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Century 120 N6 Technical Manual




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SERVICE MANUAL
80N4 and 11OT4
120N6 and 170T6
MARINE DIESEL ENGINES
45KW 60Hz 35KW 50Hz BED
55KW 60Hz 45KW 50Hz BED
65KW 60Hz 55KW 50Hz BED
95KW 60Hz 80KW 50Hz BED
MARINE DIESEL GENERATORS
PUBLICATION NO47069
FIRST EDITION
JANUARY 2002
l rWESTERBEKE
j WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319 TEL FAX WEBSITE
Mmbu Nalional Marine Manujacturur AssocIation
CALIFORNIA PROPOSITION 65
gas from diesel and
gasoline engines and some of
its constituents are known to
the State of California to cause
cancer birth defects and harm
gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine also recommends instaling DETECTORS in the quarters
of your vessel They are inexpensive and at your local marine store
WARNING
Geneoators Produce CAABON MONOIIIlE
ROIIJIar Manonanoo
Engines Generators
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are caused
by failure to follow fundamental rules and when dangerous conditions exist and take the
A WARNING Fire can cause injury or precautions to protect yourself your your machi1lery
Prevent flash fires Do not smoke or permit flames or
The following safety instructions are in compliance with the sparks to occur near thc carburetor fuel line filter fuel
American Boat and Yacht Council ABYC standards pump or other potential sources of spilled fuel or fuel
vapors Use a suitable container to catch all fuel when
PREVENT ELECTRIC SHOCK removing the fuel line carburetor or fuel filters
Do not operate with a Coast Guard Approved flame
arrester removed Backfire can cause severe injury or
A WARNING Do not touch AC electrical connections death
while engine is running or when connected to shore Do not operate with the air removed
power Lethal voltage is present at these connections Backfire can cause severe injury or death
Do not smoke or permit flames or sparks to occur ncar the
Do not operate this machinery without electrical fuel system Keep the compartment and the enclosures and covers in place
ator clean and free of debris to minimize the chances of
Shut off electrical power before accessing electrical fire Wipe up all spilled fuel and engine oil
equipment Be aware diesel fuel will burn
Use insulated mats whenever working on electrical
equipment PREVENT BURNS EXPLOSION
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
Remove wristwatch and all jewelry when working on
A WARNING Explosions from fuel vapors can cause
injury or death
electrical equipment
Do not connect utility shore power to vessels AC
circuits except through a shiptoshore double throw Follow refueling safety instructions Keep the vessels
transfer switch Damage to vessels AC generator may hatches closed when fueling Open and ventilate cabin
result if this procedure is not followed after fueling Check below for fumesvapor before running
the blower Run the blower for four minutes before start
Electrical shock results from handling a charged capacitor ll1g your engll1e
Discharge capacitor by shorting terminals together
All fuel vapors are highly explosive Use extreme care when
PREVENT BURNS HOT ENGINE handling and storing fuels Store fuel in a
area away from equipment and out of the
reach of children
A WARNING Do not touch hot engine parts or Do not fill the fuel tanks while the engine is running
exhaust system components A running engine gets Shut otf the fuel service valve at the engine when servicing
very hot the fuel system Take care in catching any fuel that might
spill DO NOT allow any smoking open flames or other
Always check the engine coolant level at the coolant sources of fire near the fuel system or engine when servicing
recovery tank Ensure proper ventilation exists when servicing the fuel
system
Do not alter or modify the fuel system
AWARNING Steam can cause injury or death
Be sure all fuel supplies have a positive shutotT valve
In case of an engine overheat allow the engine to cool Be certain fuel line fillings are adequately tightened and
before touching the engine or checking the coolant free of leaks
Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this 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
Disconnect the battery cables before servicing the engine Ensure that the exhaust system is adequate to expel gases
generator Remove the negative lead first and reconnect discharged from the engine Check the exhaust system
it last regularly for leaks and make sure the exhaust manifold
elbow is securely attached
Make certain all personnel are clear of the engine before
starting Be sure the unit and its surroundings are well ventilated
Run blowers when running the generator set or engine
Make certain all covers guards and hatches are re
installed before starting the engine Dont run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA24 Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved detectors
A WARNING Battery explosion can cause injury For additional information refer to ABYC T22
educational information on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electcal
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 systems
Never connect the negative battery cable to the posi Exhaust sulfur causes rapid deterioration of copper tubing
tive connection terminal of the starter solenoid Do 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 toxi as
Avoid contacting the terminals with tools etc to prevent
exhaust fumes from gasoline engines carbon monOXIde
burns or sparks that could cause an explosion Remoe
gas is present in diesel exhaust fumes Some of the
wristwatch rings and any other jewelry before handlIng
symptoms or signs of carbon monoxide inhalation or
the battery
poisoning are
Always tum the battery charger ofT before Vomiting
Inability to think coherently
the battery connections Remove the negative lead first
Dizziness Throbbing in temples
and reconnect it last whenservicing the battery
Headache Muscular ACID Nausea Weakness and
sleepiness
AVOID MOVING PARTS
A WARNING Sulfuric acid in batteries can cause
severe injury or death A WARNING Rotating parts can cause injury
or death
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec
Do not service the engine while it is running If a situation
tion Batteries contain sulfuric acid which is destructive
arises in which it is absolutely necessary to make operat
If it comes in contact with your skin wash it off at once
ing adjustments use extreme care to avoid touching mov
with water Acid may splash on the skin or into the eyes
ing parts and hot exhaust system components
inadvertently when removing electrolyte caps
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment avoid wearing loose jackets shirts sleeves
rings necklaces or bracelets that could be caught in INSTALLING GASOLINE AND DIESEL ENGINES AND
moving parts GENERATORS
Make sure all attaching hardware is properly tightened Read the following ABYC NFPA and USCG publications
Keep protective shields and guards in their respective for safety codes and standards Follow their recommenda
places at all times tions when installing your WESTERBEKE Do not check fluid levels or the drive belts
tension while ABYC American Boat and Yacht Council
the is operating Safety Standards for Small Craft
Stay clear of the drive shaft and the transmission coupling Order From
when the engine is running hair and clothing can easily ABYC
be caught in these rotating parts 3069 Solomons Island Rd
Edgewater MD 2 NOISE NFPA National Fire Protection Association
Fire Protection Standard for Motor Craft
A WARNING High noise levels can cause hearing Order From
loss NFPA
I Batterymarch Park
Never operate a generator without its muffler installed PO Box 901
Quincy MA 022699101
Do not run an engine with the air intake silencer
removed USCG United States Coast Guard
USCG 33CFR183
Do not run engines or generators for long periods with
their enclosures open Order From
US Government Printing Office
Washington DC 20404
A WARNING Do not work on machinery when you
are mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all ENGINE AND to install a gasoline engine or generator
should
begin with a thorough examination of the American Boat and
Yacht Councils ABYC standards These standards are from
a combination of sources including the USCG and the of the ABYC standards of particular interest are
H2 Gasoline fuel systems
PI Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure
Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper 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 Wiring Diagram 44780 84
Testing for Overhaul 3 Remote Instrument Panel 86
Engine 4 Wiring Diagram 44781 87
Angular Tightening Methods Engine 89 108
Standard Torque An extensive Disassembly 10 Torque Data 109 III
Important Measurements 11 BE Generator 112
Voltage Regulator Steps 12
Generator Information 15
