoid screws 25
3 Brush plate screws 42
8 Solenoid assembly 1
4 CE frame 14 and Oring 20
a Pivot the inside end of the solenoid assembly 1 out
Important
of engagement with the shift lever in the gear
a In the following step use care not to lose the small reduction and drive group B and withdraw the
dowel pin 28 installed between the frame field and solenoid assembly
brush holder group A and the gear reduction and
drive group B This dowel pin is required for
assembly and must be saved If the dowel pin
should be lost it must be replaced with a 2 mm
0079 in dia x 10 mm 0394 in long pin pro
cured or manufactured locally
42 4 25
1 SOLENOID ASSEMBLY
8 DE ARMATURE BEARING 9
9 CE ARMATURE BEARING
13 ARMATURE ASSEMBLY
14 CE FRAME
20 CE FRAME ORING
25 SOLENOID SCREW
28 DOWEL PIN
33 FRAME SEAL
41 THRU BOLT
42 BRUSH PLATE SCREW
A FRAME FIELD BRUSH HOLDER GROUP
B GEAR REDUCTION DRIVE GROUP
FIGURE 4 ELECTRICAL GROUP
Engines Generators
of Frame Field and Brush Holder Group
Figure 5
Remove or disconnect
1 Insulated brush screws 29
a Move the brush holder assembly 3 with the brush
es 4 and 5 away from the frame and field assem
bly 19 slightly to reach across with a screwdriver
and remove the screws 29
2 Frame and field assembly 19
3 Grounded brush screws 39
19 FRAME FIELD
4 Brushes 4 and 5 if replacement is required 3 BRUSH HOLDER
ASSEMBLY ASSEMBLY
a Grasp the brush end of each brush spring 7 with 4 BRUSH GROUNDED 29 INSULATED BRUSH
needle nose pliers twist the spring end away from 5 BRUSH INSULATED SCREW
the brush 4 or 5 and withdraw the brush 7 BRUSH SPRING 39 GROUNDED BRUSH
SCREW
5 Brush springs 7 if replacement is required
a Grasp the brush end of each brush spring 7 with FIGURE 5 FRAME FIELD AND BRUSH HOLDER GROUP
needle nose pliers twist the spring end away from
the brush socket on the brush holder assembly 3
and remove the spring 11
NOTE At this stage of disassembly all electrical com
ponents can be inspected and if required tested as specified in CLEANING INSPECTION AND
of Gear Reduction and Drive Group
Figure 6
Remove or I
1 Housing bolts 36 and 37 18
2 Armature support bracket 16 Grf
Important 30
a The washers 30 through 32 may stick to the arma
ture support bracket or to the drive shaft and clutch
group C as the armature support bracket is 31
removed In either case note the position and num 32
ber of each of these washers
3 Washers 30 through 32 21
a Save the washers they are to be installed in the same
6 DE HOUSING BUSHING
position and number at assembly 11 SHIFT LEVER
4 Drive housing plug 27 and plate 26 16 ARMATURE SUPPORT
BRACKET
a Pry out the drive housing plug using a large screw 18 DRIVE HOUSING 32 WASHER THICK
driver 21 SHIFT LEVER SCREW 34 BUSHING PLUG IF
5 Shift lever nut 23 washer 22 and screw 21 22 SHIFT LEVER WASHER USED
23 SHIFT LEVER NUT 36 DRIVE HOUSING BOLT
6 Remove the shift lever 11 and the drive shaft and 26 PLATE IF USED LONG
clutch group C from the drive housing 18 together 27 DRIVE HOUSING PLUG 37 DRIVE HOUSING BOLT
then separate them 30 WASHER FIBER SHORTER ON SOME MODELS
a Do not remove the bushing plug 34 or the bushing 31 WASHER THIN ONE OR C DRIVE SHAFT CLUTCH
6 from the drive housing 18 unless replacement TWO MAY BE USED GROUP
is required refer to CLEANING INSPECTION AND
REPAIR FIGURE 6 GEAR REDUCTION AND DRIVE GROUP
Engines Generators
STARTER of Drive Shaft and Clutch 7 and of the drive shaft and clutch group is not
required unless it is necessary to clean inspect or replace
one or more parts of the group separately Then proceed or Stop rings 35 and pinion stop 12
a Position the drive shaft and clutch group on the work
bench with the internal gear end down
b Using an open tube slightly larger than the shaft see
Figure 8 drive the pinion stop 12 toward the
clutch drive assembly 2 until it clears the stop rings
35 2 CLUTCH DRIVE 10
ASSEMBLY 15 DRIVE SHAFT
c Using care not to scratch the drive shaft 15 pry the 10 CENTER SUPPORT 17 DRIVE SHAFT
stop rings out of the shaft groove and slide them off BEARING SUPPORT
the end of the shaft 12 PINION STOP 35 STOP RINGS 2 PCS
d Inspect the edges of the shaft groove for burrs that
may have been formed through repeated cranking FIGURE 7 DRIVE SHAFT AND CLUTCH GROUP
cycles Such burrs may make removal of the pinion
stop and clutch drive assembly 2 difficult If burrs
are found use a suitable file to carefully remove the
burrs only not the base metal Thoroughly clean
away metal filings
e Slide the pinion stop 12 off the drive shaft 15
Discard the old pinion stop 12 and stop rings 35
New parts must be used at assembly
2 Clutch drive assembly 2 from drive shaft 15
3 Drive shaft support 17 from drive shaft 15
a Do not remove the bearing 10 from the drive shaft
15 unless replacement is required refer to CLEAN
ING INSPECTION AND REPAIR
142 MM
056 IN DIAfa 22 MM
087 IN DIA
OPEN
TUBE
STOP 12
DRIVE SHAFT 15
FIGURE 8 REMOVING PINION STOP
Engines Generators
STARTER INSPECTION TESTING AND REPAIR 6 Brushes 4 and 5 for excessive
a The minimum allowable brush length is 12 mm
0472 in Replace excessively worn brushes in
NOTE Do not clean or immerse starter parts in grease dis sets
solving solvents Solvents will dissolve grease packed in the
drive assembly and may damage the armature or field coil 7 The DE housing bushing 6 for scoring or other
age Replace a damaged bushing refer to REPAIR
8 Ball bearings 8 9 and 10 as follows
1 All starter parts with a soft cloth prior to testing
a Hold the armature 13 or drive shaft 15 and rotate the outer bearing race by hand
Figure 3
b Check that the bearing turns freely without binding or
Inspection in the following steps refers to visual inspection
the feel of flat spots
of the starter parts and assemblies to determine their Electrical tests for certain assemblies are described in c Replace damaged bearings
refer to ELECTRICAL TESTING 9
Armature assembly 13 for the following
1 All parts for cracks distortion other structural damage a Gear teeth that are broken or that show evidence of
Replace parts or assemblies which are cracked bent or step wear or root otherwise damaged
b Rough commutator surface Polish with a No 400
2 Threaded parts for stripped crossed or otherwise dam grit polishing cloth if necessary Thoroughly clean
aged threads Replace parts with thread damage that metal dust from between the commutator bars If the
cannot be cleaned up using a suitable tap or die commutator surface cannot be repaired in this man
Replace any hardware items that have damaged threads ner replace the armature assembly Do not tum the
commutator in a lathe
3 The solenoid assembly 1 for a cut or tom boot If the
boot is damaged replace the solenoid assembly c Worn commutator Replace the armature assembly if
the commutator OD is less than 35 mm 1378 in or
4 The clutch drive assembly 2 for the following
if the undercut depth at any point is less than 02 mm
Replace the clutch drive assembly if damaged 0008 in Do not undercut the insulation
a Pinion gear turns roughly or turns in both directions 10 Drive shaft 15 for the following Replace the drive
b Pinion gear teeth broken or showing evidence of shaft if damaged
step wear
a Scored or damaged shaft where it turns in the
c Deep scoring or other damage to the shift lever collar bushing 6
5 The brush holder assembly 3 for the following b Internal gear with teeth broken or showing evidence
Replace the brush holder if damaged of step wear
a Loose riveted joints c Damaged spline The clutch drive assembly must
b Cracked or broken insulation slide smoothly and easily over the full length of the
spline
Engines Generators
STARTER Electrical Testing 9 and 10
the following electrical tests on the solenoid assem
bly 1 armature assembly 13 and frame and field assem
bly 19 to determine their Using a suitable ohmmeter check the windings of the
solenoid assembly 1 for continuity as follows
a Check the resistance of the solenoid pullin and
holdin windings in series by measuring the resist
ance between the motor terminal see Figure 9 and
the solenoid case The resistance should be approxi
mately 095 ohms for 12volt starters and approxi
mately175 ohms for 24volt starters
b An extremely high resistance reading indicates a
break or fault in the winding continuity A very low
resistance reading indicates a short or ground in the
winding circuit Either condition is cause for MOTOR
TERMINAL
replacement of the solenoid assembly
2 Check the armature 13 as follows for shorts opens or FIGURE 9 SOLENOID TERMINALS
grounds using suitable test equipment and instruments
test lamp must be 110 volts or less
a Rotate the armature in a growler holding a steel strip
such as a hacksaw blade against the armature If a
short circuit is present the steel strip will vibrate in
that area
b Check the armature for grounds using a test lamp or
ohmmeter There shall be no continuity between the
armature shaft and any point on the commutator
c Check for opens by visually inspecting the points
where the armature conductors join the commutator
A poor connection often will be indicated by signs of
arcing or burning of the commutator
d Replace armatures which are shorted grounded or
show evidence of opens
3 Check frame and field assembly 19 for grounds or
opens using a test lamp 110 volts max or ohmmeter
as follows
a Check that there is continuity no opens between
the field terminal that connects to the solenoid and
the connection points for the insulated brushes on
the field coil straps
b Check that there is no continuity no grounds
between the frame and the field terminal that con
nects to the solenoid
c Replace frame and field assemblies that have
grounds or opens FIGURE 10 FRAME AND FIELD ASSEMBLY
Engines Generators
STARTER MOTOR
Repair Procedures Remove or 3 and 11 a The
center support bearing 10 from the drive shaft
1 If necessary replace the bearings 8 and 9 Figure 3 on 15 using a locally fabricated tool as shown in
the annature 13 as follows Figure 11
NOTE Ball bearings which are removedfrom the Install or Connect
armature must be replaced with new bearings The b The center support bearing 10 from the drive shaft
removal procedure causes internal damage to the 15 using a locally fabricated tool Figure 11 With
bearings the drive shaft in a suitable support fixture place the
Remove or disconnect tool bolt ends through the access holes in the wide
end of the drive shaft and squarely press the bearing
a CE andor DE bearings 8 andor 9 from the shaft
off of the surface on the center shaft
of the annature 13 using a suitable bearing puller
3 If necessary replace the bushing 6 Figure 3 in the
Install or Connect
drive housing 18 as follows
b New CE andor DE bearings 8 andor 9 to the
a From inside the drive housing 18 drive out the
annature assembly 13 using a tube that bears on
plug 34 if present Use a file to clean away rem
the bearings inner race only Press on the bearing
nants of the old stake to allow installation of a new
until the inner race bottoms out against the shoulder
plug Clean away any metal shavings
on the annature shaft
b Using a suitable open tube press out the bushing 6
2 If necessary replace the center support bearing 10
Figure 3 on the drive shaft 15 as follows c Using a suitable open tube press the new bushing
6 into the drive housing 18 until the end of the
NOTE Ball bearings which are removedfrom the bushing is flush with the inside of the housing
drive shaft must be replaced with new bearings The
removal procedure causes internal damage to the d Install a new plug 34 if used to the drive housing
bearings Stake housing material over the plug at three places
equally spaced
TOP VIEW SIDE VIEW PRESS
MATERIALS NEEDED
PIECE OF FLAT METAL STOCK ABOUT 5MM OR 316 IN CENTER
SUPPORT
THICK AND 55 MM OR 2 14 IN SQUARE OR ROUND
BEARING
THREE 6 MM OR 316 IN BOLTS OF EQUAL LENGTH
LONG ENOUGH TO EXTEND AT LEAST 35 MM 1 38 IN CENTER
BELOW THE FLAT STOCK WHEN INSTALLED THROUGH SHAFT I
IT TO USE NUTS INSTEAD OF TAPPED HOLES USE
LONGER BOLTS TO COMPENSATE FOR NUT THICKNESS
1 LOCATE THREE HOLES EQUALLY AROUND A 32 MM
126 IN CIRCLE ON FLAT STOCK DRILL AND TAP
HOLES AS NEEDED TO MATCH BOLT THREADS
2 INSTALL BOLTS IN FLAT STOCK AND TIGHTEN ENDS
OF INSTALLED BOLTS SHOULD PASS THROUGH
ACCESS HOLES IN END OF DRIVE SHAFT WITHOUT BINDING
FIGURE 11 TOOL FOR REMOVING CENTER SUPPORT BEARING
Engines Generators
STARTER 1 Lubricate the DE housing bushing shift lever and
drive shaft as described under LUBRICATION During Assembly ASSEMBLY
1 The armature bearings 8 and 9 Figure 3 and drive shaft Install or Connect
support bearing 10 are pennanently lubricated Do not
add lubricant to these bearings Lubricate the following 2 The arms on the shift lever 11 with the shift collar on
just before or during assembly avoid excessive grease the drive shaft and clutch group C
3 DE housing bushing 6 in drive housing 3 The assembled shift lever 11 and the drive shaft and
clutch group C into the drive housing 18 aligning the
b The pivot hole and working surface on the ends of holes in the drive shaft support 17 Figure 7 with those
the shift lever 11 in the drive housing
c The internal gear shaft and spline on the drive shaft 3 Make sure that the drive shaft support is fully seated
15 in the drive housing and that the drive shaft bearing
Drive Shaft and Clutch Group 10 Figure 7 remains fully seated in the drive 7 and 12
support
1 If disassembled position the drive shaft on the work sur 4 Shift lever screw 21 washer 22 and nut 23
face with the internal gear end down and assemble the Tighten
drive shaft and clutch group as follows
3 Nut to 45 Nm 40 lbin
Important
5 The plate 26 if used and the drive housing plug 27
3 If the center support bearing 10 is being replaced to the drive housing 18
install it on the drive shaft 15 as specified in REPAIR
PROCEDURES step 2 before proceeding with 6 Washers 30 through 32 in the same number and posi
assembly tions as noted at or Connect 7 The
armature support bracket 16 to the drive housing
18 aligning the mark made prior to disassembly with
1 The drive shaft support 17 to the drive shaft 15 seat that on the drive housing
ing the bearing 10 in the support
S Drive housing bolts 36 and 37
2 The clutch drive assembly 2 to the drive shaft 15
3 A new pinion stop 12 onto the drive shaft 15 the end METAL BLOCK APPROX
with the recess for the stop rings 35 up 9 MM 316 IN
3 Install the stop rings 35 in the groove in the drive
shaft 15
b Pick up and support the assembly under the pinion
stop 12 A metal block with a Ushaped cutout
that will slide over the shaft between the pinion gear
and the stop can be clamped in a vise to provide
support see Figure 12
c Make sure the stop rings 35 in the drive shaft APPROX
groove are fully seated in the pinion stop recess and 38 MM 1 12 IN
stake the upper edge of the pinion stop 12 over the
stop ring 35 at four places equally spaced Do not
allow staked metal to contact the drive shaft of Gear Reduction and Drive Group
Figure 6
Important
If the DE bushing 6 and plug 34 are being replaced
install them in the drive housing 18 as specified in
REPAIR PROCEDURES step 3 before proceeding with
assembly FIGURE 12 PINION STOP SUPPORT BLOCK
Engines Generators
STARTER of Frame Field and Brush Holder Group NOTE The brush leads may be damaged by 5 13 and 14
handling Do not overjlex the leads near the clip welds or
the clips may break off
BRUSH HOLDER 2 Brushes 4 and 5 if removed
ASSEMBLY a See Figure 14 for the proper installed position of all
SPRING
brushes Make sure the insulated brushes 5 go into
the brush sockets of the brush holder assembly 3
that are mounted on the insulation
b To install each brush grasp the free end of the brush
spring with needle nose pliers twist clockwise to
clear the brush socket and insert the brush partly into
the brush socket
c Gradually release the spring so that its end contacts
SPRING POST BRUSH
SOCKET
the side not end of the brush see Figure 13 This
will hold the brushes retracted until after the brush
FIGURE 13 BRUSH SPRING ON POST holder is installed over the armature commutator
3 Grounded brush screws 39
Install or Connect a Position the terminals of the grounded brush leads
behind the terminal tabs on the brush holder 3 see
1 Brush springs 7 if removed
Figure 13
a Start each brush spring onto the post on the brush
b Insert the brush screws 39 through the terminal
holder assembly 3 as shown in Figure 13 just
tabs on the brush holder and thread them into the
enough to hold the inside end of the spring from
brush lead terminals
turning
Tighten
b Grasp the free end of the spring with needle nose
pliers and twist clockwise over the top of the brush c Grounded brush screws to 15 Nm 13 lbin
socket
c Push the spring fully onto the post and release the free
end to engage the notch in the brush socket
INSULATED BRUSH
BRUSH
SPRING
GROUNDED
BRUSH
SPRING
POST
FIGURE 14 SPRINGS AND BRUSHES ON BRUSH HOLDER
Engines Generators
STARTER MOTOR
Important
4 The frame and field assembly 19 to the brush holder
assembly a The Oring can easily be damaged during installa
tion of the CE frame 14 To prevent such dam
a Position the brush holder assembly 3 with age install the Oring as described in the following
installed brushes over the terminal end of the frame steps
and field assembly 19
h Install the Oring on the frame field and brush hold
h Attach the terminals of the insulated brush leads to er group A so that it is against the shoulder on the
the conductors in the frame and field assembly with field frame that will abut the CE frame when
the insulated brush screws 29 installed This is the normal installed position for
Tighten the Oring
c The insulated brush screws to 15 Nm 13Ibin c Carefully roll the Oring out of its normal installed
position up onto the major OD of the field Assembly Allow the Oring to remain in this
position until the
Figures 4 and 15 CE frame is partially the gear reduction and drive group B with the
6 CE frame 14
pinion gear end down and proceed as follows
a Align the marks on the CE frame and frame field assembly 19 Figure 5 made prior
to disas
If the armature bearings 8 and 9 are being replaced install sembly
them on the armature 13 as specified in REPAIR PROCE h Start the CE frame onto the frame and field assem
DURES step 1 before proceeding with assembly bly leaving a gap just slightly larger than the or Connect
ness of the Oring 20
1 Solenoid assembly 1 7 Brush plate screw 42
a Pivot the plunger of the solenoid assembly into a Use a scribe or similar tool to align the tapped holes
engagement with the shift lever in the gear reduction in the brush holder assembly 3 Figure 5 with the
and drive group B screw holes in the CE frame 14
h Position the solenoid assembly mounting flange and Tighten
install the solenoid mounting screws 25 h Brush plate screws to 28 Nm 25
8 Thru bolts 41
c Solenoid screws to 28 Nm 25Ibin a Install the thru bolts and tighten them by hand but do
2 Frame seal 33 not close the gap between the CE frame and the
frame and field assembly where the Oring 20 goes
3 The armature assembly 13 with bearings 8 and 9 into
the gear reduction and drive group B h Roll the Oring 20 back down into its installed
position between the CE frame and the frame and
a Make sure the gear teeth are aligned then seat the
field assembly
bearing 8 on the armature shaft fully into the hous
ing recess c Align the timing ribs on the edge of the CE frame
14 with the timing spots on the frame and field
4 Frame field and brush holder group A
assembly A to assure proper brush alignment
a Place the dowel pin 28 in the hole in the armature Refer to Figure 15 Marks are located in 2 places on
support bracket of the gear reduction and drive the motor but will only match one way
group B
Tighten
h Position the frame field and brush holder group over
d Thru bolts 41 to 85 Nm 75 lbin
the armature assembly 13 align the hole for the
dowel pin 28 and the marks made prior to disas 9 The motor lead on the frame and field assembly 19
sembly and seat in the gear reduction and drive Figure 5
group B a Remove the nut from the terminal on the solenoid
c Twist the brush springs 7 Figure 5 away from the install the motor lead terminal and reinstall the nut
brushes 4 and 5 Figure 5 slide the brushes in to Tighten
contact the commutator on the armature 13
and release the brush springs to contact the ends of h The nut on the terminal of the solenoid assembly to
the brushes 11 Nm 100 lbin
S Oring 20
Engines Generators
STARTER MOTOR
STARTER INSTALLATION CE FRAME
Testing After Repair or repair or overhaul the starter can be tested as speci
fied in the Starter NoLoad Test found in the repair overhaul testing or replacement of the it using the following torques when making the elec
TIMING
trical connections to the starter MARKS
A CAUTION Make sure the negative banery cable
is disconnected at the banery when making the elec
trical connections to the starter Otherwise injury
may result If a tool is shorted at the solenoid bat
tery terminal the tool will heat enough to cause a
skin a Solenoid battery B terminal nut to 18 Nm 13 lbft
b Solenoid switch S terminal nut to 18 Nm
16Ibin FIGURE 15 ALIGNING TIMING MARKS
STARTER Volt models have these NoLoad Test AMPS RPM
VOLTS
Minimum Maximum Minimum Maximum
10 125 190 3000 5600
A1l24 Volt models have these NoLoad Test AMPS RPM
VOLTS
Minimum Maximum Minimum Maximum
20 75 90 3600 5400
Starter Solenoid current consumption
PULL IN WINDING HOLD IN WINDING
RATED VOLTAGE
AMPS VOLTS OHMS AMPS VOLTS OHMS
12 5259 10 017 019 12 14 10 076 081
24 100 125 20 016 020 12 14 20 115 165
Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a
temperature reading indicated by the gauge before electrical
KEY switch and RPM gauge with an ELAPSED TIME
power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and
when the key switch is turned off The temperature gauge
in 1110 hours The panel also includes a WATER TEMPER
will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees
electrical power is restored to the gauge
Fahrenheit an OlL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every
control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines
switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for
installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will
pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 11 kglcm 2
OIL PRESSURE GAUGE THIS GAUGE IS GRADU
ATED IN POUNDS PER SQUARE INCH PSI AND IS
WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED
GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL
ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi
TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem
TEMPERATURE IS 170 190 F77 88C
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OF THE ELAPSED KEY
SWITCH AND SHOULD BE
POWER ONLY TO THE
USED AS A GUIDE FOR
INSTRUMENT PANEL
THE MAINTENANCE
DC VOLTMETER
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED
SHOULD SHOW 13V TO 14V
PREHEAT BUTTON WHEN PRESSED ENERGIZES EXCITER THE FUEL LIFT PUMP THE FUEL AUTOMATIC ALARM ON THE
INJECTION PUMP AND THE ENGINES
AIR INTAKE HEATER IT BYPASSES THE ENGINES OIL COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN
PRESSURE ALARM SWITCH IN ADDITION THIS BUTTON SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES THE
START BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS BUTTON WHEN PRESSED ENERGIZES THE OIL PRESSURE ALARM AN OIL
PRESSURE ALARM SWITCH IS
STARTERS SOLENOID WHICH CRANKS THE ENGINE
THIS BUTTON WILL NOT OPERATE ELECTRICALLY
I LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH MONITORS
THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL THE PREHEAT BUTTON IS PRESSED AND HELD FALL TO 5
10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND
AT THE SAME TIME ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A
PULSATING
SIGNAL
Engines Generators
CAPTAIN CONTROL on PRESSURE or high COOLANT lEMPERATURE The
RPM gauge is illuminated when the KEY switch is turned on
This control panel is equipped with a
and remains illuminated while the engine is in switch an RPM gauge PREHEAT and START but
tons an INSTRUMENT lEST button and three one for ALlERNATOR DISCHARGE one for low
On PRESSURE and one for high ENGINE It also includes an alarm buzzer for low
ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE FALLS
BELOW 5 10 psi 04 07 kgem IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAl THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
RPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAl
PER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY FROM
SOUNDING IS NORMAl ONCE THE ENGINE STARTS AND THE ENGINES OIL
THE REAR OF THE PANEl PRESSURE REACHES 15 psi 11 kgem THE ALARM WILL SILENCE
TEST BUTTON WHEN
PRESSED TESTS THE
ALTERNATOR THE OIL
PRESSURE AND THE
COOLANT TEMPERA
TURE CONTROL CIR
CUITS WHEN PRESSED
THE AlTERNATOR THE
OIL PRESSURE AND
THE WATER TEMPERA
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND
ING THE ALARM
BUZZER
KEY SWITCH PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER
WATER TEMPERATURE
ALARM LIGHT
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUTTON WHEN PRESSED ENERGIZES THE
BUTTON WILL NOT OPERATE ELECTRICAlLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMP AND THE ENGINES
TIME AIR INTAKE HEATER AND BYPASSES THE ENGINES OIL
PRESSURE ALARM SWITCH IN ADDITION THIS BUTTON
ENERGIZES THE START BUTTON
Engnes Generators
CONTROL PANEL Tachometer used in propulsion engine instru a With a handheld tach on
the front of the panels contains two separate electrical circuits with a pulley retaining nut or with a strobetype tach read the
common ground One circuit operates the hourmeter and the front crankshaft pulley rpm at idle
other the tachometer The hourmeter circuit operates on 12 h Adjust the tachometer with a small Phillips type screw
volts alternator charging voltage supplied to the terminal driver through the calibration access hole in the rear of
on the back of the instrument the tachometer Zero the tach and bring it to the rpm
The tachometer circuit operates on AC voltage 68 volts fed indicated by the strobe or hand tach Verify the rpm at
from one of the diodes in the alternator and supplied to the idle and at high speed 30003600 rpm Adjust the input terminal while the
engine is running and as needed
the alternator producing battery charging voltage DC
NOTE Current model tachometers use a coarse adjustment
dial to set the tachometer to the crankshaft pulley rpms The
The following are procedures to follow when calibrating screw is then used for fine tuning
a fault in either of the two circuits in a for the proper DC voltage between and
ADJUSTMENT
1 Voltage present meter is defective repair or replace
2 Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter
TERMINAL
terminal to verify the operation
TjCHltlMETER Inoperative CURRENT TACHOMETER AC for the proper AC
voltage between tachometer and terminal with the engine running
1 Voltage present attempt adjusting meter through calibra
tion access hole No results repair or replace meter
2 AC voltage not present check for proper alternator DC
output voltage
3 Check for AC voltage at tach terminal on alternator to
ground
4 Check electrical connections from tachometer input ter
rpinal to alternator Sticking
1 Check for proper AC voltage between tach inp terminal EARLY MODEL TACHOMETER
and terminal GROUND
TERMINAL
2 Check for good ground connection between meter ter
minal and Check that alternator is well grounded to engine block at
alternator pivot bolt
GROUND
GROUNDl
TERMINAL LIGHT h TACHOMETER INPUT
AC VOLTAGE
TERMINAL
EARLY MODEL Engines Generators
DC ELECTRICAL SYSTEM
12 VOLT DC CONTROL CIRCUIT AIR INTAKE HEATER
The engine has a 12 volt DC electrical control circuit that is The air heater consists of a small heating coil located just
shown on the wiring diagrams that follow Refer to these dia inboard of the air intake silencer housing The coil heats the