AC Voltage Connections 115
Cylinder Head Disassembly 16 Internal Wiring diagram 34
Refer to the index for specific items in this section Electronic Governor Adjustments 117
such as pistons flywheel crankshaft valves push the Electronic Governor 118
rods camshaft etc BE 119
Assembly 46 Generator Maintenance 120
Refer to the index for specific items in this section
such as rocker arms oil cooler engine timing etc 45 BED Generator System 4 7 55 BED Generator 122
Cooling System 49 65 BED Generator 123
Raw Water Pump 95 BED Generator BON4 Engine 125
Engine Adjustments 110T4 Engine 126
Fuel System 120N6 Engine 170T6 Engine 69 Layup and 46
Complete testing and breakdown of the Manda 51A
alternator
Metric Conversions Data 129
Starter Motor 83 Special Tools l31
Complete testing and breakdown of the starter motor Index 132
Engines Generators
SOFTWARE Customer Card
Product software technical data parts lists and catalogs provided from sources other are not within WESTERBEKES control
CANNOT BE RESPONSIBLE FOR THE Engines OF SUCH SOFTWARE MAKES NO WAR
RANTIES OR WITH RESPECT Customer INCLUDING ACCURACY TIMELINESS OR MR GENERATOR THEREOF
AND WILL IN NO EVENT
MAIN STREET
BE LIABLE FOR ANY TYPE OF DAMAGE OR IN CONNECTION WITH OR ARISING OUT HOMETOWN USA
OF THE FURNISHING OR USE OF SUCH SOFTWARE Model 55 BED Ser customers should keep in mind the time
Expires 1112001
span between printings of WESTERBEKE product software
and the unavoidable existence of earlier software The product software provided with The WESTERBEKE serial number is an
alphanumeric
number that can assist in determining the date of products whether from WESTERBEKE or
other suppliers must not and cannot be relied upon exclu ture of your WESTERBEKE The manufac
turers date code is placed at the end of the engine serial
sively as the definitive authority on the respective product It
number and consists of a character followed by three num
not only makes good sense but is imperative that appropriate
bers The character indicates the decade A1960s of WESTERBEKE or the supplier in question
C1980s 0 I 990s E2000s the first number represents the
be consulted to determine the accuracy and currentness of the
year in the decade and the second and third numbers software being consulted by the customer
sent the month of CAUTIONS AND WARNINGS SERIAL NUMBER LOCATION
As this manual takes you through the operating procedures The engines serial number can be found stamped into schedules and of your
marine engine block just out board of the injection pump An critical information will be highlighted by NOTES fication plate
on the engine manifold also displays the and WARNINGS An explanation follows model and serial number
NOTE An operating procedure essential to note The generator serial number is stamped on the left side of the
generator housing and on the flat surface above the rotary
A CAUTION Procedures which if not strictly carrier bearings
observed can result in the damage or destruction of ENGINE OVERHAUL
your engine
The following sections contain detailed information
relating to the proper operation of the major
components and systems of the engine Included are
A WARNING Procedures which if not properly disassembly inspection and reassembly instructions for the
guidance of suitable equipped and staffed marine engine
followed can result in personal injury or loss of life
service and rebuilding facilities The necessary procedures
should be taken only by such PARTS Additional detailed information and are
Whenever replacement parts are needed always provide the provided in other sections of this manual covering the
engine model number and serial number as they appear on generator alternator starter motor engine silver and black nameplate located
on the manifold You cooling pumps etc
must provide us with this information so we may your engine In addition include a complete and part number for each part needed see furnished Parts
List Insist upon parts because will fit or generic parts are made to the same as original
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL of Low Compression
Compression pressure tends to increase a little in a the time at which an engine should be overhauled engine until piston rings and valve
seats have been broken in
is determined by various conditions such as lowered engine Thereafter it decreases gradually with the progress of wear
power output decreased compression pressure and increased of these parts
fuel and oil consumption The lowered engine power output When decrease of compression pressure reaches the repair
is not necessarily due to trouble with the engine itself but is limit the engine must be caused by injector nozzle wear or injection pump
The engine requires overhaul when oil consumption is high
wear The decrease in compression pressure is caused by blowby evident and compression values are at minimum or
many factors It is therefore necessary to determine a cause below Engine compression should be 31 kgcm 441 psi at
or causes on the basis of data produced by periodic 200 rpm The maximum difference between cylinders and maintenance Oil analysis
on a seasonal basis not exceed 10
is a good means of monitoring engine internal wear When
caused by worn cylinders or piston rings the following will occur
1 Before disassembly and cleaning carefully check for
1 Low engine power output defects which cannot be found after disassembly and
2 Increased fuel consumption cleaning
3 Increased oil consumption 2 Drain water fuel and oil before disassembly
4 Hard engine starting 3 Clean or wash the engine exterior
5 Noisy engine operation 4 Do not remove or disassemble the parts that require no
These symptoms often appear together Symptoms 2 and 4 result also from excessive fuel injection improper injec S Perform
disassembly in a proper order using proper tools
tion timing and wear of the injectors They are caused also Keep disassembled parts in order Apply oil when neces
by defective electrical devices such as the battery alternator sary Take special care to keep the fuel system parts from
starter and glow plugs Therefore it is desirable to judge the intrusion of dust and dirt
optimum engine overhaul time by the lowered compression 6 Parts must be restored to their respective components from
pressure caused by worn cylinders and pistons plus increased which they were removed at disassembly This means that all
oil consumption Satisfactory combustion is obtained only parts must be set aside separately in groups each marked for
under sufficient compression pressure If an engine lacks its component so that the same combination or set can pressure incomplete
combustion of fuel will reproduced at place even if other parts of the engine are operating
7 Pay attention to marks on assemblies components and
properly To determine the period of engine overhaul it is
parts for their positions or directions Put on marks if
important to measure the engine compression pressure regu
necessary to aid At the same time the engine speed at which the mea
surement of compression pressure is made should be checked S Carefully check each part or component fore any sign of
because the compression pressure varies with engine rpm faulty condition during removal or cleaning The part will
The engine rpm can be measured at the front end of the tell you how it acted or what was abnormal about it
accurately during removal or To test engine compression see the ENGINE ALTERNATOR
section of this manual
When rebuilding the engine the alternator should be and inspected The housing can be
wiped off with a solvent
and the alternator terminal studs should be cleaned with a
1 Wah all parts except for oil seals arings rubber sheets wire brush Make certain the studs are tight and clean the
etc with cleaning solvent and dry them with pressure air
wiring connections that connect to the wiring harness
2 Always use tools that are in good condition and be sure
Tum the rotor pulley by hand It should tum smoothly
you understand how to use them before performing any
job Depending on when the alternator was last serviced the
brushes may need replacing If the alternator is at all suspect
3 Use only good quality lubricants Be sure to apply a coat
send it to a service shop for testing and overhaul
of oil grease or sealant to parts as specified
For additional information on alternators refer to the
4 Be sure to use a torque wrench to tighten parts for which
ALTERNATOR and MANDO
torques are specified
SERVICE in this manual
S Ant time the engine is assembled new gaskets and
arings must be Engines Generators
ENGINE following chart describes certain Refer also to the more detailed relating to engine service the probable causes of
in the back of this manual
these problems and the to overcome NOTE The engines electrical system is protected by a 20
these problemsThis chart may be of assistance in determining ampere manual reset circuit breaker The preheat solenoid is