grams when or when servicing the DC elec engine intake air It is wired through the preheat system
When PREHEAT is pressed at the control panel this sole
noid will click on and the heating coil will begin to get hot
A CAUTION To avoid damage to the battery charging A CAUTION 00 not keep the air heater on for more
circuit never shut off the engine battery switch while
than 30 seconds
the engine is running Shut off the engine battery switch
however to avoid electrical shorts when working on the No maintenance is required for the air heater
engines electrical minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600 900 Cold
Cranking Amps Care
Review the and then estab
lish a systematic maintenance schedule for your batteries and house batteries
o Monitor your voltmeter for proper charging during
engine operation
o Check the electrolyte level and specific gravity with a
hydrometer
o Use only distilled water to bring electrolytes to a proper
level TO WIRING
o Make certain that battery cable connections are clean and HARNESS
tight to the battery posts and to your engine
AIR INTAKE
o Keep your batteries clean and free of corrosion SILENCER
HOUSING
AIR INTAKE HEATER
A WARNING Sulfuric acid in lead batteries can
cause severe burns on skin and damage clothing Wear
protective gear
Engines Generators
charging system consists of a DC belt driven a voltage regulator an engine DC wiring harness a
A WARNING When testing with a DC circuit breaker and a battery with connecting DC and AC circuits are often mixed together in
Because of the use of integrated circuits ICs the applications Always disconnect a shore power voltage regulator is very compact and is
mounted isolate DC and AC converters and shut down the or on the back of the alternator before
performing DC testing No AC tests should be
made without a proper knowledge of AC circuits
14 GREY
14 BLUE
1 Start the engine
14 BROWN
10 Tachometer 2 After the engine has run for a few minutes measure the
14 PINK starting battery voltage at the battery terminals using a
multimeter set on DC volts
51 AMP 110 RED a1f the voltage is increasing toward 14 volts the
11 OUTPUT tor is working omit Steps 3 through 8 and go to Starter Motor
to Checking the Service Battery on the next page
h1f the voltage remains around 12 volts a problem
exists with either the alternator or the charging circuit
continue with Steps 3 through 8
14 14 MULTIMETER
to Fuel Solenoid
Fuel Lift Pump
51 AMP
ALTERNATOR
TESTING THE STARTING
ENGINE RUNNING
A WARNING A failed alternator can become very
hot Do not touch until the alternator has cooled down GROUND
3 Tum off the engine Inspect all wiring and this section to determine if a with the charging circuit or with the alternator If it is
Ensure that the battery terminals and the engine that the alternator or voltage regulator is faulty connections are tight and clean
have a qualified technician check it
The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery
and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery
or a battery selector switch is usually mounted in the circuit switch when the engine is running
to iselate the batteries so the starting battery is not with the service battery If the alternator is charging the 4 If a battery selector
switch is in the charging battery but not the service battery the problem is in ensure that it is on the correct setting
the service batterys charging circuit and not with the alterna 5 Tum on the ignition switch but do not start the engine
6 Check the battery voltage If the battery is in good the Alternator tion the reading should be
12 to 13 volts
A CAUTION Before starting the engine make certain
that everyone is clear of moving parts Keep away from
sheaves and belts during test Engines Generators
ALTERNATOR
If 12 volts is not present at the EXC terminal trace the
MULTIMETER
wiring and look for breaks and poor connections
Jump the 12 V to the Exc terminal from a known 12V
source and operate the alternator If the voltage output
is 1314 volts the alternator is ok Trace the cause for
12 volts not present at the Exc terminal
Checking the Service Battery
Check the voltage of the service battery This battery should
have a voltage between 13 and 14 volts when the engine is
running If not there is a problem in the service battery
TESTING THE charging circuit Troubleshoot the service battery charging
ALTERNATOR VOLTAGE
IGNITION ON ENGINE OFF circuit by checking the wiring and connections the solenoid
isolator battery switch and the battery itself
GROUND Now check the voltage between the alternator output ter
minal B and ground If the circuit is good the voltage at
the alternator will be the sarne as the battery or if an isola
tor is in the circuit the alternator voltage will be zero If
neither of the above is true a problem exists in the circuit
between the alternator and the battery Check all the con
nections look for an opening in the charging circuit
SERVICE BATTERY
TESTING THE SERVICE
BATTERY ENGINE RUNNING
TESTING THE STARTING
A CAUTION To avoid damaging the altemator diodes
ENGINE RUNNING
ENGINE do not use a high voltage tester ie a megger when
GROUND
perfonning tests on the altemator charging circuit
8 Start the engine again Check the voltage between the
alternator output and ground ALTERNATOR INSPECTION
The voltage reading for a properly operating alternator When rebuilding the engine the alternator should be cleaned
should be between 135 and 145 volts If your alternator and inspected The housing can be wiped off with a solvent
is over or have it repaired at a reliable and the alternator terminal studs should be cleaned with a
service facility wire brush Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness
NOTE Before removing the alternator for repair use a
voltmeter to ensure that 12 volts DC excitation is present Turn the rotor pulley by hand It should tum smoothly
at the EXC terminal if the previous test showed only bat Depending on when the alternator was last serviced the
tery voltage at the B output terminaL brushes may need replacing If the alternator is at all suspect
send it to a service shop for testing and 83
DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING
output and high output alternators are available as
optional equipment on most WESTERBEKE engines can be installed during factory assembly or as
addon equipment at anytime
Dual alternators can be configured to charge two banks of
batteries at the same time or using a battery selector each set of batteries an optional dual alternator has already been factory follow the
WESTERBEKE wiring diagram and the
engine installation the new dual alternator is being added to an existing engine carefully follow the alternator below
1 Disconnect the alternators negative cable from the battery
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse
3 Install the new Attach a new heavy gauge output cables from the
alternators output terminal s Using the cable sizes
indicated
DUAL OUTPUT ALTERNATOR
CHARGING ONE BATTERY
5 Make certain that the batteries negative post ground cable
to the engine block is the same heavy gauge as the
positive cable
6 Mount the regulator to a flat surface in a cool dry location
a Connect the black wire to the ground terminal on the
A CAUTION Do not connect any power source TO
without first grounding the regulator
h Plug the 2pin connector into the alternator make certain
it is firmly seated
c The red battery sense wire should be connected to the
batteries positive post or the positive cable
d The brown wire keyed ignition is the key circuit
which actuates the regulator this wire must connect BATTERY SENSE
TO BATTERY POSITIVE POST
to a switched 12 volt source Refer to the
WESTERBEKE WIRING DIAGRAM for the proper
DUAL OUTPUT ALTERNATOR
CHARGING TWO Engines Generators
DUAL OUTPUT Alternator Testing
NOTE Before make certain that the drive The regulator is functioning properly and the are tight and the batteries are in good condition
are in good Testing 1 Test the voltage at the alternator plug with the engine
offkey on The voltage at the alternator tenninal F and
The red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the always read battery voltage If
battery voltage is not should read the trace the wire for a bad connection
2 Hold a screw driver close 12 to the alternator pulley
The orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field If
volts with the key on If the readings are not the problem may be the brushes worn or the trace the wire for a bad connection
open circuit
The blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output tenninals will vary depending on the
battery charge or ctual indicate 142 volts no load A reading of 126 The readings can vary from 4 to 12 volts WIth the
indicate the alternator is not perfonning properly
key on 0 volts with the key off
Apply a load such as an electric bilge pump the voltage
KEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or less
KEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER VOLTAGE
Ignition Off Ignition On Engine Running
I Brown ovolts 2 12 volts 142 volts When the engine is first started it takes a few moments
A Red 126 volts 12 volts 142 volts for the alternator to kick in and take the load fa
S Orange ovolts ovolts 6 8 volts noticeable change in the sound of the engine
F Blue ovolts 10 11 volts 4 12 volts A slight whine from the alternator when the load is
All Output 126 volts 12 volts 142 volts normal
When the alternator is producing high amperage it will
become very hot
When replacing the alternator drive belts always
purchase and replace dual belts in matched pairs
Engines Generators
gOA FOUR PROPULSION ENGINE
WIRING DIAGRAM 41343
It R D
1148RM
SEE NOTE 2 I
I J
12 VDC
NOTE
AN ONOFF SWITCH
SHOULD BE IN
STALLEO BETWEEN
THE BATIERY AND
t p
ALARM
BUZZER
ADMIRAL
PANEL
STARTER TO DIS
CONNECT THE BAT
TERY IN AN EMER
GENCY AND WHEN
LEAVING THE BOAT
A SWITCH WITH A
CONTINUOUS
RATING OF 300
AMPS AT 12 VDC
WILL SERVE THIS
FUNCTION THIS
SWITCH SHOULD
NOT BE USED TO
MAKE OR BREAK I
0 RED
THE CIRCUIT PI
CAPTAIN
PANEL
UIIP
Engines Generators
gOA FOUR PROPULSION ENGINE
WIRING SCHEMATIC 41343
IZ VlC 17
M
UARTER
PREHEAr
r I I
NOTES
1 TIlls product is protected by a manual reset circuit
breaker located near the starter Excessive current will
cause the breaker to trip and the engine will shut down
The builderowner must be sure that the instrument panel
FUEL SOLENOII wiring and engine are installed to prevent contact
between electrical devices and seawater
2 An OnOff switch should be installed between the battery
and the starter to disconnect the battery in an emergency
and when leaving the boat A switch with a continuous
rating of 300 amps at 12 VDC will serve this function
TIlls switch should not be used to make or break the cir
cuit
3 The pink wire at plug 2 is unused and should be insu
lated Captain Panel only
ADMIRAL
TACHOMETER
PANEL 4 The gray wire at plug 2 is unused and should be insu
lated Admiral Panel only
START o
ALARM
o LEECE NEVILLE 90 AMP ALT
PREHEAT
SWITCH
2U2IIPH
CAPTAIN
PANEL
LAMP
TEST
114 LT BLU
Tl 03
110 RED
51 AMP ALTERNATOR PRESTOLITE 72 AMP ALT
STANDARD ALTERNATOR ON THE
cr 82B cr 4 BRM
CTACtUD
OPTIONAL ALTERNATORS
135A 1l00 1t0A LESTEK AL TERNATOR
AVAILABLE ON THE US a
uc IX 718 tL 82ft IX 100Da 10K XI ONLY
Engines Generators
HURTH HSW INITIAL OPERATION
For safety reasons the transmission is not filled with trans Set the shifting lever to neutral position N Start the fluid during shipment
and the selector lever is tem and let it run long enough in idle to fill the cooler and attached to the actuating shaft
with transmission fluid Shift into gear forward and leaving the WESTERBEKE plant each transmission shifting should
be smooth and positive Direct changes a test run with Dextron III ATF transmission fluid forward to reverse are permissible since the
multiple disc
The residual fluid remaining in the transmission after drain clutch permits changing at high rpm including sudden revers
ing acts as a preservative and provides protection against cor ing at high speeds in the event of for at least one year if properly stored
After initial operation make a visual inspection of the output
coupling oil cooler and hoses and the cable connections to
the tlolAIR VENT
LOCKING THE PROPELLER
Locking of the propeller shaft by an additional brake is not
required use the gear shift lever position opposite your direc
tion of travel for this purpose Never put the gear shift in the
position corresponding to the direction of travel of the boat
L FLUID
FILTER
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without a load such as when the
boat is being sailed being towed or anchored in a river as
OUTPUT well as operation of the engine with the propeller stopped
COUPLING for charging the battery will have no detrimental effects on
HSW MODEL 630 the COOLER NOTE When the boat is being sailed engine
stopped the
gear shift must be in the neutral position The propeller is at
The oil cooler mounted above the transmission provides
idle and can cooling for the transmission fluid Raw water
passes through the tubes of the cooler and discharges over DAILY The transmission fluid is cooled as it flows around the
tubes and back into the transmission o Check the transmission fluid
o Visually check the gear shift linkage and WESTERBEKE RECOMMENDS CARRYING
A SPARE OIL COOLER ABOARD
RAW WATER
CONNECTION
o Start the engine in neutral allowing a few minutes at idle
to warm the fluid
o Shift into gear
NOTE Too Iowan idle speed will produce a chattering noise
from the transmission gear and damper plate In such cases
the idle speed should be increased
TRANSMISSION OIL COOLER
Operating Temperature
The operating temperature of the transmission should FLUID exceed 176F 80C A connection for a
temperature probe
Fill the transmission with Dextron III ATF The fluid level is provided At maximum output of the engine the fluid may
should be up to the mark on the dipstick After checking the reach 220F press the dipstick into the case and tum it to the first 25
operating hours inspect the bell shaft and transmission cooler for leakage The fluid A CAUTION If the transmission fluid
temperature is
should be changed after the first 25 hours and every 300 too high stop the engine immediately and check the
hours thereafter transmission SWITCH
These transmissions are equipped with a neutral This is to prevent the engine from starting in gear
Unless the transmission selector lever is perfectly aligned in
neutral the engine starter will not Engines Generators
HURTH HSW THE TRANSMISSION FLUID Replacing the Fluid
Pour in new Dextron III ATF fluid and check the quantity
with the dipstick
Transmission fluid quantities will vary with the use of cool
ers length of hoses and the angle of the Approximate
Quantities
HSW450 212 quarts 20 Liters
HSW630 32 quarts 30 Liters
HSW630V 42 quarts 40 Liters
Reinsert the filter assembly into the housing Press it in place
ACTUATING and tighten the Allen screw
LEVER
NOTE Some HSW transmissions use a T handle in place of
16mm 8 SCREW a screw on their filter assemblies
After running the engine shut down and recheck the fluid level
A WARNING Never pullout the dipstick while the
engine is running Hot fluid will splash from the dipstick
hole This could cause severe bums
ORINGS
MAINTENANCE
HSW MODEL 450 Transmission maintenance is minimal Keep the exterior
housing clean check the fluid level as part of your regular
routine and change the fluid every 300 operating hours
Periodically inspect the transmission and the cooler for leaks
FILTER ELEMENT and corrosion Make certain the air vent is clear and when
checking the fluid level look for signs of water fluid will appear as
strawberry cream
Element Storage requires special care Follow these Hurth HSW transmission has a filter
element located D Drain water from the transmission oil cooler and the dipstick 1bis filter must be replaced whenever
with a proper mixture of antifreeze coolant
the fluid is changed NOTE This operation will normally occur when the
Remove the filter by loosening the screw on the cover using a engine raw water cooling system is properly Allen wrench
D Clean up the transmission and touch up unpainted areas
Twist and pull out the filter and remove the element Place use heat resistant paint
the new filter onto the cover and lock it into place by turning
it clockwise Check the Orings for damage and replace if D Fill the transmission with Dextn III ATF fluid to the
full mark on the Replacement filters can be obtained from your
local WESTERBEKE dealer or ZF Hurth dealer D Loosen attaching hardware from the transmission output
flange and propeller shaft coupling flange before the Fluid ing the boat from the water
Separate the flanges and
Push a suction pump hose down through the pipe hole under spray with filter to the bottom of the housing and suck out the fluid
D Inspect the gear shift cable linkage and the oil return line from the cooler and allow the oil Look for corrosion of the end
fittings cracks or cuts in
to drain into a container then reconnect the oil return line the conduit and bending of the actuator rods Lubricate
all moving parts
Wipe down the transmission and properly dispose of the used
fluid NOTE If the transmission is to be storedfor a long time
Replacement Filter twelve months or more it should be topped offwith
fluid to prevent internal corrosion Reduce the fluid level
Hurth Part No 500012
before putting the engine back into service
Engines Generators
HURTH HSW CONNECTIONS SHAFT COUPLINGS
The transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible connection between
Upon loosening the retaining screw the actuating lever see the transmission and the propelIer shaft if the engine is can be moved to
any position required for the bly mounted in order to compensate for angular elements cable or rod linkage Make certain that the
The instalIation of a special propelIer thrust bearing is not
actuating lever does not contact the lever hub the minimum required since the propelIer thrust will be absorbed by the
distance between the lever and hub should be transmission bearing provided the value specified under
The control cable or rod should be arranged at a right angle is not exceeded However the output
to the actuating lever when in the neutral position The neu shaft should be protected from additional loads Special care
tral position of the gear shift lever on the control console should be taken to prevent torsional vibration When using a
should coincide with the neutral position of the lever on the universal joint shaft make certain to observe the
turers Positions Even with the engine solidly mounted
the use of a flexible
A PropelIer rotation opposite of engine rotation coupling or DRNESAVER will reduce stress in the gearbox
N Neutral position bearings caused by hull distortions especially in wooden
B PropelIer rotation same as engine rotation boats or where the distance between the transmission output
coupling and stem gland is less than about 800mm
NOTE When shifting to A or B positions make sure the
shift lever travel is sufficient for the lever to contact its stop NOTE When installing the transmission make certain that
N shifting is not impeded by restricted movability of the cable
or rod linkage by unsuitably positioned guide sheaves too
small a bending radius or other restrictions In order to
mount a support for shift control cable connections use the
two threaded holes located on the cable bracket mounted on
the gear housing Refer to the WESTERBEKE parts list
PROPELLER
ROTATION
N NEUTRAL GEAR SHIFT LEVER
B LH
ACTUATING
LEVER
LEVER HUB
1 O02in
ACTUATING rO5mm
LEVER TYPICAL STEERING STATION
A greater amount of actuating lever travel is in no and is recommended However if the lever travel
is shorter proper clutch engagement might be impeded For additional information in turn would mean premature wear excessive
heat HURTH MARINE and clutch plate failure This would be indicated ZF Industries
by slowc1utch engagement or no engagement at all see Marine US CABLES under TRANSMISSION
3131 SW 42nd Fort Lauderdale FL 33312
Tel 954 Check for proper actuating lever travel at least each
Fax 954 A CAUTION The position of the mechanism behind
the actuating lever is to ensure equal
actuating lever travel from Neutral position N to
Reverse position A and Forward position B If this
mechanism is in any way tampered with the transmis
sion warranty will be void
Engines Generators
HURTH HBW 250 NOTE When installing the gearbox make certain that shifting
The 90A Four engine is also being equipped with the HBW is not impeded by restricted movability of the Bowden cable
250 transmission The information below is specific to the or rod linkage by unsuitably positioned guide sheaves too
HBW 250 the TRANSMISSION small a bending radius etc In order to mount a support for
SECTION applies to all models shift control cable connections use the two threaded holes
located above the shift cover on top of the gear OF GEAR BOX WITH PROPELLER Refer to the WESTERBEKE parts list
HBW recommend a flexible connection between the gearbox
CONTROL CABLES
and the propeller shaft if the engine is flexibly mounted in
order to compensate for angular deflections The installation The gearbox is suitable for single lever remote control Upon
of a special propeller thrust bearing is not required since the loosening the retaining screw the actuating lever can be
propeller thrust will be taken by the transmission bearing moved to any position required for the control the value specified under
is not cable or rod linkage Make certain that the shift lever However the output shaft should be protected not
contact the actuating lever cover plate the minimum dis
from additional loads Special care should be taken to pre tance between lever and cover should be 05mm
vent torsional vibration When using a universal joint shaft The control cable or rod should be arranged at right angle to
make certain to observe the instructions the actuating shift lever when in the neutral position The
Even with the engine solidly mounted the use of flexible neutral position of the operating lever on the control reduces stresses in
gearbox bearings caused by hull should coincide with the neutral position of this especially in wooden boats or where the distance
The shifting travel as measured at the pivot point of the actu
between gearbox output flange and stem gland is less than ating lever between the neutral position and end positions A
about 800mm and B should be at least 35mm for the outer and 30mm for
the inner pivot point
A greater amount of shift lever travel is in no way
detrimental and is recommended However if the lever travel
is shorter proper clutch engagement might be impeded
which in tum would mean premature wear excessive heat
generation and clutch plate failure This would be indicated
by slow clutch engagement or no engagement at all
NOTE Checkfor proper lever travel at least each season
FORWARD B A REVERSE
SHIFT
LEVER
ATF DRAIN
A CAUTION The position of the mechanism behind
the actuating lever is to ensure equal
actuating lever travel from Neutral position N to
Reverse position A and Forward position B If this
mechanism is in any way tampered with the transmis
sion warranty will be void
MAKE CERTAIN THIS
LEVER IS TIGHTLY
FASTENED TO THE
SHAFT
Engines Generators
HURTH HBW 250 OPERATION OPERATING HBW marine transmissions are testrun on a test stand
The maximum permissible ATF temperature should not
with the engine at the factory prior to delivery For safety exceed 230F 1lOC This temperature can only be the fluid is drained before
shipment for a short time
Fill the gearbox with Automatic Transmission Fluid
DEXRON II or DEXTRON ill The fluid level should be
up to the index mark on the dipstick To check the fluid level
just insert the dipstick do not screw it in Screw the dipstick
A CAUTION If the transmission fluid temperature is
too high stop the engine immediately and check the
into the case after the fluid level is checked and tighten Do
not forget the sealing ring under the hexhead of the dipstick
transmission fluid
Check for leaks and change the fluid after the first 25 hours
also make a visual inspection of the coupling oil cooler and
hoses and shift cables LOCKING THE PROPELLER
Locking of the propeller shaft by an additional brake is not
required use the gear shift lever position opposite your direc
tion of travel for this purpose Never put the gear shift in the
position corresponding to the direction of travel of the boat
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without load such as when the boat is
being sailed being towed or anchored in a river as well as oper
ation of the engine with the transmission in neutral for charging
the battery will have no detrimental effects on the FLUID LEVEL DAILY OPERATION
o Check the transmission fluid
o Visually check the gear shift linkage and TO CHECK TRANSMISSION o Start the engine in
neutral allowing a few minutes at
FLUIO IN OPERATION idle to warm the fluid
FLUID CHANGE o Shift into gear
Change the fluid for the first time after about 25 hours of
operation then every 250 operating hours or at least once a NOTE Too Iowan idle speed will produce a chattering noise
year or when you change engine oil from the transmission gear and damper plate In such cases the
Removing the fluid idle speed should be a suction pump hose down through the dipstick hole to
For additional information refer to the following text in this
the bottom of the housing and suck out the fluid If space Transmission Section SHAFT COUPUNGS use the transmission drain Remove the drain
plug AND TRANSMISSION the bottom of the transmission and allow the fluid to
drain into a container then reinstall the plug with its Wipe down the transmission and properly dispose of HBW 250 TRANSMISSION
used fluid After running the engine shut down and
recheck the fluid level General Hurth Standard Transmission Case
hardened helical gears with a servo
Drain plug torque 20 25 Mbs operated multiple disc clutch
Gear ratio standard 274 1 HBW250 3R
NOTE When changing the fluid take care not to lose the
Propeller Shaft Right handed standard plug sealing washer The drain plug will leak without
Direction of Rotation
this sealing washer
Propeller 240 X 12 P2 blade or 220 x 14 P3
blade propeller should allow the engine
using standard to reach its full rated rpm 3600 000
A WARNING Never pullout the dipstick while transmission
2741 reduction
100 at full open throttle while under
way in forward gear
the engine is running Hot fluid will splash from the
lubricating Fluid ATF type A or Dextran or III
dipstick hole This could cause severe burns
Transmission Sump 079 US qts 075 liters approximate
Capacity
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
SHIFT LEVER POSITION
OIL COOLER
The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A detent
ball located behind the transmission lever must work freely
DIPSTICK to center the lever in each position The gear shift positions at
the helm must be coordinated with those of the Velvet Drive
REVERSE CLUTCH actuating lever through shift mechanism adjustments An
PRESSURE GAUGE
CONNECTION improperly adjusted shift mechanism can cause damage to
the transmission The shifting mechanism and transmission
actuating lever should be free of dirt and well lubricated to
ensure proper operation
Shifting Into Gear
Place the gear shift in Neutral before starting the engine
Shifting from one selector position to another selector posi
tion may be made at any time below 1000 rpm and in any
FROM COOLER order Shifts should be made at the lowest practical engine
CONNECTION
speed Start the engine and set the throttle at idle speed
allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with trans fluid during shipment and the