the need for an engine overhaul mounted on the same bracket
PROBLEM PROBABLE CAUSE HARO STARTING LOW CRANKING SPEEO
1 Engine oil viscosity too high 1 Replace engine oil with less viscous oil
2 Rundown battery 2 Recharge battery
3 Worn battery 3 Replace battery
4 Battery terminals loosely connected 4 Clean terminals and correct cables
5 Defective starter 5 Repair or replace starter
DEFECTIVE INJECTION SYSTEM
1 Air trapped in fuel passage 1 Bleed air from fuel system
2 Clogged fuel filter 2 Clean or replace filter
3 Low injection pressure 3 Adjust injection pressure
4 Inadequate spray 4 Clean or replace nozzle
5 Injection pump delivering insufficient fuel 5 Repair or replace injection pump
6 Injection too early 6 Adjust injection timing
MAIN ENGINE TROUBLES
1 Low compression
a Incorrect valve clearance a Adjust valve clearance
b Inadequate contact of valve seat b Lap valve
c Valve stem seized c Replace valve and valve guide
d Broken valve spring d Replace valve spring
e Compression leaks through cylinder head gasket e Replace gasket
I Piston ring seized I Replace piston and piston ring
g Worn piston ring and cylinder g Overhaul engine
2 Burnt glow plug 2 Replace glow plug
3 Faulty glow plug operation 3 Correct lead wire connection
4 Incorrect governor lever position 4 Set lever to starting position
LOW OUTPUT LOW COMPRESSION See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1 Incorrect injection timing 1 Adjust injection timing
2 Insufficient injection 2 Repair or replace injection pump
3 Low injection pressure 3 Check injection nozzle and adjust pressure
INSUFFICIENT FUEL
1 Air trapped in fuel system 1 Check and retighten connector
2 Clogged filter 2 Clean or replace filter
3 Contaminated fuel tank 3 Clean tank
INSUFFICIENT INTAKE AIR
1 Clogged air cleaner 1 Clean or replace air cleaner
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT cont OVERHEATING
1 low coolant level 1 Add coolant
2 Loose Vbelt 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low engine oil level 6 Add engine Oil Oil 1 Defective oil seals 1
Replace oil seals
2 Broken gear case gasket 2 Replace gasket
3 Loose gear case attaching bolts 3 Retighten bolts
4 Loose drain hose 4 Retighten hose
5 Loose oil pipe connector 5 Retighten oil connections
6 Broken rocker cover gasket 6 Replace gasket
7 Loose rocker cover attaching bolts 7 Retighten attaching bolts
Oil lEVEL RISING
1 Incorrectly positioned piston ring gaps 1 Correct ring gap positions
2 Displaced or twisted connecting rod 2 Replace connecting rod
3 Worn piston ring 3 Replace ring
4 Worn piston or cylinder 4 Replace piston and rebore cylinder
Oil lEVEL FALLING
1 Defective stem seal 1 Replace stem seal
2 Worn valve and valve guide 4 Replace a valve and valve FUEL ENGINE BODY 1 Noisy knocking
1 See KNOCKING
2 Smoky exhaust 2 See SMOKY EXHAUST
3 Moving parts nearly seized or excessively worn 3 Repair or replace
4 Poor compression 4 See LOW COMPRESSION HARD STARTING
5 Improper valve timing 5 Adjust
6 Improper valve clearance 6 Adjust
INSUFFICIENT INTAKE AIR
1 Air intake obstructed 1 Remove NOZZLE TROUBLES
1 Seized nozzle 1 Replace
2 Worn nozzle 2 Replace
IMPROPER FUEL Replace with proper fuel
FUEL lEAKS Find fuel leaks
SMOKY EXHAUST WHITISH OR PURPLISH
1 Excessive engine oil 1 Correct oil level
2 Excessive rise of oil into combustion chamber
a Poor piston contact a Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST cont WHITISH OR PURPLISH cont
d Worn valve stem and valve guide d Replace
e Low engine oil viscosity e Replace
f Excessive oil pressure f Correct
3 Injection timing is too late 3 Adjust
4 Insufficient compression 4 See LOW COMPRESSION HARD STARTING
BLACKISH OR DARK GRAYISH
1 Engine body troubles
a Poor compression a See LOW COMPRESSION HARD STARTING
b Improper valve clearance b Adjust
2 Insufficient intake air air cleaner clogged 2 Clean air cleaner
3 Improper fuel 3 Replace with proper SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE 1 Badly worn bearing 1 Replace bearing and grind crankshaft
2 Badly worn crankshaft 2 Grind crankshaft
3 Melted bearing 3 Replace bearing and check lubrication system
CONNECTING ROD AND CONNECTING ROD BEARING
1 Worn connecting rod big end bearing 1 Replace bearing
2 Worn crankpin 2 Grind crankshaft
3 Bent connecting rod 3 Correct bend or replace
PISTON PISTON PIN AND PISTON RING
1 Worn cylinder 1 Rebore cylinder to oversize and replace piston
2 Worn piston pin 2 Replace piston
3 Piston seized 3 Replace piston and rebore cylinder
4 Piston seized and ring worn or damaged 4 Replace piston and rings
VALVE MECHANISM
1 Worn camshaft 1 Replace
2 Excessive valve clearance 2 Adjust
3 Worn timing gear 3 Replace
4 Worn fan pulley bearing 4 OPERATION INJECTION PUMP SYSTEM
1 Uneven injection 1 Adjust injection or replace parts
2 Control rack 2 Disassemble check and correct injection pump
3 Worn delivery valve 3 Replace
4 Inadequate injection nozzle spray 4 Replace injection nozzle
GOVERNING SYSTEM
1 Governor lever 1 Check governor shaft and correct operation
2 Fatigued governor spring 2 Replace
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE ENGINE KNOCKS WITHOUT MUCH SMOKE
1 Main engine troubles
a Overheated cylinder a See OVERHEATING LOW OUTPUT
b Carbon deposits in cylinder b Clean
2 Too early injection timing 2 Correct
3 Too high injection pressure 3 Correct
4 Improper fuel 4 Replace with proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See LOW COMPRESSION HARD STARTING
2 Injection pump 2 3 Improper nozzle
a Poor spray a Clean or replace nozzle
b Poor chattering b Repair or replace nozzle
c drip c Repair or replace nozzle
d Nozzle needle valve seized d 1 Fuel filter clogged 1 Clean or SOUND 2
Water mixed in fuel 2 Replace 1 Vbelt slackening or slippery with oil 1 Adjust replace or
clean
2 Damaged water pump 2 Replace
3 Lack of coolant 3 Add
4 Low oil level or poor oil quality 4 Add or change
5 Knocking 5 See KNOCKING
6 Moving parts seized or damaged 6 Replace
7 Defective thermostat 7 Replace
LOW OIL PRESSURE 1 Worn Bearings 1 Engine overhaul replace bearings
2 Relief valve malfunction 2 Overhaul oil pump
3 Clogged oil cooler 3 Repair
4 Diesel dilution of the oil 4 Injection pump repair
Engines Generators
ANGULAR NUT AND BOLT TIGHTENING METHOD
1 Carefully wash the nuts and bolts to remove all oil and 6 Draw another line FG on the face of each of the parts
grease to be clamped This line will be in the direction of the
2 Apply a coat of molybdenum disulfide grease to the specified angle Q across the center E of the nut or
threads and setting faces of the nuts and bolts bolt
3 Tighten the nuts and bolts to the specified torque snug 7 Use a socket wrench to tighten each nut or bolt to the
torque with a torque wrench point where the line AB is aligned with the line FG
CENTER LINE Example Specified Angle and Tightening Rotation
LINE A 30 1112 of a turn
l C D
16 of a turn
114 of a turn
112 of a turn
E 360 One full turn
4 Draw a line AB across the center of each bolt
S Draw another line CD on the face of each of the parts
to be clamped This line should be an extension of the
line AB
COINCIDING LINE
Engines Generators
STANDARD BOLTS I TIGHTENING TORQUE The torque values given in the followillg table should be applied where a particular torque is not specified
Id I
I e
M 8 X 125 13 05 16 1 06 21 07 07
M10 X 125 28 07 33 38 43 09 I 51 13
M10 X 15 27 07 32 08 37 09 42 10 49

6 2 13 67 14 16 8 8 18 9 19
M12 X 125 12 13 77 15 7 20
M12 X 175 58 12 63 12 72 14 82 16 91
r
2 2 9 23 13 6 26
M14 X 15 97 19 104 21 11 24 145 29
M14 X 20 91 18 98 19 112 22 128 25 136 27
M16 X 15 133 27 151 31 173 35 197 40 204 41
f 4
M18 X 25 192 38 218 250 50 285 57 I 294

M20 X 25 243
278
I 318 64
L
3 R 72
73 374 75
M22 X 15 i 320 1 II 404 81 I 463 528 10 5
106 541 108
M22 X 25 i 278 56 376 75 I 431 86 491 98 503 101
M24 X 20 i 458 92 r9 1Ir 5 626 20 1
126 706
M24 X 30 431 86 451 90 517103 589 118 664133
NOTE Bolts marked with all asterisk are usedfor female threaded parts made of soft materials slIch as
Engines Generators
ENGINE DISASSEMBLY
GENERATOR ENGINE DISASSEMBLY
Disconnect the AC wiring and unplug the engines DC Take the following precautions
wiring harness at the generator control panel Remove the Clean the exterior of the engine of any deposits of
battery cables from the engine and tape over the terminals dirt and oil
NOTE Label any lines hoses or cables as you separate tzem Be careful not to damage the disassembled parts
Separate the exhaust hose at the water injected elbow and Arrange parts in the order of disassembly Mark or
disconnect the fuel supply and return lines label parts as needed to insure proper mating and
Drain the engine oil and the coolant from the engine reassembly Keep parts clean
Carefully support and then unbolt the generator backend Mount the engine on a suitable engine stand for