selector lever is tem Move the gear shift lever to the middle position You attached to the actuating shaft feel
the detent This centers the actuating lever on the trans
Before leaving the WES1ERBEKE plant each transmission mission With the control in this position hydraulic power is
undergoes a test run with Dextron III ATF transmission fluid completely interrupted and the output shaft of the transmis
The residual fluid remaining in the transmission after drain sion does not turn
ing acts as a preservative and provides protection against
NOTE Some transmissions are equipped with a neutral for at least one year if properly stored
switch Unless the transmission actuating lever is FLUID aligned in neutral the engine starter will
not the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25
hours of opera Move the gear shift lever to the forward position You should
tion keep a lookout for any leakage at the bell housing out feel the detent The actuating lever on the transmission is in
put shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300 move the boat in a forward hours thereafter andor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in
and the correct size cooler is properly installed before the reverse position The output shaft and the propeller
should move the boat in a reverse direction astern
starting the engine
NOTE Moving the transmission actuating lever from Neutral
Position to Forward is always toward the engine Reverse is
always away from the engine If boat moves backwards with
the gear shift control in the forward position shut off the
engine This problem may be a result of incorrect movement
of the actuating lever by the gear shift lever
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
o Clean off the transmission and properly dispose of the
used fluid
o Refill the transmission with DEXTRON III ATF The
quantity will vary depending on the transmission model
and the installation angle Fill through the dipstick hole
o Check the dipstick for the proper fluid level
o Replace the oil filler cap and dipstick Press the dipstick
into place and tum clockwise until o Run the engine shutdown and recheck the
fluid NEUTRAL
TRANSMISSION ACTUATING LEVER POSITIONS
REVERSE
A WARNING Never pull out the dipstick while the
engine is running Hot fluid will splash from the OPERATION hole This could cause severe bums
o Check the transmission fluid
o Visually check the gear shift linkage and transmission Oil Capacity
o Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis
for the fluid to warm sions to the oil level fill mark on the dipstick Many variables
NOTE Too low an idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil
noise from the transmission gear and dmnper plate In will be required to fill the oil cooler and the cooler lines The
such cases the idle speed should be increased angle of installation will make a difference in the quantity of
oil required to fill the Shift into gear
A CAUTION Shifting gears above 1000 rpm can Make certain the rubber
seal is screwed tight
to the handle
cause damage to the engine damper plate Pulling the
throttle back to idle when shifting gears will save wear
on the transmission and the damper
o Visually check for oil leaks at the hydraulic connections
Check for wear on the hydraulic lines and replace if
worn
o Lubricate the detent ball and shift cable Inspect the shift linkage
o Inspect the transmission bolts retorque if necessary
A CAUTION Clutch failure will occur if the transmis OIL DIPSTICK
sion shift lever does not fully engage the detent ball Oil Temperature
pOSitions A maximum oil temperature of 190F 88C is recom
mended Discontinue operation anytime sump oil THE TRANSMISSION FLUID ture exceeds 230F the initial 50 hour
change the transmission fluid should PRESSURE GAUGE
be changed at every 300 operating hours thereafter or at win
ter haulout However the fluid must be changed whenever it An optional mechanical pressure gauge can be installed at
becomes contaminated changes color or smells rancid the control panel to constantly monitor the pressure of the
transmission fluid A normal reading at 2000 rpm in forward
o Remove the oil filler cap and dipstick gear should indicate 95 120 Ibin 2 67 84 kgcm 2 and be
o Remove the oil cooler return line and allow the oil to constant
drain into a container
o Reconnect the oil cooler return line
o Use a suction pump to remove the transmission oil
through the filler capdipstick hole
Engines Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300 operating
hours For assistance inspect the transmission and the cooler for leaks BORG WARNER
and corrosion Make certain the air vent is clear and when 200 Theodory Rice the fluid level look for signs of water contamination
New Bedford MA 02745
fluid will appear as strawberry cream Tel 508 BORG WARNER
is aware of the shock loads that can be
placed on its gears as the result of mechanical propeller oper
Storage requires special care Follow these procedures ation or fully reversing of the propeller blades while shifting
o Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be
replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was
NOTE This operation will usually occur when the engine caused by a shock load any warranty claim will be denied
raw water cooling system is properly winterized
o Clean up the transmission and touchup unpainted areas A CAUTION noises or vibrations can
use heat resistant paint occur at low engine speeds which can cause gear rattle
o Fill the transmission with Dextron 1II ATF fluid to the resulting in damage to the engine andor full mark on the dipstick
BORG WARNER is not responsible for total system
o Loosen attaching hardware from the transmission related torsional vibration of this type
output flange and propeller shaft coupling flange before
removing the boat from the water Separate the flanges If any problems occur with the transmission see
and spray with lubricant TRANSMISSION in this manual
o Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE lfthe transmission is to be storedfor a long time
twelve months or more it should be topped offwith
fluid to prevent internal corrosion Reduce the fluid level
before putting the engine back into service
Engines Generators
TRANSMISSION CABLES OIL COOLERS
The majority of transmission difficulties arise as a result of The continued flow of raw water through the cooler will in
improper clutch adjustments manual or prob time erode the inside of the cooler causing cross leaks to
lems with control cables hydraulic rather than occur These internal cooler leaks will cause one of the fol
from problems with the transmission itself lowing two clutches in particular are very sensitive to improper
1 Transmission fluid will leak into the flow of raw water
cable adjustments and be discharged overboard through the engine exhaust
If you experience operating problems with the transmission A loss of transmission fluid will cause the transmission to
shut the engine down First check the level fail
then have a helper move the cockpit shift lever through the 2 The raw water will leak into the transmission fluid caus
full range from neutral to full forward back to neutral ing an increase in transmission fluid This full reverse and
back to neutral while you observe fluid will appear as strawberry cream The actuating lever on the transmission If the
remote is stiff will eventually fail
to operate break the cable loose at the transmission and try Either case requires an immediate If it is still stiff check the
cable for kinks or exces
sively tight bends and check any linkage for binding A new 1 Install a new oil cooler
cable and perhaps a new linkage mechanism may be needed 2 Refill the transmission with DEXTRON III ATF
While the cable is loose shift the transmission in and out of If water has contaminated the fluid the transmission fluid
gear using the lever on the side of the transmission to make needs to be cleaned out and replaced with fresh fluid It will
sure theres no binding inside the case take several fluid changes to get rid of the the transmission passes
these tests crank the engine and Check your dipstick each time until it appears as pure trans
have a helper put it in forward and reverse while you observe mission fluid Change the transmission filter and clean out
the propeller shaft if the shaft isnt turning the transmission the fluid lines that connect to the cooler
needs professional attention If it does tum but theres no If the transmission fails to shift properly it will most check to see
you still have a propeller on the end of need the attention of a qualified transmission service facility
the shaft or if you have a folding or feathering propeller that A transmission cooler may last ten years or more but in
it isnt stuck in the no pitch position some depending on operating hours tropical
waters maintenance etc it might only last half that time
WESTERBEKE recommends having a spare cooler aboard
Problem Probable Cause Transmission gears cannot be shifted 1 Shifting
lever is loose 1 Tighten damping bolt on shifting lever
2 Shifting cable is broken bent or 2 Check the cable reattach or replace
unattached
3 Loss of transmission fluid 3 Check for leaks at transmission seal and output shaft
Tighten gear case bolts Check all oil hoses for leaks
Oil cooler leak see OIL COOLER
4 Water in transmission fluid 4 Replace oil cooler see OIL COOLEFf High water in engine
compartment remedy cause Shifting pressure too low see
item 2
Shifting pressure too low 1 Improper fluid 1 Replace with DEXTRaN 11 ATF
2 Filter is dirty if applicable 2 Replace filter
3 Water in transmission fluid 3 Replace oil cooler see OIL COOLER
4 Transmission fluid too low 4 Add fluid
5 Air vent is clogged 5 Remove paintdirt from vent
Transmission noise becomes louder 1 Fluid level too low 1 Top up with fluid to marking on dipstick
so that pump sucks in air
2 Damage starting on flexible coupling due 2 Replace flexible coupling Check alignment between engine
to wear or fatigue possibly due to misalign and ment between engine and
3 Beginning damage of bearings in trans 3 Transmission needs professional attention
mission due to torsional vibrations running
without fluid overload wrong alignment of
transmission or excessive engine output
Engines Generators
TRANSMISSION Problem Probable Cause Chattering transmission noise
1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor
mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with
a chattering noise in the transmission a higher stiffness factor might be sufficient
Transmission shifts into gear but 1 Output coupling is not turning 1 Transmission needs professional attention
fails to propel the boat
2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping
Output coupling is turning on the propeller shaft Tighten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and 3 Inspect the propeller it may be missing or damaged
propeller shaft are turning A folding propeller may be jammed
Variable pitch propeller may be in no pitch If you suspect a major problem in your contact your WESTERBEKE dealer or an
authorized marine transmission Engines Generators
STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt Metric bolt class numbers identity bolts by their strength with 109
Customary inch bolts are identifed by markings two to grade eight The marks correspond to two marks less than the actual grade
Le a grade seven bolt will display five embossed 1 Use the torque values listed below when specific torque values are not available
2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used
3 Reduce torques by 30 or more when threading capscrews into aluminum
STANDARD BOLT NUT TORQUE METRIC BOLT NUT TORQUE SAE Grade 5 SAE
Grade 67 SAE GradeS
Capsrew Body Size Torque Torque Torque Bolt Grade 46 Grade4S Grade 88 9S
Grade 109
Inches Thread ALbNm ALbNm ALbNm Dia Wrench Size ALbNm FtLb Nm FtLbNm FtLb Nm
14 20 8 11 10 14 12 16
28 10 14 14 19 M3 55mm 03 05 05 07 1 13 15 2
M4 7mm 08 11 1 15 2 3 3 45
5116 18 17 23 19 26 24 33 M5 8mm 15 25 2 3 45 6 65 9
24 1926 27 37
3816 31 42 34 46 44 60 M8 10mm 3 4 455 75 10 11 15
24 35 47 49 66 M9 13mm 7 95 10 13 18 25 35 26
716 14 4966 55 75 7095 Ml0 16mm 14 19 18 25 37 50 55 75
20 55 75 78 106
12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 63 85 97 130
20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205
M16 24mm 59 80 85 115 159 215 232 315
916 12 110149 120 163 155 210
18 120 163 170 231
M18 27mm 81 110 118 160 225 305 321 435
51811 150 203 167 226 210 285 M20 30mm 118 160 166 225 321 435 457 620
18 170 231 240 325 M22 33mm 159 215 225 305 435 590 620 840
34 10 270 366 280 380 375 508
16 295 400 420 569 M24 36mm 203 275 288 390 553 750 789 1070
M27 41 mm 295 400 417 565 811 1100 1154 1565
78 9 395 536 440 597 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130
14 435 590 675 915
1 8 590 800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900
14 660 895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720
NOTE Formula to convert FtLbs to Nm Newton Meters multiply FtLb x 1356
SEALANTS based PERMATEX 2 and its HIGH TACK equivalent are excellent all Use LIQUID TEFLON for sealing pipe plugs and fillings that
connect sealers They are effective in just about any joint in contact with passages Do not use tape raw water oil or fuel
A light coating of Ollar LIQUID TEFLON can be used on rubber gaskets BOLTS Orings
Lightly oil head bolts and other fasteners as you assemble them Bolts and
lOCTITE hydraulic red sealant shou Id be used on oil adapter hoses and the oil plugs that penetrate the water jacket should be sealed with
PERMATEX 2 or
filter assembly HIGH TACK
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When assembling the flywheel coat the bolt threads with lOCTITE
blue
When installing gaskets that seal around water coolant passages coat both Antiseize compounds and thread locking adhesives such as lOCTITE
protect
sides with WHITE SILICONE grease threaded components yet allows them to came apart when necessary
lOCTITE offers levels of locking according to the ADHESIVE SPRAYS are useful for holding gaskets in position dur
ing assembly LITHIUM based grease is waterproof ideal for water pump bearings
and stuff
ing gasket sealers such as HYlOMAR work well in applications requir
ing nonhardening properties HYlOMAR is particlariy effective on Heavily oil all sliding and reciprocating components when assembling
Always
copper cylinderhead gaskets as it resists fuel oil and water use clean engine oil
Engines Generators
gOA FOUR TORQUE Component ft Ib kgm Component
ft Ib kgm
Alternator bracket 38 38 53 Injection pipe flare nut 22 25 30
Back plate 38 38 53 Injector to head 17 16 24
Camshaft thrust plate 19 19 26 Intake manifold 19 19 26
Connecting rod cap 65 82 90 Main bearing cap 77 100 107
Coolant temperature sender 18 29 25 40 Oil filter 1113
Coolant temperature switch 18 29 25 40 or tighten firmly by hand
Crankshaft pulley nut 289 350 400 Oil pan bolts 19 19 26
Cylinder head bolts NOT TORQUE Oil pan drain plug 434 50 60
Cylinder head cover 25 02 035 Oil pump pipe 80 08 11
Damper 24 22 34 Oil pressure sender 13 12 18
Engine mounts 34 32 47 Oil pressure switch 13 12 18
Exhaust manifold 20 23 27 Rear oil seal cap 19 19 26
Flywheel 145 18 20 Rocker arm assembly 19 19 26
Coolant pump bolts 13 12 18 Thermostat housing 80 08 11
Idler gear 19 19 26 TIming gear case 17 16 24
Injection pump drive gear 29 52 40 90 Timing gear cover 19 19 factor to get Nm
FHb x 1356 Nm
Engines Generators
32 KW BEDA GENERATOR FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming 1 bleed point
watercooled Vertical inline overhead valve
mechanism 46 hp at 1800 rpm maximum Fuel No2 diesel oil cetane rating of 45 or Naturally
aspirated Fuel Injection Pump ZEXEL Model PE Electronic Governing
Fuel Injection Timing 12 Chamber Swirl type Nozzle
Orifice type
Bore Stroke 394 x 433 inches 1001 x 1100 mm Fuel Riter Full Row Replaceable
on Displacement 2108 cubic inches 35 liters
Air cleaner Metal screen type Order 1342
Air Row 110 cfm 31 of Rotation Clockwise when viewed from the front engine Torque 166 Ibft
23 kgm
at 1800 rpm COOLING Ratio 181
General Fresh watercooled block
controlled with heat Height 300 inches 7620mm
Width 220 inches 5588 mm Operating Temperature 170 190 F n 88 C
Length 446 inches 1133 mm
Fresh Water Pump Centrifugal type metal impeller 10381bs 4718 kgs
Raw Water Pump Positive displacement rubber impeller
belt driven
TUNEUP Raw Water Flow 150 gpm 567lpm Pressure
427 psi 30 kgcm at 200 rpm at 1800 rpm before discharging into exhaust of difference between
cylinders 472 psi 30 kgcm System Capacity 85 qts 804 liters
fresh water
Valve Timing Intake Opens 19 BlDC
Intake Closes 47 ABDC
LUBRICATION SYSTEM
Exhaust Opens 52 BBDC General Pressu re fed system
Exhaust Closes 14 ATDC
Oil Filter Full flow paper element spinon type
Engine Timing Static timed drop valve method
0180 005 inches BlDC Sump Capacity 63 US qts 60 liters
not including filter plus filtercooler Pressure 2450 35 psi 1 50 kgcm
Operating Oil Pressure 30 35 psi 21 25 kgcm
Valve Seat Angle Intake 45 engine hot
Exhaust 30
Oil Grade API Specification of CF or CG4
Valve Clearance Intake 0012 inches 03 mm SAE 30 10W30 cold Exhaust
0014 inches 035 mm
Engine Speed 1800 RPM 60 Hertz
1500 RPM 50 Hertz
Engines Generators
32 KW BEDA GENERATOR ELECTRICAL SYSTEM AC GENERATOR 3 Battery
12Volt negative ground General 3 Phase Brushless six pole revolving field
200 KW 60 Hertz Sealed lubricated single Capacity 600 900 Cold Cranking Amps CCA 160 KW 50 Hertz
design 12 Lead reconnectable for low voltage
DC Charging Altemator 51 Amp rated beltdriven WYE and for Delta Solid State voltage regula
tor with protection 12Volt 3 KW
Voltage 3 Phase Low voltage WYE 208 Aid Glow plugs sheathed type 60 Hertz
High voltage WYE 480 volts
12 ohm DELTA 240 volts
DC NoLoad Cu rrent 2 of rated Amps Voltage 3 Phase High voltage WYE 380 volts
50 Hertz DELTA 230 volts
DC Cranking Current 250 300 Amps engine cold
Amperage 3 Phase Low voltage WYE 1110 Amps
60 Hertz High voltage WYE 481 Amps
AC GENERATOR SINGLE PHASE 8 power factor DELTA 962 Amps
General Single Phase Brushless fourpole revolving field Sealed Amperage 3 Phase High voltage WYE 475 Amps
lubricated single bearing design 50 Hertz 820 Amps
DELTA
Reconnectable single phase for 1201240 volts 8 power factor
with solid state voltage Single Phase 120 or 1201240 Volts 60 Hertz GENERATOR COOLING
230 Volts 50 Hertz
Air Requirements 10 power factor 500 cfm 150 cmm
Voltage regulation 2 no load to full load 60 Hertz at 1800 regulation 3 Hertz no load to full load
Note Increase air supply 15 for 50 Hertz operation 1500 rpm
Rating Volts AC 32 KW 60 Hertz 1800 rpm Engine Combustion Air 110 cfm 31 cmm
120 Volts 266 Amps Requirements
1201240 Volts 2661133 Amps 60 Hertz at 1800 RPM
25 KW 50 Hertz 1500 rpm
230 Volts 1087 Amps
Engines Generators
32 KW BEDA GENERATOR PARTS AIR INTAKE SILENCER ACTUATOR
EXHAUST TEMPERATURE SWITCH
20 AMP DC CIRCUIT BREAKER
AC CONNECTIONS OUTLET
SlOE OIL FILL
GENERATOR
DECAL
OIL PRESSURE SENDER
FRONT LEFT SIDE REAR
ZINC LUBE OIL FILL CAP
COOLANT FILL CAP
EMERGENCY STOP
ENGINE
70 EXHAUST ELBOW DC CHARGING LED LIGHTS
HEAT XHANItHI
RAW WATER PUMP
LUBE OIL DRAIN HOSE
BLOCK DRAIN PLUG STARTER WITH SOLENOID
REAR RIGHT SIDE FRONT
Engines Generators
GENERATOR OF ELECTRIC MOTORS Generator Frequency power required to start an electric motor is
considerably Frequency is a direct result of speed as
more than is required to keep it running after it is started indicated by the motors require much more current to start them than
When the generator is run at 1800 rpm the AC Splitphase AC motors require more current to start output frequency is 60 Hertz
under similar than other types They are
When the generator is run at 1500 rpm the AC used on easystarting loads such as washing
output frequency is 50 or where loads are applied after the motor is
started such as small power tools Because they require 5 to Therefore to change the generators frequency the genera
7 times as much current to start as to run their use should be tors drive engines speed must be changed Along with a
avoided whenever possible if the electric motor is to be dri reconfiguring of the AC output connections at the by a small generator
Capacitor and a regulator board voltage output adjustment must also be
motors require from 2 to 4 times as much current to start as made See ELECTRONIC GOVERNOR in this manual
to run The current required to start any motor varies with the
load connected to it An electric motor connected to an air Generator for example will require more current than a
Maintaining reasonable cleanliness is to which no lad is connected Connections of terminal boards and rectifiers
may become
In general the current required to start 115Volt motors con corroded and insulation surfaces may start conducting if
nected to medium starting loads will be approximately as salts dust engine exhaust carbon etc are allowed to
follows build up Clogged ventilation openings may cause exces
MOTOR SIZE AMPS FOR AMPS FOR sive heating and reduced life of windings
HP RUNNING STARTING For unusually severe conditions thin AMPERES
AMPERES
16 32 64 to 224 coatings should be sprayed or brushed
14 46 92 to 322 over all surfaces to reduce rusting and corrosion
13 52 104 to 728 In addition to periodic cleaning the generator should be
12 72 144 to 292 inspected for tightness of all connections evidence of
34 102 204 to 408 overheated terminals and loose or damaged wires
1 13 26 to 52 The drive discs on single bearing generators should be
checked periodically if possible for tightness of screws
NOTE In the above table the maximum Amps for Starting is and for any evidence of incipient cracking failure Discs
more for some small motors than for larger ones The reason
should not be allowed to become rusty because rust may
for this is that the hardest starting types splitphase are not
accelerate cracking The bolts which fasten the drive disc
made in larger sizes
to the generator shaft must be hardened steel SAE grade
Because the heavy surge of current needed for starting 8 identified by 6 radial marks one at each of the 6 cor
motors is required for only an instant the generator will not ners of the head
be damaged if it can bring the motor up to speed in a few The rear armature bearing is lubricated and sealed no
seconds If difficulty is experienced in starting motors turn maintenance is required However if the bearing becomes
off all other electrical loads and if possible reduce the load noisy or have it replaced
on the electric motor
Examine bearing at periodic intervals No side movement
of shaft should be detected when force is applied if side
Required Operating Speed motion is detectable bearings are wearing or wear on
Run the generator first with no load applied then at half the shaft of bearing socket outside bearing has capacity and finally loaded to
its full capacity as Repair must be made quickly or major components will
indicted on the generators data plate The output voltage rub and cause major damage to be checked periodically to ensure proper
operation of
the generating plant and the appliances it supplies If an AC Carbon Monoxide or ampmeter is not installed to monitor voltage and
WESTERBEKE recommends mounting a carbon
load check it with a portable meter and ampprobe
monoxide detector in the vessels living quarters Carbon
NOTE When the vessel in which the generator is installed monoxide even in small amounts is AC equipment of 120 volts only it is
recommended The presence of carbon monoxide indicates an exhaust
that the generators AC terminal block be configured to pro leak from the engine or generator from the exhaust
vide one 120 volt AC hot leg for the vessels distribution elbowexhaust hose or that fumes from a nearby vessel
panel This will ensure good motor starting response from the are entering your
If carbon monoxide is present ventilate the area with clean
air and correct the problem Engines Generators
GENERATOR CONTROL PANEL 3 START The START toggle switch is a double pole single
This manually controlled series ofWESTERBEKE marine throw switch The switch serves two purposes generators is equipped with
toggle switches on the the engine and defeating of bypassing the engine oil pres
engine control panel and optionally at remote panels The sure switch The defeat function turns on the fuel instructions and methods of
correcting minor prob noid instrument power and alternator apply only to such toggle switch controls While
the PREHEAT switch is still depressed depressing
the START switch engages the start solenoid Panel
All three switches are momentary contact type and serve the power and the fuel solenoid will be activated When the
following functions engine begins to fire the START switch should be
1 PREHEAT The PREHEAT toggle switch is a double pole released The PREHEAT switch should not be released
single throw switch The switch serves two purposes pre until the oil pressure reaches alarm stops
heating the engine for easy starting and defeating of
bypassing the engine oil pressure switch The defeat func NOTE When the engine is shut down the water tempera
tion turns on the fuel solenoid instrument power and ture gauge and the oil pressure gauge will continue to
alternator excitation register the last temperature and oil pressure readings
When the PREHEAT switch is depressed the voltmeter displayed They will return to zero once electrical power
panel lights gauges and meters and fuel solenoid will is restored
activate The PREHEAT switch should be depressed for 4 EMERGENCY STOP The EMERGENCY stop switch at
twenty seconds the rear of the control box is normally closed When
2 STOP The STOP toggle switch is a single pole single depressed it will open the DC circuit to the control panel
throw normally closed switch The switch provides and shut the engine down As the switch is not toggled it
power to the fuel solenoid instrument cluster and alterna can be used when performing maintenance
tor excitation after the oil pressure switch has closed
upon starting Opening of this switch opens the power
REMOTE PANEL
circuit to the fuel solenoid stopping the flow of fuel to For remote operation of the generator system the same three
the engine and shuts down the engine switches are used The PREHEAT and START switches are
To stop the engine depress the STOP switch When the connected in parallel with the gauge panels switches and
STOP switch is depressed the power feed to the fuel serve the same functions as in the gauge panel The STOP
solenoid is opened and the fuel flow to the engine is switch is in series with the gauge panels STOP switch and
stopped The STOP switch should be depressed until the serves the same function
generator stops rotating
o o
STOP
RElEASE
STARIEI
START
MUST
PRESS
PRESS
FIRST W 2ND
1B7 GENERATOR
o o
REMOTE PANEL OPTIONAL
CONTROL PANEL
Engines Generators
CONTROL PANEL MANUAL STARTER DISCONNECT TOGGLE SWITCHES
NOTE The engine control system is protected by a 20 amp manual reset circuit breaker
located on the engine as close as possible to the power source
Problem Probable Cause PREHEAT depressed no panel indications 1 Oil Pressure
switch 1 Check switches andor battery connections
electric fuel pump and preheat solenoid
not energized 2 20 amp circuit breaker tripped 2 Reset breaker If it opens again check preheat solenoid cir
cuit
and run circuit for shorts to ground
START SWITCH DEPRESSED no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Low DC voltage to solenoid terminal 2 Check Voltage Jump voltage to S terminal
3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
NO IGNITION cranks does not start 1 Faulty fueling system 1 Check for fuel
2 Check for air in the fuel system 2 Allow system to bleed