from the engine See SPECIAL TOOLS in this manual disassembly
Additional generator information will be found in the With the separated from the engine
GENERATOR section of this manual begin the following step by step procedure to disassemble
the engine
PROPULSION ENGINE
1Remove the transmission damper plate from the
Switch off the batteries and disconnect the battery cables engine flywheel
from the engine and tape over the terminals
2 Remove the engine oil cooler and oil hoses Note oil
Drain or pump out all the engine oil and drain the coolant hose connections from the oil cooler to the engine
from the engine and engine hoses
3 Remove the engine heat exchanger If possible leave
Unplug the instrument panel wiring harness Drain the one end of each hose connected to the part being removed
transmission fluid and the transmission oil cooler hoses
Detach the oil cooler hoses and unbolt the transmission from 4 Remove the bell housing and the circuit breaker
the engine preheat solenoid mounting bracket
5 Remove the engine back plate
6 Remove the start motor drive belt and the alternator
Label the wires and cables
7 Remove the engine mounted raw water pump
complete with its adapter mounting plate See RAW
WATER PUMP for parts PETCOCK
DRAIN fJ 8 With the hoses disconnected remove the thermostat
housing and housing gasket leaving the temperature
0 sender in place
9 Remove the coolant circulating pump Refer to
TRANSMISSION COOLANT PUMP ASSEMBLY
If the transmission is not being rebuilt it should be visually 10Remove the air intake silencer and the intake manifold
inspected Flush out and pressure test the oil cooler and 1lRemove the oil filter and the mounting bracket from the
replace the coolant hoses Inspect and lubricate the gear shift engine block
linkage and the propeller shaft coupling Clean and repaint 12Unbolt the elbows and remove the exhaust manifold in
the transmission and change the transmission fluid its entirety
For transmission service and maintenance refer to your 13Remove the fuel injection pump Disconnect the fuel
transmission manual To rebuild a transmission contact injection pipes and fuel leakoff pipe from the fuel injection
your WESTEEKE dealer or an authorized pump and nozzles
transmission service center
NOTE Put plugs or caps on the openings of the injection pump
and nozzle connectors Golf tees work well as plugs
DAMPER PLATE 14Remove the fuel injection nozzle Loosen the fuel
BOLTS
injection nozzles with a wrench Remove the nozzles and
gaskets from the cylinder head
lSPepare to disassemble the engine block
DAMPER
PLATE
Engines Generators
TO MAIN ENGINE DISASSEMBLY
1 Idler Gear
Measure the following points before disassembly
FEELER GAUGE
mmin
Standard Limit
t f
Idler Gear End 0058 0115 02
Play 0002 0005 0008
mmin
Standard Limit MEASURE IDLER GEAR END
0
Timing Gears 010 017 03
Backlash 0004 0007 the crankshaft gear the camshaft gear and the
DIAL
idler gear 2 Cam Shaft
Measure the following points before disassembly
mmin
Standard Limit MEASURE TIMING GEARS BACKLASH
Cam Gear End 0050 0114 02
Play 0002 0005 0008
CAMSHAFT GEAR
3 Crankshaft Bearing Cap THRUST PLATE
Measure the crankshaft end play at the thrust bear
ing center main bearing before disassembly FEELER GAUGE
mmin
Standard Crankshaft End 015 033 04
Play 0006 0014 0016
MEASURE CAM SHAFT GEAR END PLAY
MEASURE CRANKSHAFT BEARING CAP END PLAY
Engines Generators
DISASSEMBLY
6 2
Steps
1 Dipstick and guide tube e tu be
2 Air breather
3 Turbo adapter
4 Oil feed pipe
5 Oil drain pipe 9
6 Turbocharger 5
7 Gasket
8 Starter Drive belts Plug oil ports in turbocharger body
Alternator after removal of the Waterpump pulley
1 3 6
12 Cylinder head cover
Engines Generators
Steps
1 Rubber hose water bypass 9 Oil pump driving pinion
2 Rocker arm shaft assembly 10 Starting handle nut
3 Push rod 11 Taper bushing
4 Clinder head bolt 12 Crankshaft pulley and dust thrower
5 Cylinder head assmbly 13 Timing gear cover
6 Cylinder head gasket 14 Oil thrower
7 Water pump assembly
8 Tappet chamber cover 15 Flywheel
11 14
10 J
Engines Generators
INDICATE
SIX CYLINDER ORDER SHOWN
OF DISASSEMBLY
14 CRANKSHAFT
11 CRANKSHAFT 3 OIL PUMP
AND COUPLING
8EARING LOWER AND ARING CAP
2 OIL PAN
NOT SHOWN
3 THRUST
BEARING
5 PISTON AND
CONNECTING RODl
8TAPPETS1j Irj I
4 FLYWHEEL
HOUSING
9 TIMING GEAR
CASE
1 OIL COOLER
INSPECT OIL COOLER ASSEMBLY
7 CAMSHAFT 0 REPLACE ANY PARTS THAT
jJ 10 IDLER GEAR SHOW EXCESSIVE WEAR
SHAFT OR DAMAGE
6 IDLER
Steps
1 Oil cooler
2 Oil pan
OIL COOLER
3 Oil pump and coupling INSPECT OIL COOLER ASSEMBLY
4 Flywheel housing REPLACE ANY PARTS THAT
5 Piston and connecting rod SHOW EXCESSIVE WEAR
OR DAMAGE
6 Idler gear
7 Camshaft
8 Tappet
9 Timing gear case OIL COOLER
10 Idler gear shaft ELEMENT
11 Crankshaft bearing cap
12 Crankshaft bearing lower half
13 Thrust bearing
14 Crankshaft
15 Crankshaft bearing upper half
16 Oil Jet 6 cyl turbo only BYPASS VALVE
ORING SPRING
AND PLUG
Engines Generators
TOPRING
CARBON DEPOSITS
2ND RING
SQUARE
COMBUSJION
3 CHAMBER
REMOVE CARBON NUMBERS INDICATE
3 ORDER OF DISASSEMBLY
1 PISTON RINGS
2 SNAP RINGS
3 PISTON PIN AND
CONNECTING ROD
4 CONNECTING ROD
BEARINGS
5 PISTON
REMOVING THE PISTON RINGS
SNAP RING
any carbon deposits from the upper part of the
cylinder bore
This will prevent damage to the piston and the piston
rings when they are removed from the cylinder bore
1 Piston Rings
REMOVING THE SNAP RINGS
Use a piston ring remover to remove the piston
rings
Do not attempt to use some other tool Piston ring
stretching will result in reduced piston ring 3 SNAP RINGS and Piston Pin PISTON PIN
1 Use a pair of snap ring pliers to remove the
snap ring
2 Tap the piston pin out with a hammer and
brass bar
REMOVING THE PISTON PINS BRASS BAR
Engines Generators
CYLINDER HEAD DISASSEMBLY
NUMBERS INDICATE THE SUGGESTED ORDER OF SPLIT COLLAR
7 SPRING SEAT UPPER
B VALVE SPRING INTAKE SIX CYLINDER SERIES SHOWN
11 VALVE STEM
9 VALVE SEAT OIL SEAL
LOWER
FOUR CYLINDER
SERIES
5 THERMOSTAT
10 VALVE 1 EXHAUST
INSPECTION AND REPAIR
Make all necessary adjustments repairs and part
replacements if excessive wear or damage is
discovered during WHEN REMOVING THE SPLIT COLLAR
USE VALVE SPRING Engines Generators
CYLINDER HEAD Water Jacket Water Pressure Test
Cylinder Head Lower Face Warpage Use the hydraulic gauge to check the water jacket water
pressure
1 Use a straight edge and a feeler gauge to measure Apply water pressure to the water jacket at 5 kgcm2
the four sides and the two diagonals of the cylinder 711 psi for three minutes
head lower face
Check the entire cylinder head for water leakage
2 Regrind the cylinder head lower face if the mea
sured values are greater than the specified limit but
less than the maximum grinding allowance
TESTING THE WATER
JACKET PRESSURE
If the measured values exceed the maximum grind
ing allowance the cylinder head must be replaced
Cylinder Head Lower Face Warpage mmin
Maximum Grinding
Standard Limit
Allowance
02 0008 03 0012
0002 or less
A VALVE GUIDE
Valve Stem and Valve Guide Clearance
Measuring Method I
1 With the valve stem inserted in the valve guide set
the dial indicator needle to 0
2 Move the valve head from side to side
INSPECT THE STRAIGHT EDGE AND Note the total dial indicator reading
FEELER GAUGE This value is the clearance between the valve stem
HEAD FACE and the valve guide
If the measured values exceed the specified limit
the valve and the valve guide must be replaced as a
Cylinder Head Height Reference
Standard
8995 3544 9005 3548
Limit
8965 3530
mmin
Valve Stem Clearance
Intake Side TIR
Exhaust Side TIR
Standard
0039
00015
0064
00025
0068
00027
0093
00038
mmin
Limit
0008
00098
Note
If the cylinder head lower face is reground valve
depression must be checked
MEASURE THE VALVE STEM AND GUIDE Engines Generators
Measuring Method II Valve Depression
1 Measure the valve stem outside diameter
1 Install the valve CD to the cylinder head ClJ
2 Use a caliper calibrator or a telescoping gauge to
2 Use a depth gauge or a straight edge with steel rule
measure the valve guide inside diameter
to measure the valve depression from the cylinder
The difference between the valve stem outside di head lower surface
ameter and the valve guide inside diameter is equal
If the measured value exceeds the specified limit
to the valve stem clearance
the valve seat insert andor valve must be replaced
If the valve is replaced the valve guide must be
also replaced
VALVE GUIDE 10 Standard I Limit
Intake and Exhaust
Valve Depression
10 0039 I 25 Guide Guide Removal
Use a hammer and the valve guide remover to drive out
the valve guide from the cylinder head lower face
Valve Contact Width
1 Inspect the valve contact faces for roughness and
unevenness
Make smooth the valve contact surfaces
2 Measure the valve contact width
If the measured value exceeds the specified limit
the valve seat insert must be replaced
mmin
Standard Limit
The height of the valve guide top edge from the
cylinder head upper face should be 141 mm 055 in Valve Contact Width 15 0059 20 0078
Engines Generators
Seat Insert Seat Insert Removal
1 Arc weld the entire inside circumference CD of the
valve seat insert
2 Allow the valve seat insert to cool for a few
minutes
This will invite contraction and make removal of the
valve seat insert easier
Valve Seat Insert Correction
1 Remove the carbon deposits from the valve seat
insert surface
2 Use valve cutters 15 30 or 75 blades to remove
scratches and other rough areas
This will bring the contact width back to the stand
ard value of 90
Remove only the scratches and rough areas Do
3 Use a screwdriver to pry the valve seat insert
not cut away too much Take care not to cut away
free
unblemished areas of the valve seat surfaces
Take care not to damage the cylinder head V
4 Carefully remove carbon and other foreign material
from the cylinder head insert bore
Valve Seat Installation
1 Carefully place the attachment CD having the
smaller outside diameter than the valve seat insert
on the valve seat insert smooth side of the attachment must contact the
valve seat insert Angle Location Standard
2 Use a bench press to slowly apply pressure to Intake Valve Seat Angle 45
the attachment and press the valve seat insert into Exhaust Valve Seat Angle 45
place Amount of pressure needed is more than
2500 kg Note
Note Use an adjustable valve cutter pilot
Do not apply an excessive amount of pressure with the Do not allow the cutter pilot to wobble inside the valve
bench press Damage to the valve seat insert will 3 Apply abrasive compound
to the valve seat insert
surface
4 Insert the valve into the valve guide
5 Hand lap the valve and the valve seat with a lapp
ing cup
This will provide optimum valve and valve seat con
tact for effective gas sealing
6 Check that the valve contact width is correct
7 Check that the valve seat insert surface IS in contact
with the entire circumference of the valve
Engines Generators
SPRING Valve Spring Spring Free Length Use a spring
tester to measure the valve spring tension
If the measured value is less than the specified limit the
Use a vernier caliper to measure the valve spring free
valve spring must be kglb
If the measured value is less than the specified limit the
valve spring must be replaced Standard Limit
mmin Valve Spring
Tension at 40 mm 145 3086 115 2436
Standard Limit
Set length
Exhaust and Intake
Valve Spring Free 490 1929 470 1850
Length
TAPPET Cam Follower or Valve Lifter
Inspect the tappets for excessive wear damage and any
Q Spring a surface plate and a square to measure the valve
Use a micrometer to measure the tappet inclination
mmin
If the measured value exceeds the specified limit the
valve spring must be replaced Standard Limit
mmin 2797 2798 2792
Tappet Diameter
11020 11024 11000
Standard Limit
Valve Spring less than
27 0106
Inclination 13 0051
Use a dial indicator to measure the clearance between
the tappet and cylinder body tappet travelling bore
mmin
ELlNATION Standard Limit
SQUARJ1Sj
Tappet and Tappet i
0020 0054 01
Travelling Bore
0002 0004
0001
Clearance I w
VALVE SPRING
TESTER
Engines Generators
MEASURING THE ROCKER ARM SHAFT
Use a filler gauge to measure the valve push rod the push rod along a smooth flat surfase
mmin
Limit
Push Rod RunOut 03 0012
PUSH ROD Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm outside
bof FEELER diameter
GAUGE If the measured value is less than the specified limit the
shaft must be replaced
mmin
Standard Limit
Rocker Arm Shaft 1898 1900 1885
Rocker Arm Correction Diameter 0747 0749 the rocker arm valve
stem contact surfaces for
ridgesG and scoring
If the surfaces have light ridge or scoring they may be
honed with an oil stone
ROCKER ARM
t SCORING 2
Rocker Arm Shaft and Rocker Arm Clearance
1 Use a vernier caliper to measure the rocker arm
bushing inside diameter
mmin
Standard I Limit
Rocker Arm Bushing 1901 1903 1905
Inside Diameter 0749 0750
1 0751
2 Measure the rocker arm shaft outside diameter
Replace either the rocker arm or the rocker arm
ROCKER ARM SHAFT AND ROCKER ARM shaft if the clearance exceeds the specified all disassembled
parts for wear damage and
any IEE T 0 00
ROCKER ARM SHAFT T
mmin
ROCKER ARM Standard Limit
ASSEMBLY I
Rocker Arm Bushing
001 005 02
and Rocker Arm I
00004 00020 00079
Shaft Clearance I
3 Check that the rocker arm oil port is free of obstruc
tions
If necessary use compressed air to clean the rocker
arm oil port
WESTERBEKE
Engines Generators
GEAR AND IDLER GEAR SHAFT
1 Use a micrometer to measure the idler gear shaft CAM BEARING
outside diameter II
If measured diameter exceeds specified limit
replace the idler gear shaft
mmin
Standard Gear Shaft 449 3 Align the camkshaft bearing oil holes with the mat
Outside Diameter 1768 ing oil ports machined on the cylinder body cam
shaft bearing fitting bore
MEASURING
IDLER GEAR SHAFT
2 Use a dial indicator to measure the idler gear inside
diameter
4 Use a micrometer to measure the cam lobe height
Standard Limit
If the cam lobe height is less than the specified li
Idler Gear and Idler 02 mit the camshaft must be replaced
Gear Shafft Clearance 0008
mmin
Standard Limit
Cam Lobe Height CD 771 0304 721 0284
MEASURING Cam Journal
IDLER GEAR 560 2205 556 2189
Diameter AB
1 Use the camshaft bearing remover and installer to
remove camshaft bearing from the cylinder body
Camshaft Bearing Remover and Installer
2 Measure the clearance between the cam journal
and the camshaft bearing
mmin I
Standard Limit
Cam Journal and Cam
Bearing Clearance
003 009
0001 0004
0006
sE 1
REMOVER
ANO INSTALLER
MEASURING THE CAMSHAFT
Engines Generators
5 Place the camshaft on a measuring stand Cylinder Liner Projection Inspection
Use a dial indicator to measure the camshaft run
1 Hold a straight edge CD
along the top edge of the
cylinder liner to be measured
Note the total indicator reading TIR
2 Use a feeler gauge to measure each cylinder
If the measured runout exceeds the specified limit liner projection
the camshaft must be replaced
mmin
mmin
Limit
Limit
I Camshaft RunOut TIR 012 0005
Cylinder Liner Projection 003 010 0001 0004
The difference in the cylinder liner projection height
i CYLINDER BODY AND LINER between any two adjacent cylinders must not
exceed 003 mm 0001 in
Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder liner
bore at measuring position CD
in line with the crank
STRAIGHT
EDGE
shaft and across the crankshaft
Measuring Point CD mm in 200 079 Maximum
Wear Portion
If the measured value exceeds the specified limit the
cylinder liner must be replaced
Cylinder Liner Replacement
CD Cylinder Liner Removal
1 Set the cylinder liner remover to the cylinder liner
2 Check that the remover shaft ankle is firmly gripp
ing the cylinder liner bottom edge
3 Slowly turn the remover shaft handle wise to pull the cylinder liner
free
Cylinder Liner Remover Cylinder Liner Remover Ankle
For all models except 6BG1 For 6BG 1
NOTE Take care not to damage the cylinder body upper face
during the cylinder liner removal REMOVER
TOOL
mmin
I Standard Limit
Cylinder 102021 102060 10220
4 Cyl
Liner Bore i 4017 4018 4024
Total Indica 1105021 105060 10520
6 Cyl
tor Reading 4135 4136 4142
Note The inside of the dry type cylinder liner is chrome
plated It cannot be rebored or honed If the inside of the
cylinder liner is scored or scorched the cylinder liner must
be Engines Generators
Bore Measurement Cylinder Liner Outside Diameter Liner Grade Selection
1 Take measurements at measuring points CD
and
The term grade refers to the cylinder body and the cylinder liner outside diameter combi Measuring Points
CD 200 the cylinder body inside diameter and select 2 1050 4137
the appropriate cylinder liner grade 3 1950 7683
Loose fitting cylinder liners the liner is too small for the 2 Calculate the average value of the 6 bore will adversely affect engine cooling
effi to determine the correct cylinder liner grade
MMIN
ciency and may lead to serious engine liners which are too large for the cylinder bore CYLINDER LINER FITTING 0001 0019
will be difficult to install CLEARANCE STANDARD 000004 00007
MEASURING THE MEASURING
CYLINDER BODY 10 POINTS
Body Inside Diameter Measurement
Cylinder Bore and Cylinder Liner Outside Diame
1 Take measurements at measuring point CD across ter Combinations
the positions WW XX VV and ZZ
Measuring Point CD 115 mm 4531 in Reference
80N4110T4 mmin
2 Calculate the average value of the four measure
Cylinder Liner
ments to determine the correct cylinder liner grade Grade I Cylinder Bore
Outside Diameter
105001 105010 105011 105020
MEASURING
41339 41343 41343 41346
I POINT 1 2
105011 105020 105021 105030
41343 41346 41347 41350
I 105021 105030 105031 105040
41347 41350 41350 120N6170T6
mmin
LINERS i 0 Cylinder Liner
P I Grade I
Cylinder Bore
I Outside Diameter
I 107001 107010 107011 107020
1
i 42126 42130 I 42130 42134
107011 107020 107021 107030