3 Faulty fuel lift pump 3 Replace fuel lift pump
4 Faulty fuel solenoid 4 Check fuel solenoid
NOT CHARGING BAmRY 1 Faulty alternator drive 1 Check the drive belt and its tension Be sure the alternator
turns freely Check for loose connections Check the
output with a voltmeter Ensure 12V are present at the
regulator Terminal
BAmRY RUNS DOWN 1 Oil pressure switCh 1 Observe if the gauges and panel lights are activated when the
engine is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check the wiring Insert sensitive 025 amp meter in battery
lines Do NOT start engine Remove connections and replace
after short is located
WATER TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the bat
2 Connect the sender terminal at the gauge to ground and tery is connected to the starter both plus and minus termi
see if the gauge reads full scale which is the normal nals the ground side will not necessarily be connected to the
reading for this situation block
Engines Generators
THE BE GENERATOR
SINGLE AND THREE CIRCUIT BREAKER
This generator is a fourpole brushless selfexcited generator A circuit breaker is installed on all WES1ERBEKE genera
which requires only the driving force of the engine to pro tors This circuit breaker will automatically disconnect gener
duce AC output The copper and laminated iron in the exciter ator power in case of an electrical overload The are responsible for the
selfexciting feature of this gen breaker can be manually shut off when servicing the The magnetic field produced causes an AC voltage to
tor to ensure that no power is coming into the boat
be induced into the related excitor rotor windings Diodes located in the exciter rotor rectify this volt NOTE This circuit breaker is available as
a to DC and supply it to the windings of the rotating field addon kitfor earlier model generations contact your
This creates an field which rotates through WESTERBEKE dealer
the windings of the main stator inducing an AC voltage PART CIRCUIT is supplied to a load An AC voltage is produced
in the 42703 32 Kw 60 Hz
auxiliary windings of the main stator and is in turn supplied 43271 25 Kw 50 Hz
to a voltage regulator The regulator produces a DC voltage
to further excite the exciter stator windings enabling the gen
erator to produce a rated AC output The voltage AC voltage output and adjusts DC excitation to the
exciter stator winding according to amperage load the gener
ator is furnishing To maintain a constant voltage output
Engines Generators
GENERATOR AC VOLTAGE CONNECTIONS regulator is equipped with seven numbered terminals 0
to 6 and their related brass jumpers The illustrations points and jumpers for the 3 phase the generator The sensing leads connect between pin 1
and pin 2 on the AC terminal block and connection 2 and
0 on the voltage regulator board
NOTE Series Delta requires the installation of a jumper on
the regulator board between tenninal B and 1 170 270 V 80 160 V
NGND
CASE GND
L1 L2 L3 RN AVR
D D
BE THREE PHASE SIX WIRE 3 PHASE VOLTAGE REGULATOR
CONNECTIONS FOR BOTH 60 50 HERTZ
NOTE IF WIRING FOR 50 HZ THE 60 HZ
JUMPER MUST BE REMOVED FROM
THE REGULATOR
L1 o
13 24
L3 o L3 N L3 0
9 10 11 89 1011
SERIES Y PARALLEL Y SERIES DELTA
480V60 Hz 208V120V 160 Hz 240V60 Hz
380V50 Hz 230V50 Hz
6 STUD 3 PHASE AC WIRING
PARALLEL WYE STAR SERIES WYE STAR SERIES DELTA
L L 208 VAG 38 60 Hz L L 450 VAG 311 60Hz L L 240 VAG 20 60Hz
L N 120 VAG 19 60 Hz L N 265 VAG t8 60 Hz L2 L3N 120 VAG 10 60Hz
L L 190 VAG 39 50 Hz L L 380 VAG 39 50Hz L L 230 VAG 39 50Hz
L N 110 VAG 19 50 Hz L N 230 VAG 1 50Hz L2 L3N 115 VAG 19 50Hz
BE THREE PHASE TWELVE WIRE A SERIES DELTANote the
repOSitioning of the ground
lead from neutral to
generator housing
J Jumper using 10 AWG
Engines Generators
GENERATOR AC VOLTAGE VOLTAGE CONNECTIONS Generator The frame ground wire whitegreen must be prop
1 Frequency is a direct result of speed
erly positioned when changing the AC output configuration 1800 rpm 60 hertz 1500 rmp 50 hertz
of the AC terminal block For making connections to the AC 2 To change generator frequency follow the steps block use terminal ends for
114 inch studs that will
Configure the AC tenninal block for the desired multi strand copper wire sized for the amperage rating
frequency as shown Ensure that the case ground wire is
from the hot lead connection The frame ground wire is white
connected to the correct terminal block neutral ground
or white with a green strip It connects between the neutral
stud
stud and the generator frame
NOTE The whitegreen ground wire may be removed in those
installations where the AC circuit has a separate neutral and
ground circuit This will prevent the unit from being a ground
source in the vessel
120240V 60Hz 120V60Hz 230V50Hz 115V 50Hz
o o o 0 o o 0
L1 fl
L2 L1
AJUMPER IS
REQUIRED il
BETWEEN LOAD I I
i 00 i I
L l
I II
Engines Generators
VOLTAGE REGULATOR AmpHertz
The voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the two
optimum AC alternator performance It is equipped with protection circuits in the voltage regulator that are protection circuitry to
guard against operating by the illumination of a colored LED that could be detrimental to the AC alternator 1 Delayed
overload protection yellow LED
2 Low speed protection red LED
Both systems have an intervention threshold which can be
adjusted using the respective Each of the two
circuits are able to cause an adequate reduction in excitor
voltage to safeguard the excitor windings and prevent their
overheating
The overload protection system has a delay which permits
temporary overloading of the generator during times such as
motor startup or other similar load surge demands The regu
lator also has a third LED green that glows during genera
tor operation to indicate correct operation of the regulator
with the potentiometer is used to adjust output voltage At proper
engine operating speed the output voltage should be held at Setting the Overload Protection
1 from a noload condition to a full rated generator output In order to set the AMP overload protection the from power factor 10 08 with
engine drive speed vari must be loaded to its full output up to 6 1 Load the alternator
to its rating then decrease the speed of
Prior to starting the engine turn the VOLT and STAB trim the engine by 1010 54 Hertz on 60 hertz units 45
mers using a mini phillips screwdriver fully in a counter hertz on 50 hertz Minimum direction until you feel them hit their 2
Rotate the AMP adjustment until it hits
stops its stop Wait about 1520 seconds after which the AC out
Turn the AMP and HERTZ trimmers completely clockwise put of the alternator should drop and the yellow LED in the same manner
should come on
With the alternator running at noload at normal speed and 3 Slowly rotate the AMP adjustment clockwise until the
with VOLT adjust at minimum it is possible that output volt output voltage increases to approximately 97 of the volt
age will oscillate Slowly rotate the VOLT adjust clockwise age output at the start of the adjustment At this point the
The voltage output of the alternator will increase and stabi yellow LED light should come on
lize Increase the voltage to the desired value In this situa 4 Return to nominal speed the yellow LED will turn off
tion only the green LED will stay lit and the alternator voltage will rise to its normal value
Should this not happen repeat the potentiometer permits variation of the regulators NOTE When changing from 60 hertz to 50 hertz to
generator load changes so as to limit overcom remove the 60 hertz jumper bar from the regulator and obtain a minimum recovery time to the
output Setting the Underspeed Protection
In order to adjust the regulator stability the alternator must be NOTE lfthe unit is operating at 60 Hertz ensure that the
running at noload and the output must be monitored jumper strap is in place on the regulator board between the
Turn the STAB adjust slowly clockwise untilthe voltage two 60 Hertz terminals In order to adjust the to fluctuate At this point rotate
the STAB adjust coun setting the alternator should be running at until the voltage is stable within 1 or 2 tenths of
1 To adjust the underspeed low frequency protection circuit
a volt
lower the engine speed at 90 of its normal running speed
54 hertz on 60 hertz units 45 hertz on 50 hertz units
2 Rotate the Hertz adjustment slowly until
the alternators AC output voltage starts to decrease and at
the same time the red LED light comes on
3 Increase the engine speed to its normal speed frequency
The red LED light will go out and the AC voltage out
put will return to normal
With the above adjustments made the regulator should func
tion normally
VOLTAGE REGULATOR DIAGRAM
v WESTERBEKE
Engines Generators
INTERNAL WIRING SCHEMATICS
SINGLE EXCITER STATOR
EXCITER
ROTOR 1
I STATOR
I RED
I TERMINAL
I BLOCK
AUX
WINDINGS W2
REGULATOR
FUSE
63 AMP U1 V1
BLACK
GREEN
NOTE This fuse
BLUE may be located
on the YEllOW
THREE PHASE
6 WIRE EXCITER STATOR 1
I STATOR I
ROTOR FIELD U2 UI
I 1 1 I AC
1 EXCITER 1 POll 1 V2 GREEN I GREEN VI TERMINAL
I ROTOR I RESISTER I I BLOCK
a I 1 W2
rREiI
RED I
b I rII1
I I I I
I I I J
I I AUX
L WINDINGS
REGULATOR
FUSE
63 AMP NOTE This fuse
o may
be located
J w on the
regulator
J l
UJ J Q green
Ql yellow L
Herlz
Voll
BLUE
YElLOW
Engines Generators
INTERNAL WIRING SCHEMATICS
3 PHASE TWELVE WIRE EXCITER STATOR
1IIi
t 12
I J
Ljr1iI
3 1
EXCITER
ROTOR
I ROTOR FIELD I
I 8 AC
I I I 4 4
7 TERMINAL
BLOCK
I
7 1
I I 8 I
L J
AUX
WINDINGS
FUSE NOTE This fuse
63 AMP may be located
on the REGULATOR
BLUE
YELLOW
BE GENERATOR WINDING RESISTANCE VALUES IN OHMS
SINGLE PHASE 20 25 BE 32 BE
EXCITER STATOR 1806 1820
EXCITER ROTOR a b 068 072
bc 068 072
ROTATING FIELD 175 201
MAIN STATOR 12 005 005
34 005 005
AUXILLARY WINDING 119 098
THREE PHASE 20 25 32 BE
EXCITER STATOR 1820
EXCITER ROTOR ab 07
bc 07
ROTATING FIELD 201
MAIN STATOR 006 each winding
AUXILLARY WINDING 098
Engines Generators
BE NOTE AC GENERATOR MUST
BE PERFORMED WITH ENGINE OPERATING AT 60 HERTZ
PROBLEM PROBABLE CAUSE
No AC voltage output at no load 1 Short or open in the 4 Short or open in exciter
main stator winding stator winding
2 Shorted poziresistor 5 Short or open in rotating
on exciter rotor field winding
3 Four or more shorted or
open diodes on exciter voltage produced at no load 1 Blown 6 AMP buse fuse 3 Shorted or open
main
15 20 volts AC auxiliary circuit feed to AVR stator auxiliary winding
2 Faulty voltage AC voltage output at no load 1 Open or shorted diodes in 3 Faulty voltage
regulator
60 100 VAC exciter rotor 1 to 3 diodes
2 Open or shorted exciter
rotor winding
High AC output voltage 1 Faulty voltage VAC or voltage output
1 STB pod on regulator 2 Faulty voltage regulator
needs voltage drop under load 1 Diodes on exciter rotor
60 100 volts AC breaking down when load is
applied inductive 13 diodes
EXCITER
STATOR
I I I RED
I I I
I EXCITER I ROTOR FIELD I 11
I ROTOR I I I
I I I I
I DIODES
I STATOR
I I AUX II
REGULATOR
FUSE
RED U1
BLACK
GREEN
Heftz RED
e BLUE
YELLOW
Engines Generators
ELECTRONIC Governor System
The system is composed of three basic ControUer Mounted in the instrument panel
2 Sensor Installed on the bellhousing over the flywheel
ring gear
3 Actuator Mounted at the front of the engine and
attached with linkage to the throttle arm of the injection
Adjustment
1 Speed This adjustment is used to raise or lower the
engines speed to the desired hertz
2 Gain This adjustment affects the reaction time of the
actuator to the load changes
NOTE A high gain adjustment can induce an oscillating
of the actuator producing a hunting mode In such cases
SENSOR
lessen the gain adjustment
ELECTRONIC LINEAR ACTUATOR
1 With no power to the governor adjust the GAIN to 900
oclock
2 Start the engine and adjust the speed by turning the speed
pot clockwise to desired speed KEEP ACTUATOR
NOTE Controllers are factory adjusted to minimum rpm LINKAGE WELL
LUBRICATED
However for safety one should be capable of disabling D
the engine if an overspeed should exist
3 At noload turn the GAIN potentiometer clockwise until
the engine begins to hunt if the engine does not hunt
physically upset the governor linkage LINEAR ACTUATOR
4 Turn the GAIN potentiometer until stable TO ELECTRONIC
DC 14 RED RED
TO TERMINAl
BOARD f1 14 BLACK
BLACIUWHITE
SHIELDED TO GOVERNOR
TO SENSOR CABLE CONTROL
WHITE
FLYWHEEL HOUSING
ELECTRONIC GOVERNOR
MAGNETIC SENSOR
TO LINEAR ACTUATOR
14 PURPLE
14 PURPLE
PURPLE
PURPLE j
TERMINAL BOARD 3
SENSOR
O030in
FLYWHEEL rr
TEETH 7 v
v
Engines Generators
THE ELECTRONIC GOVERNOR
Problem Probable Cause appears dead 1 Low battery voltage at
controller 1 Check wiring for cause Check battery state of runs at idle
2 Stuck linkage 2 Lubricate free up linkage between controller and throttle arm
3 No signal or weak signal from sensor 3 Check for improperly installed or damaged sensor in flywheel
Measure AC voltage from sensor while housing Replace or adjust
engine is running at idle Voltage should
be 15 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 Perfonm the following check between
terminals at the actuator and the negative
DC lead at the controller terminal block
Preheat depressed
a Low voltage 12020 VDC at either a Broken actuator lead
actuator connection
b Battery voltage at both actuator b Broken actuator lead
connections
c Battery voltage at one actuator lead c Replace the actuator
but not the fully extends when PREHEAT 1 Check controller Lift one of the purple
is depressed and stays extended actuator leads from the tenminal block
Depress PREHEAT
a Actuator fully extends a Short in lead to actuator
b Actuator does not fully extend and b Replace controller
connections
NOTE Release PREHEAT and reconnect
the purple hunts oscillates and 1 Linkage between actuator and throttle 1 running binding
2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the Controller
controller
3 Inadequate DC power supply to
controller complete the folloWing tests
Connect a DC voltmeter across the