i 42130 42134
42134 42138
107021 107030
107031 107040
y 3
I 42134 42138 42138 42142
Engines Generators
Liner Installation Piston Grade Selection
1 Carefully wipe away any foreign material from the The term piston grade refers to the piston diameter
cylinder liner inside and outside surfaces and the and cylinder liner bore combination
cylinder bore Selection of the proper piston grade will ensure efficient
2 Use new kerosene or diesel oil to thoroughly clean engine operation free from cylinder liner and piston
the cylinder liner and bore surfaces problems
3 Use a clean rag to remove all traces of kerosene or Measure the cylinder liner bore after installing the cylin
diesel oil from the cylinder liner and bore surfaces der liner Then select the appropriate piston grade for
the installed cylinder liner
CYLINOER
LINER
INSTALLER
TOOL
I I
CYLINDER
LINER
BORE
I I
fUNDER BODY
4 Insert the cylinder liner CDinto the cylinder body
from the top of the cylinder body Cylinder Liner Bore Measurement
5 Set the cylinder liner installer to the top of the 1 Locate the two measuring points
cylinder liner
Cylinder Liner Measuring Point CD 20 mm 0788 in
Cylinder Liner Installer Cylinder Liner Measuring Point 2 105 mm 4173 in
For 4 Cyl 2 Measure the cylinder liner bore at measuring
point
For 6 CYL CD and in four different directions
6 Position the cylinder body so that the installer cen XX VV and ZZ
ter is directly beneath the bench press shaft
3 Calculate the average value of the eight measure
center
ments
mmin
4 PRESS SHAFT
Cylinder Liner Bore Total Indicator Reading
NSTALLER
4 Cyl
102021 102060
6 Cyl
105021 105060
40166 40181 41347 41362
Notelt is most important that the correct piston grade be
used Failure to select the correct piston grade will result in
piston seizure Always measure the cylinder bore and select
7 Check that the cylinder liner is set perpendicular to the appropriate piston grade
the cylinder
Check that the cylinder liner does not wobble
8 Use the bench press to apply an initial seating force
of 500 kg 11025 Ig to the cylinder liner
9 Use the bench press to apply a final seating force of
2500 kg 55125 Ib to fully seat the cylinder liner
10 After installing the cylinder liner measure the cylin
der liner projection
Refer to Cylinder Liner Projection Engines Generators
Outside Diameter
1 Piston outside diameter vary depending on the pis
ton type to be used
2 Measure the piston outside diameter at the measur
ing piston 0
shown in the 3 Piston Grade
Steel Strut Builtin Type Type
You can find steel strut on the inner surface of
piston as shown in the illustration FEELER GAUGE
Piston Ring Gap mmin
1 Insert the piston ring horizontally in the position it
Grade i 4 Cyl 6 CYL would assume if it were installed to the piston into
r
the cylinder liner
101955 101974 104955 104974
A 2 Use an inverted piston to push the piston ring into
40140 40147 41321 41328
the cylinder liner until it reaches either measuring
i 101975 101994 104975 104994 point CD or measuring point f Cylinder liner
40148 40155 41329 41336
diameter is the smallest at these two points
Do not allow the piston ring to slant to one side or
STEEL STRUT the other It must be perfectly horizontal
Cylinder Liner Measuring Point CD 10 mm 039 in
Cylinder Liner Measuring Point f 130 mm 512 in
PISTON
PISTON RING
Cylinder Liner Bore and Piston Clearance
3 Use a feeler gauge to measure tne piston ring gap
1 Steel strut Builtin Type Type
For all 4B 6B series If the measured value exceeds the specified limit
0055 0085 mm 00021 00033 in the piston ring must be replaced
mmin
PISTON AND PISTON RING Standard I
Limit
1st Compression 025 045 I 150
Piston Ring and Piston Ring Groove Clearance Ring Gap 00098 00177 i 00591
Use a feeler gauge to measure the clearance between 2nd Compression I 020 040 I 150
the piston ring and the piston ring groove Ring Gap 00079 00157 00591
Do this at several points around the piston I 020 040 150
Oil ring Gap
If the clearance between the piston ring and the piston 00079 00157 i 00591
ring groove exceeds the specified limit the piston ring
must be replaced
mmin
Standard Limit
0085 0110 020
1st compression ring
00033 00043 00079
0030 0055 015
MEASURING PISTON
2nd compression ring RING GAP
00012 00022 00059
0030 0070 015 o
Oil ring
00012 00028 00059
Engines Generators
Piston Pin Outside Diameter PIN HOLE
DIAMETER
Use a micrometer to measure the piston pin at several points
If the measured piston pin outside diameter exceeds the
specified limit the piston pin must be replace
mmin
I Standard Limit
Piston Pin Outside 35000 35005 3495 If an inside dial indicator is not available use the follow
Diameter I 13780 13781 I 13760 ing procedure to check the piston pin fit
1 Use a piston heater to heat the piston to approxi
mately 60C 140F
2 Push strongly against the piston pin with your
thumbs
The piston pin fitting should feel tight
USING A HOT PLATE TO
HEAT THE Pin and Piston Clearance
Use an inside dial indicator to measure the piston pin
hole
mmin
Piston Pin Hole Diameter I Standard
35000 35008
4 CYL
I 13780 13783
6 CYL I
35010 35018
13783 13787
PISTON PIN SHOULD
FIT PISTON
PIN HOLE Pin and Piston Pin Hole the clearance between the piston pin and the
piston pin hole by calculating the difference between
the piston pin hole diameter and the piston pin mmin
I Limit
Piston Pin and Piston Pin
0050 0002
Hole Clearance I
Engines Generators
CONNECTING ROD Connecting Rod Bushing Removal
Connecting Rod Alignment 1 Clamp the connecting rod in a vise
2 Use a brass bar and a bench press or hammer to
Use a connecting rod aligner to measure the parallelism
remove the connecting rod bushing
between the connecting rod big end hole and the con
necting rod small end hole
If either the measured parallelism exceeds the specified BENCH
limit the connecting rod must be replaced PRESS
Connecting Rod Alignment CONNECTING ROD
Per Length of 100 mm 394 in mmin SMALL END
I Standard Limit OLD BUSHING
005 00020 020
Parallelism
or less 00079
Connecting Rod Bushing Installation
Use the connecting rod bushing installer to install connecting rod bushing
ROD ALIGNER Connecting Rod Bushing Installer
J29765
NOTE The connecting rod bushing oil port must be aligned
with the connecting rod oil port
3 Use a piston pin hole grinder CD fitted with a
reamer or an adjustable pilot reamer to ream
the piston pin hole
mmin
Standard
Piston Pin and Connecting Rod Small End Bush
Connecting Rod Bushing 35017 35025
ing Clearance
Inside Diameter 13786 13789
Use a caliper calibrator and a micrometer to measure
the piston pin and connecting rod small end bushing
clearance
If the clearance between the piston pin and the connect
ing rod small end bushing exceeds the specified limit
replace either the piston pin or the connecting rod
bushing
mmin
Standard Limit
ALIGN OIL
Piston Pin and Connec SOLID PORTS
0010 0030 005
ting Rod Small End
00004 00012 00020 REAMING THE PISTON HOLES
Bushing PISTON PIN CONNECTING ROD
MEASURING SMALL
END BUSHING
CLEARANCE
TAKING Engines Generators
Rod Bearing Inspection CRANKSHAFT
1 Fit the connecting rod bearing lower half into the Crankshaft and Bearing Inspection
connecting rod bearing cap
2 Check the connecting rod bearing lower half ten 1 Inspect the crankshaft journal surfaces and the
sion crank pin surfaces for excessive wear and damage
If the tension is insufficient the bearing must be 2 Inspect the oil seal fitting surfaces of the crankshaft
replaced front and rear ends for excessive wear and damage
3 Tighten the connecting rod and the bearing cap to 3 Replace or repair the crankshaft if any excessive
the specified torque wear or damage is discovered
4 Inspect the crankshaft oil ports for kgmlb ft
1st step 2nd step 5 Use high pressure air to clean the oil ports if neces
Rod and Bearing 4 60o3
Cap Bolt Tightening Torque 289
FITTING THE LOWER
BEARING
Crankshaft Journal and Crankpin Outside Diame
4 Use an inside dial indicator to measure the connect ter
ing rod inside diameter
1 Use a micrometer to measure the crankshaft journal
mmin
outside diameter across points CD CJ and
Connecting Rod Bearing
64 2520
Nominal Diameter
2 Use the micrometer to measure the crankshaft jour
nal outside diameter at the two points and
3 Repeat steps 1 and 2 to measure the crankshaft out
side diameter
If the measured crankshaft journal diameter andor
the crankpin outside diameter are less than the
standard value the crankshaft must be reground
mmin
6 Cyl Position at i Standard
Center 1 79905 79925
Crankshaft Journal Bearing Only I 31459 31467
Diameter I Other 79919 79939
Bearings i 31464 31472
mmin
4 Cyl Position at I StClndard
Crankshaft Journal All B i 79905 79925
Diameter earmgs 31459 31467
Engines Generators
mmin
Standard
63924 63944
Crankshaft Pin Diameter
25167 25175
4 Measure the crankshaft journal outside diameter
andor the crankpin outside diameter and the
bearing inside diameters to determine the bearing
Journal and Bearing the bearing clearance exceeds the specified limit must be reground except for the 120N6 and Connecting Rod
Bearing Inside or the bearing must be replaced
Tighten the connecting rod and the bearing cap with
mmin specified torque and use inside dial indicator to mea
6 CYL Position at Standard Limit sure the connecting rod bearing inside diameter
Center kgmlb ft
Journal Bearing 1st step 2nd step
and Main Bearing Only Connecting Rod and Bearing 4
Clearance Other 00250084
00043
Cap Bolt Tightening Torque 289
60 o 3 g
Bearings mmin
mmin Connecting Rod Bearing
4 Cyl Position at Standard 1 Limit Nominal Journal
All 00390098 I I 011
and Main Bearing
Bearings MEASURING
CONNECTING
mmin ROD BEARING
Standard Limit 10
Crankpin and
003007 Rod
Clearance
Crankshaft RunOut
1 Mount the crankshaft on a set of Journal Bearing Inside Diameter
2 Set a dial indicator to the center of the crankshaft
1 Install the main bearing cap with bearings to the journal
cylinder body with the specified torque and facing 3 Gently turn the crankshaft in the normal direction of
the arrow mark on the bearing cap toward engine rotation
front Place them in order of punched cylinder
numbers Read the dial indicator TIR as you turn the crank
shaft
2 Use an inside dial indicator to measure the main
bearing diameters If the measured value exceeds the specified limit
the crankshaft must be replaced
kgmlbtt
241 1
Main Bearing Cap Torque
1735 72
mmin
Main Bearing Nominal 80
Diameter 3150
Engines Generators
mmin
Crankshaft Regrinding Procedure 4 CyL
Model Standard Limit
I i
1 Regrind the crankshaft journals and the crankpins
Crankshaft I 6 Cyl I I 040 0016 2 Fillet the crankshaft journal and crankpin radious to
005 0002
RunOut I 4 Cyl I 030 0012 a minimum of R35 02
If the crankshaft generated a crack after repair There must be no stepping around the fillet area
replace the crankshaft 3 Finish the crankshaft journal crankpin and oil port
The crankshafts for the 120N6 and the 170T6 engines corners to a smooth surface having a chamfer
can not be bench pressed because they are finished in radius of 1 mm 004 in
the Tufftride method
Crankshaft Journal and
Main Bearing and Connecting Rod Bearing Ten 04 11 or less
Crankpin 4 Measure the crankshaft journal and crankpin clear
Check to see if the bearing has enough tension so that
ance
good finger pressure is needed to fit the bearing Refer to Crankshaft
Journal Clearance and Crank
pin and Clearance on
FITTING THE BEARINGS 5 Measure the crankshaft runout
Refer to Crankshaft RunOut
Crankshaft Grinding Limit 4 CyL
mmin
Limit
Crank Journal Diameter 794 19 Regrinding 4 CyL
Crankpin Diameter 63424 2497
To ensure crankshaft reliability pay close attention to
the following items during and after the crankshaft Undersize bearings 025 mm 0010 in and 050 mm
grinding procedure 0020 in are available to compensate for excessive
mmin clearance between the crankpin bearing and the crank
Undersize Bearing shaft Regrinding of the crankshaft to fit the undersize
025 0010 050 0020 bearings is required
Availability
mmin
Note Crankshafts for the 120N6 and the 170T6 can not be
Standard because they are finished in the Tufftride metwd
Crankpin and I 003007 010
No attempt should be made to grindfinish these faces of the Connecting Rod
and crankpins as they are Tufftrided special Bearing Clearance I
hardening the undersize bearings are not prepared Undersize bearings 025 mm 0010 in and 050 mm
0020 in are available to compensate for excessive
clearance between the crankshaft journal bearing and
the crankshaft Regrinding of the crankshaft to fit the
undersize bearings is required
mmin
z 6B Engines Only Position at I Standard Limit
tj n
and Main Bearing Only
Clearance
Centr
Other
I 00390098
Crankshaft Journal Beanng i
i 00250084
Bearings i
00043
4B Engines Only i Position at Standard Limit
Crankshaft Journal i All
and Main Bearing B
1 00390098 011
Clearance eanngs 00043
Engines Generators
Clearance is another method to measure the clearance
PlASTIGAGE Journal Bearing Clearance
1 Clean the cylinder body the journal bearing fitting
portions the bearing cap and the inside and out
side surfaces of the bearing
2 Install the new journal bearing to the cylinder body
3 Carefully place the crankshaft on the bearing
4 Rotate the crankshaft approximately 30 to seat the
bearing Crankshaft Pin Bearing Clearance
5 Place the Plastigage arrow over the crankshaft 1 Clean the crankshaft the connecting rod the bear
journal across the full width of the bearing ing cap and the bearings
Apply engine oil to the Plastigage to keep it from 2 Install the bearing to the connecting rod
falling Do not allow the crankshaft to move when installing
the bearing cap
3 Hold the connecting rod with the bearing installed
PlASTIGAGE against the crankshaft pin
4 Attach the plastigage to the crankshaft pin
Apply engine oil to the plastigage to keep it from
falling
5 Install the connecting rod bearing cap and tighten it
to the specified torque
Do not allow the connecting rod to move when
o o installing and tightening the bearing cap
6 Remove the bearing cap
6 Install the bearing cap with the bearing
7 Compare the width of the plastigage attached to
7 Tighten the bearing cap to the specified torque either the crankshaft or the bearing against the
Do not allow the crankshaft to turn during bearing scale printed on the plastigage container
cap installation and tightening If the measured value exceeds the limit perform the
following additional steps
TIGHTEN THE BEARING CAP 1 Use a micrometer to measure the crankshaft
outside diameter
2 Use an inside dial indicator to measure the
bearing inside diameter
3 Replace the crankshaft andor the bearing if the
measured values exceed the limit
8 Remove the bearing cap
9 Compare the width of the plastigage attached to
either the crankshaft or the bearing against the
scale printed on the plastigage container
If the measured value exceeds the limit perform the
following additional steps
1 Use a micrometer to measure the crankshaft
outside diameter
2 Use an inside dial indicator to measure the
bearing inside diameter
3 Replace the crankshaft andor the bearing if the
measured values exceed the limit
Engines Generators
Tufftriding Inspection 6 Cyl Oil Seal Wear Ring Replacement 6 120N6 and 170T6
Removal
1 Use an organic cleaner to thoroughly clean the Use the oil seal wear ring remover to remove the oil
crankshaft There must be no traces of oil on the seal wear ring from the crankshaft front end
surfaces to be inspected Oil Seal Wear Ring Remover
2 Prepare a 10 solution of ammonium cuprous chlo
ride dissolved in distilled water OIL SEAL WEAR
3 Use a spot glass rod to apply the solution to the RING REMOVER
surface to be inspected
Hold the surface to be inspected perfectly horizontal
to prevent the solution from Do not allow the solution to come in contact with the
oil ports and their surrounding area
TEST LIQUID SHOULD
AMMONIUM NOT BE APPLIED Installation
CUPROUS NEAR THE OIL PORT
CHLORIDE Use a brass bar and a hammer to drive the oil seal
Jt wear ring into place
FACE IN CONTACT
WITH CRANKPIN
OR 1 Wait for thirty to forty seconds
If there is no discoloration after thirty or forty sec
onds the crankshaft is useable
If discoloration appears the surface being tested will
become the color of copper the crankshaft must be Crankshaft Gear Inspection
replaced
Visually inspect the crankshaft gear
2 Clean the surface being tested with clean water of Replace the crankshaft gear if excessive wear or
steam immediately after completing the test damage is The ammonium cuprous chloride solutiol is highly
Because of this it is imperative that the tested be cleaned immediately after completing the lest Use the crankshaft gear remover to remove
the crank
shaft gear
Crankshaft Gear Remover Engines Generators
Flywheel Housing Oil Seal Replacement
Removal
Use a pry bar to remove the flywheel housing oil seal
Installation
o Use the oil seal installer to install the flywheel housing
oil the crankshaft gear installer to install the AND FL VWHEEL HOUSING
OIL SEAL
THE OIL
Ring Gear Inspection the ring gear
TIMING GEAR CASE COVER
If the ring gear teeth are broken or excessively worn
the ring gear must be replaced Crankshaft Front Oil Seal Replacement
Removal
Use an adapter and a hammer to remove the crank
front end oil seal
Installation
Use the crankshaft front oil seal installer to instal
crankshaft front oil seal
REMOVING THE
RING GEAR
Ring Gear around the edges of the ring gear with a hammer
and chisel to remove it INSTALLING FRONT OIL SEAL
Ring Gear Installation
1 Heat the ring gear evenly with a gas burner to invite
thermal expansion
Do not allow the temperature of the ring gear to
exceed 200C 390F
2 Use a hammer to install the ring gear when it is suf
ficiently heated
Engines Generators
ASSEMBLY
SNAP RING
PLIERS
4 PISTON ASSEMBLY 3SNAPRING
2 PISTON PIN