plus and negative leads at the
controller terminal block
Lift both purple leads from the
terminal block
Connect one purple lead to the
Cplus terminal and the other to the
DC negative
Momentarily depress PREHEAT
The actuator should fully extend 3 If actuator does not fully extend check the actuator leads
If the voltage is less than specified check for loose or poor
connections low battery voltage voltage drop in DC circuit
due to remote panel installation and small wire sizes making
connections
DC voltage registering on the meter should be
12 VDC System 96 VDC or higher
24 VDC System 192 VDC or higher
NOTE Reconnect actuator leads properly after making this test
3a Sensor positioned marginally too far 3a Check the position of the sensor
away from flywheel teeth giving
erratic signal voltage to Engines Generators
SHORE POWER TRANSFER SWITCH
SHORE POWER CONNECTIONS 60 HERn 120 VOLT60 HZ THREE WIRE
Notice the repositioning of the white wire ground load on the
Genrator NOTE Diagram shows connections for a two
terminal block to the generator case
wire 120 Volt system For a three wire system
use dotted lines for the other hot leg
i TL
Generator NOTE Diagram shows connections tor a two
I
wire 120Volt system from the generator
with threewir 120Volt boat system
I I
I I
I I
j I
ShiptaShore Switch 3 Pole
PH 32008
PH 32009
SO Amps Pole
PH 32010
Neutral 125 Amps POle
I N Shp Load PH 32133
It L2
Sl T N
I No 240Volt
Shore POwer I Ground II
EqUipment
Z GRN
If the installer connects shore power to the vessels AC cir
cuit this must be done by means of the Shore Power Transfer Shore Set the transfer switch shown in the
diagrams to the
OFF position This switch prevents simultaneous connection
of shore power to generator output Switching Shore Power to Generator Power
A CAUTION Damage to the generator can result if A CAUTION Heavy motor leads should be shut off
utility shore power and generator output are connected before switching shore power to generator power
at the same time This type of generator damage is not viceversa because voltage surges induced by
switching
covered under the warranty it is the installers responsi with heavy AC loads on the vessel being operated
bility to make sure all AC connections are correct cause damage to the exciter circuit components in
Engines Generators
32 KW BEDA GENERATOR
WIRING DIAGRAM 040425 SINGLE RELAY
110 ORN
ALTERNATOR 51A
114 PUR 114 PUR
WATER TEMPERATURE
114 REDPUR
aLliJl
WATER TEMPERATURE
14 PUR
fUEL SOLENOID
AIR INTAKE
tAllB 01 L PRESSURE
114 RED
Ie RED
IIII
BATTERY SWITCH
r V
LI C tt
114 PURWHT
OIL PRESS
llAlliB
IlQIQB
0
GROUND
TO B L O C K 114BLU
114 TA
rHIELDED
Ill 0
112R00 112 RED
ewsJf 20A CIRCUIT
EMERGENCY
STOP SWITCH
114 BRN
REMOVE TH IS
JUMPER WHEN
4 I
CONNECT I KG A
REMOTE PANEL
114 REO Ii
14 GftN
114 RED
r
114 RED I III 10
t
1 SlK
LT83
14 YEL
14 PUR
BlK 110 REDWHT
L WHT
1
b I
10RtO
14 YEL 10 ItEOWHT
PRESSURE
WATER
fEY

INSTRUMENT
o o
10
VOLT
METER
Engines Generators
32 KW BEDA GENERATOR
WIRING SCHEMATIC 040425 SINGLE RELAY
1 STARTER
1 BATTERY SOLENOID STARTER
SWITCH r I
L I
PREHEAT AIR INTAKE
SOLENOID
r I HEATER
ALTERNATOR
I 20 AMP
I C I RCU IT
START
SWITCH
1 I BREAKER
r I EMERGENCY
I STOP
I SWI TCH r I PREHEAT
SWITCH
I I K
STOP
I SWITCH FUEL SOLENOID
OIL PRESS EXHAUST TEMP WATER TEMP
SWITCH SWITCH SWITCH
TEMP VOLTMETER
OIL WATER
PRESS TEMP
SENDER SENDER
Engines Generators
32 KW BEDA GENERATOR
WIRING DIAGRAM 040425 TWO RELAYS
110 ORN
ALTfRNATOR 51A
IU PUR
l FUfl SOl fNOI P AIR INTAKf
OIL PRfSSURf
U
11410
1111
8A HERr SW 1 T C H J r
o Jij 114 PURWMT
I 12 VDC
OIL PRfSS
L ijamRO
GROU TO BOC J 114
14 TAN
RE U REO
ZOA CIRCUIT fMfRGfNCVlY
STOP SWITCH
I 6M
I REMOVE
JUMPER S WHEN
THI1
r g ED
IZ I
i II eL i 1
14 IlK
II RED Be
14 RED
lAED
141 D
114 PUR
10 REDWMT f
IU WNT
1010
IL 101DWNT
IMTCH 1
f
INSTRUMfNT
fA1EJ
I
Sf
IMTCH
10lEOUT
IMTCH
Engines Generators
32 KW BEDA GENERATOR
WIRING SCHEMATIC 040425 TWO RELAYS
E8 e
BATTERY 12VDC
20 AMP
CIRCUIT
I I
BATTERY
SWITCH
BREAKER STARTER
r 0 0 1 I
r EMERGENCY AIR INTAKE
I CH HEATER
AL TERNATOR
KISTART
30 R
K2RUH FUEL SOL
r87 OIL PRESS EXH TEMP WATER TEMP
SW SW SW
I N4002 K2RUN RELAY
L r85
KISTART RELAY
OIL PRESS SENDER
WATER TEMP SENDER
T812 T813 T814 T822 T81S T821 T824 T82S T8110
VOL TMETER
Engines Generators
32 KW BEDA GENERATOR
WIRING DIAGRAM 44737 TWO RELAYS
PLUGIN REMOTE STARTSTOP PANEL
114 BRN
XC A
WATER
WATER

T nn
110 OftG
S J
OGNDE
I IIEDYIO
FUEL SOb ENOl
0 1lrT
E OOIE
TEU4
wlilI
aM
ro k
I ZZ YDC
0 I IU flLlIU IOlr
RRfAulf 04 YDC
IIIIlIm1
AUX 0 It PRESSURE
SIITCH 11111
QIIUR
D
STARTER MOTQR
RNH
I TAli
lilliE2R
1411111
I I I VIO
l It III
REONT
GROUND TO
f rill ENGINE
lii I
BLOCK
II T
RED
1101 RED
114 RED
II IIIL b ILI
ruSE 811
Blit IU Bu
IFb
eUIHT
VIO
lrUL
IIIIRIl
IIID
11 OIlG
1
Aillit
rIELDED lliU WMT
lit ILl
REMOVE JUIIPER IHEN CONNECTING A 5COIO REMOTE PANEL
WHT
2 GROUND TERMINAL or PREHEAT SOLENOID ON 2cv SYSTEM ONLY
T821
0
PREHEAT
swrrcH
la I j
START
swrrcH
STOP
swrrcH
HOUR VOLT
Engines Generators
32 KW BEDA GENERATOR
WIRING SCHEMATIC 44737 TWO RELAYS
PLUGIN REMOTE STARTSTOP PANEL
C I RCU IT
BREAKER STARTER
cJr L J
AIR INTAKE
HEATER
r EMERGENCY
I Ib I PREHEAT I
ISOlENOI
AL TERNATOR
KISTART
KlRUN
WATER TEMP
EXH TEMP SWITCH Oil PRESS
SWI TeH SWITCH
IUDDl KlRUN RELAY
86 85
PREHEAT START
SWITCH
r r
SWI TCH
J LJ
AUX OP SWITCH
OIL PRESS T813 T61 TBl2 TBI5 TB21 TB28 WATER TEMP SENDER
TBIIO
WA TER TEMP GAUGE
STOP
SWI TCH
PREHEAT START
51 reH sw reH OIL PRESS GAUGE
IND LIGHT
TTP ICAl REMOTE STARTSTOP PANEL CORECT IONS
NOTE VOL TMETER
o REMOTE CONECTOR PINS
Engines Generators
32 KW BEDA GENEBATOR
WIRING DIAGRAM 041128 SINGLE RELAY
24 VDC SPECIAL SPEC
110 ORN ALTERNATOR 42A 24V
o O C fA 0
14 PUR 114 PUR
WAIER TEMeERATuRE
aillIf IAF I RDPUR
I
WTEB IEMPEBATUBE
0
I PUR
n FUEl SQI EQIQ
AIR INTAKE
lllllR QIL PRESSURE
aillIf
4 RtD
sow1QlQ
AUlAlQB
t RED a
lilt 1111
BATTERY SWIICH
ro 1 PURHI
I 2 VOc
GROUND TO IILOCK fl
llARilll
14 TAN
114 BlU
I z tLREO
QIL PRESS
fSHED
fWIlIf
112 AO
20A CIRCUIT
aRAlIER
II BRH
liZ REO
EMERENY
STQP SWITCH
if EXHAUURE
aillIf
14 PUR I O T H
MTIS7IP SI
PUI IAML

I GAN
114 RED
TBH MIl
BQtQY urEB AQfQSS
a l11JZ BEFORE BeMl2
STARTtSltP AIEL
BQtQ CROSS lBl N2
PR 0 8
IS IU IU
ZBZ sEFClQE CCVIEClM ERE
14 ell
FRED
I RED
114 PUR
114 TtL
f WT
0BlLlE
I 00 00 fAr 10 00 00 00 00 00
00 00 00 00 I
I r to
1 I I t U Olll
ID DWM
llALQABIl
1111 IUlff
INSTRUMENT
n D ro Ill CL
PRESSUIE fMEJ
I I I
1111
WIIIf
00 00 00
IISfOTl STARTSTrJP PANEl
VOLT
METER
Engines Generators
32 KW BEDA GENERATOR
WIRING SCHEMATIC 041128 SINGLE RELAY
24 VDC SPECIAL SPEC
STARTER
SOLENOID STARTER
PREHEAT
SOLENOID
r 1 AIR INTAKE HEATER
AL TERNATOR
OUTPUT
20 AMP
I RCU I T
START
SWITCH
30 0 START
L BREAKER r 86
r EMERGENCY
I I STOP
L SWI TCH rI
PREHEAT
SW ITCH
K2 0
r STOP
I I SWITCH FUEL SOLENOID
OIL PRESS EXHAUST TEMP WATER TEMP
SWITCH SWITCH SWITCH
T826 T827
FIRE ALARM
N C CONTACTS
TENP VOL TMETER
OIL WATER
PRESS TEMP
SENDER SENDER
Engines Generators
32 KW BEDA GENERATOR
WIRING DIAGRAM 44806 TWO RELAYS
PLUGIN REMOTE STARTSTOP PANEL
WI 1 R liffflATURE
uIERNAIOR 1ge1VDC
WATER itlIflATURE 0
Jt1 BRN
R Ie
10 OIG
IIC eRN
RrDVID
II ltD
FUEL SOU NO Q
TEYwfut
II In
IUIT
0 AUX OIL PRESSURE
Z4 VDC
0 I IllrEUID
BRtAKtR2 vDe
IIIlII
fi 011 dHHURf
STAOOMOIOR WHT
14 TAli tRiet
SIll
I I VIO
III 1141
I IEDWHT
r 11
GROUND TO
L I ENGINE
BLOCK
t
E7 I
oinT
y
RED TB3
IIRO
FUSE 86
IU REO
s
ID
BLHT
IU eLK fIiRN
IHT
I Ro
1 WMT
rED illV
IIIU
REMOVE JUMPER OEM CONNECT IIG A SCONO REMOTE PANEl
PRaAT
SWITCH
TIUS
START
SWITCH
TIIIIO
STeP
SWITCH
HOlR YaT 115 0
Engines Generators
32 KW BEDA GENERATOR
WIRING SCHEMATIC 44806 TWO RELAYS
PLUGIN REMOTE STARTSTOP PANEL
BATTERY 122VDC
CIRCUIT
BREAKER STARTER
AIR INTAKE
HEATER
r I EMERGENCY
I ImCH I PREHEAT
ISOLENOI
L
ALTERNATOR
KISTART
KZRUN
WATER TENP
EXH TEMP SWITCH Oil PRESS
8A 5WI rCH 5WI rCH
r I SlOP
I ISWITCH IUOOZ KZRUN RELAY
rB21B6 85
F IRE ALARM
MC CONTACTS
PREHEAT START
SW I rc H SW I rCH K I START RELAY
r 1oi 85
LJ LJ
AUX DP SIITCH
Oil PRESS T813 T814 T822 T815 1621 182e T824 T825 WATER TEMP SEMDER
TBIIO
WATER TENP GAUGE
STOP
SWI TCH
PREHEAT START
SWITCH SWITCH
I NO LIGHT OIL PRESS GAUGE
r 1 r
L J LJ
TYP ICAL RENDTE STARTSTOP PANEL CDNECT IONS
NOTE VOL TNETER
o RENDTE CONECTOR PINS
Engines Generators
SPECIAL TOOLS FABRICATED TOOLS
These drawings provide a means by which simple tools can
be made to assist in the removal of the generator end from the
engine and in the replacement of the generator end on the
engine A local machine shop should be able to fabricate these
tools at a modest price but first check with your local WEST
ERBEKE dealer to see if these tools are available on loan
475 Lifting Eye Tool
125353 This tool allows a mechanic to safely remove the generator
end from the engine Attach this Generator End Lifting
ffiffi
I Eye to the four screw holes located under the control panel
I I
r To use this Lifting Eye remove the generators control panel
and screw the Lifting Eye to the generator end using four
M6 x 10 pitch capscrews
I I I
II I
ffi
I I 028 6 HOLES
11250 I 1131
0125 MATERIAL 316 STEEL
IFr DIMENSIONS
ARE IN INCHES
I 2501
Back End Lifting Eye Tool
This Lifting Eye mounts to the back end of the 375
generator Attach this Lifting Eye with two
M12 x 175 pitch capscrews using the two holes that are adjacent to the rear carrier
bearing housing MATERIAL STEEL
DIMENSIONS
ARE IN INCHES
continued
Engines Generators
SPECIAL TOOLS GENERATOR
1850
ooJl
1285 861
2188
DIMENSIONS
ARE IN INCHES
1025 MM DRill 404
125DEEP AND TAP
11112 X 175 100 DEEP
Pilot Tool
This tool prevents the rotor from damaging the windings
when the generator housing is removed from the engine or
when it is installed on the engine Screw the MI2 threaded
rod into the end of the Pilot Tool then screw the Pilot Tool
M12 THREADED ROD
into the rotor shaft to use as a guide 158 lG OVERAll
X 175 Alignment Tool
This tool allows a mechanic to safely remove and install the
generator drive disks by aligning the disks with the Drive
mwmwnWm c
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
I 25 in 635 mm APPROX I
Material One M1D x 125 pitch bolt with the hex head machined
the drive plates weight while removing or replacing these off and a screwdriver slot cut in the machined
Engines Generators
INDEX
AC Voltage Connections 107 108 Fuel System Intake 81 Feed Pump 60
Air Intake 42 42 45 44 82 Injection Pump 63
Alternator Bracket 40 Injectors 42 61
Alternator Dual Output 84 Lift Pump 59
Back Plate 19 3645 Return Lines 81 83 Flywheel 15 29 36
BE Generator Single and Three 106 Frequency Adjustment 103
BE Generator 112 15 45 AC Voltage Connections 107 108
Camshaft 19 23 32 BE Single and Three Phase 106
Circuit 106 Circuit Test 6 49 Control Panel Switches 192734 Frequency Adjustment 103
Control Panel Admiral 103
Control Panel 79 Internal Wiring Schematics ll0 111
Control Panel Switches 104 Maintenance 103
Control Panel 80 46
Control Panel 105 Removal 14
Coolant 4546 Special Tools 126
Coolant Pump 54 55 100
Coolant Pump Connector and Hose 44 112
Crankcase Breather 45 Heat 45 54 19 28 32 80
Crankshaft 40 Idle Speed Adjustment 29 Injection Pump 63
Cylinder 16 20 40 Intake 42
Cylinder Head Bolts 16 41 49 Lifting Eyes 42
Cylinder 19 26 33 Lower 18 37
Drive Belt Adjustment 48 Main Bearing 19 32
Electronic 113 Metric Conversions 130 Governor 114 Oil
Engine 38
Adjustments 48 Filter Housing 18 38
14 Jet 3031
Inspection and 20 Level 43
Overhaul 6 51
Parts 5 Pressure Gauges 105
31 Pressure 184551
4 Pressure Switch 184551
7 Pump 18 38 51
Exhaust Manifold 45 46 47 Sump 18 38
Fuel System Parts 5
Bleeding 60 Parts 102
Feed Line 43 Piston and Piston Rings 19 25 34
Engines Generators
INDEX
Pumps Valve
Coolant 40 54 55 Valves 17 20 21 31
Fuel Lift 59 Clearance Adjustment 48
Injection 63 Guide 21
Raw 54 58 Seal 31
Push 24 40 Seat 20
Raw Water Pump 44 54 58 Spring 22
Rear Oil Seal Crankshaft 19 29 36 Stem Caps 41
Remote Panel 104 Voltage Regulator l09
Rocker Ann and Shaft 16 24 41 Water Temperature 105
Rocker 16 45 Wiring and Lubricants 98 90A Four Propulsion Engine
Shore Power Transfer 115 Wiring Diagram 41343 86
Special Tools 126 90A Four Propulsion Engine
Wiring Schematic 41343 32 KW BEDA Generator Wiring
Diagram 040425
Engine 4 Single Relay 116
100 32 KW BEDA Generator Wiring Schematic 040425
Lubrication 53 Single Relay 117
Standard 98 32 KW BEDA Generator Wiring Diagram 040425
Two Relays 118
Starter 45 64
32 KW BEDA Generator Wiring Schematic 4980 Two Relays 119
Tappets 23 32 32 KW BEDA Generator Wiring Diagram for Overhaul 6 Two Remote StartStop Panel 16 44 54 55
32 KW BEDA Generator Wiring Schematic 44737
Timing Gear Case 17 37 Two Remote StartStop Panel 121
Timing Gear 17 39 32 KW BEDA Generator Wiring Diagram 041128
Single Relay 24 VDC Special Spec 122
Timing Gears 17 30 38
32 KW BEDA Generator Wiring Schematic Single Relay 24 VDC
Special Spec 123
90A Four Engine 99 32 KW BEDA Generator Wiring Diagram 44806
Standard 98 Two Relays Plugin Remote StartStop Panel
32 KW BEDA Generator Wiring Schematic 44806
Two Relays Plugin Remote StartStop Panel 125
Borg Warner Velvet Drive 93
Wiring Harness 45
Damper Plate 15 45
Hurth HBW 250 91
Hurth 88
Oil Coolers 45 88 96
BE 112
Electronic 114
Engine 7
Engine Control Panel 80
Generator Control Panel 105
Transmission 96
Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO Liters Gallons Liters Liters Gallons
Liters Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 of
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet tt x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 Cubic Inches in3 x 16387 Cubic Centimeters x 061 in3
Imperial Pints IMP pt x 568 Liters L x 176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x 13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ttIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 US Degree Fahrenheit oF DC X 18 32
Degree Celsius DC OF 32 x 56
Engines Generators
Engines 0095C900

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