1 PISTON 4 Piston Ring
1 Use a piston ring installer to install the three
piston rings
Install the piston rings in the following order
1 Oil ring
2 2nd compression ring
2 CONNECTING 3 1st compression ring
ROD l
The marked side of the two compression rings
must be facing up
5 CONNECTING The undercut side of the second compression
ROO BEARING ring will be facing down
As the oil ring has no any facing mark it may
face in either direction
2 Lubricate the piston ring surfaces with engine
NUMBERS INDICATE THE
SUGGESTED ORDER OF
ASSEMBLY
3 Check that the piston rings rotate smoothly in
the piston ring grooves
1STCOMP
PISTON AND CONNECTING ROD
2NDCOMP
Important Operations
1 Piston PISTON
Use a piston heater to heat the pistons to approxi OIL
mately 60C 140F
2 Connecting Rod PISTON RINGS
1 Install the connecting rod to the piston with
5 Connecting Rod Bearing
setting the marks as illustrated
1 Install the connecting rod bearings to the con
2 Install the piston pin into the piston and the
necting rod largeend and the connecting rod
connecting rod bushing
PISTON
HEAD
2 Install the bearing cap to the connecting rod
with the cap bolts
FRONTMARK 3 Lubricate the bearing with engine oil
USING A PISTON
HEATER
3 Piston Pin Snap Ring
1 Use a pair of snap ring pliers to install the pis
ton pin snap ring
2 Check that the piston moves smoothly on the
piston pin
Engines Generators
6 SPRING SEAT
SPLIT COLLAR T ASSEMBLY
5 SPRING SEAT
UPPER
10 INTAKE MANIFOLD 1 VALVE STEM
SPRINGS OILSEAL
3 SPRING SEAT CYLINDER HEAD
LOWER
EXHAUST MANIFOLD
HOUSING AND GASKET
GASKET
8 9
PIPE
OUTLET
INTAKE AND
Important Operations EXHAUST VALVES
1 Valve Stem Oil Seal
1 Lubricate the oil seals and valve stem sealing
area with engine oil
2 Use a valve stem oil seal installer to install the
oil seal
INSTALLER
3 Intake and Exhaust Valve Springs
Install the valve springs with their painted end the
close pitched end facing down
2 Intake and Exhaust Valves
1 Place the cylinder head on a flat wooden sur
face
2 Lubricate valve stems with engine oil
3 Install the valves to the intake or exhaust
guides PAINTED PORTION
Install the valves to their original lapped valve
seats
Engines Generators
ASSEMBLY
TORQUE
Spring Seat Split Collar
1 Use a spring compressor to push the valve spr
ing into position
2 Install the spring seat split collar 6 Exhaust Manifold and Gasket
3 Set the spring seat split collar by tapping lightly 1 Install the exhaust manifold gasket
around the head of the collar with a rubber The TOP mark must be facing up
hammer
4 CYL AND 6 CYL USE
DIFFERENT MANIFOLD GASKETS
SETTING THE SPRING 6CYL SHOWN
SEAT SPLIT COLLAR
2 Install the exhaust manifold
3 Tighten the exhaust manifold bolts to the speci
fied torque a little at a time in the numerical
order shown in the kgmlbft
Exhaust Manifold Bolt
5 Intake Manifold and Gasket 29 05 210 36
Torque
1 Install the intake manifold gasket
The intake manifold gasket must be installed SIX CYL
with its unchamfered corner facing up and to
the front of the engine G I
11 I
I I
1 12
lREAR UNCHAMFERED
CORNER FOUR YL
2 Install the intake manifold 6
3 Tighten the intake manifold bolts to the speci
fied torque a little at a time in the numerical
order shown in the 1 5
kgmlbft
Intake Manifold Bolt
26 05 188 36
Torque
INSTALL EITHER END OF THE
TUBE TO THE SPOT
FACING 6 CYL ONLY
Engines Generators
ASSEMBLY
5 CRANKSHAFT THE ROCKER ARM MUST
BEARING LOWER AND BEARING CAP BE INSTALLED WITH THE
OIL PARTS FACING UP
20lL PUMP
AND INDICATE SUGGESTED ASSEMBLY SEDUENCE
14 OIL PAN
NOT SHOWN
1 OIL
8 CAMSHAFT
1 OIL COOLER
GEAR
jJ 9
IDLER GEAR
SHAFT
MAJOR COMPONENT REASSEMBLY Operations
WITH OIL HOLE
DJiJ
1 Oil Jet 6 Cyl Turbo
Install the oil jets taking care not to damage the oil
jet nozzles
kgmlbft
Oil Jet Torque 21 05 152 36 I
2 Crankshaft Bearing Upper Half
3 Crankshaft Bearing Lower Half and Crankshaft
Bearing Cap
4 Crankshaft
NO OIL GROOVE
LOWER
D HOLE
The Crankshaft Bearing Crankshaft counterweight size will vary from engine
With Oil Groove Without Oil GroovE to engine Check your Parts Catalog Part Number
listing to determine crankshaft counterweight size
Bearing Upper 4 All Upper Halves for your engine
Half 6 All Upper Halves 5 Thrust Bearing
All Lower Halves
Center Bearing Install the thrust bearings with the oil groove side
Bearing Lower 4 Except Center facing the crankshaft sliding face
Only
Half Bearing
6 All Lower Halves
Take care not to misinstall the bearing halves
Engines Generators
ASSEMBLY
8 Camshaft
Tighten the thrust plate bolts through the camshaft
gear hole
kgmlbft
Thrust Plate Bolt Torque 26 05 188 36 I
kgmlbft
Camshaft Gear Bolt
Torque
6 Crankshaft Bearing Cap
1 Lubricate the bearing cap bolts with engine oil
2 Install the bearing caps to the crankshaft
The arrow mark must be pointing to the front of
the engine
3 Tighten the bearing cap bolts to the specified
torque a little at a time in the numerical order
shown in the kgmlbft
Crankshaft Bearing Cap
240 1 1735 72 9 Idler Gear Shaft
Bolt Torque
Use the thrust collar fixing bolt as a guide to install
the idler gear shaft
4 Check that the crankshaft turns smoothly by
manually rotating it The oil port must be facing the
10 Idler Gear
1 Install the idler gear
Set the timing marks A and B as shown in
the 2 Tighten the idler gear bolts seating the thrust
collar to the specified torque
The thrust collar must be installed with the
7 Timing Gear Case chamfered side facing the front of the engine
1 Apply liquid gasket to the timing gear case sur kgmlbft
faces contacting the cylinder body
Idler Gear Bolt Torque 55 1 398 72 I
2 Tighten the timing gear case bolts to the speci
fied torque
kgmlbft INJECTION
PUMP GEAR
CAMSHAFT
GEAR
CMARK
Engines Generators GEAR
ASSEMBLY
Piston and Connecting Rod 7 Lubricate the connecting rod cap bolt threads
Position the piston ring gaps as shown in the illus and setting faces with Mos grease
tration 8 Use the angular tightening method to tighten
1 Set the piston ring gaps as shown in the illus the connecting rod cap bolts to the specified
tration torque
kgmlb ft
2 Lubricate the piston the piston rings and the
connecting rod bearings with engine oil 1st step 2nd step
3 Position the piston front mark towards the front Connecting Rod Bolt Torque 4 60 o 3g
of the engine and Angle 289
2 Oil Pump and Coupling
PISTON RING
ALIGNMENT 1 Lubricate the oil pump with the specified grade
of engine oil
4 Use the piston ring compressor to compress
the piston rings
2 Install the oil pump with the coupling
3 Tighten the oil pump bolts to the specified
torque
FRONT kgmlbft
MARK
Oil Pump Bolt Torque 53 10 383 72 I
3 Flywheel Housing
1 Apply a liquid gasket to the shaded area of the
2 Install the flywheel housing
5 Use a hammer grip to push the piston in until it
makes contact with the crankpin Tighten the flywheel housing bolts to the speic
fied torque
At the same time rotate the crankshaft until the
crankpin reaches its highest point kgmlb ft
Flywheel Housing Outer Bolt 161 1 1157 72
6 Set the bearing cap cylinder number marks and Bolt Torque Inner Bolt 26 05 188 36
the connecting rod cylinder number marks
The marks must be facing the exhaust CYLINDER
NUMBERS
APPLY LlaUID GASKET
REFER TO THE ANGULAR TIGHTENING METHOD
FLYWHEEL HOUSING
Engines Generators
ASSEMBLY
14 Oil Pan MAJOR COMPONENT REASSEMBLY
1 Apply liquid gasket to the areas indicated by
the arrows in the illustration Important Operations
2 Install the oil pan gasket
1 Flywheel
3 Install the oil pan
1 Lublicate the flywheel bolt threads
Tighten the oil pan bolts to the specified torque
2 Install the flywheel
kgmlbft
Oil Pan Bolt Torque 26 05 185 36 I The crankshaft rear end dowel pin and the fly
wheel dowel hole must be aligned
3 Tighten the flywheel bolts to the specified
torque in the numerical order shown in the
kgmlbft
Flywheel 116 15 1157 108
Bolt Torque 223 22 1612 159
LUBRICATE WITH ENGINE OIL
15 Oil Cooler
1 Apply liquid gasket to the oil cooler gasket
2 Install the oil cooler gasket to the oil cooler
body case
3 Install the oil cooler
Tighten the oil cooler bolts to the specified
torque
Start from the middle and work out to either
side 2 Injection Pump and Injection Pump Gear Assembly
kgmlbft 1 Install the injection pump bracket with the injec
Oil Cooler Torque 26 05 185 36 I tion pump to the timing gear case
Dowel the injection pump bracket with the tim
OIL COOLER ing gear case
ASSEMBLY 2 Tighten the injection pump bolts to the speci
fied torque
3 ELEMENT kgmlbft
I Injection Pump Bolt Torque I 26 05 188 36 I
3 Align the injection pump gear C timing mark
with the idler gear C timing mark
INJECTION
PUMP
1 BYPASS VALVE ORING
SPRING AND PLUG
INJECTION
PUMP GEAR
OIL COOLER BOLT WESTERBEKE
Engines Generators
TORQUE SEQUENCE
ASSEMBLY
3 Crankshaft Pulley Nut 6 Cylinder Head Gasket and Bolts
a Apply MoS2 to the crankshaft pulley nut threads a Carefully place the cylinder head gasket on the
and fitting face cylinder body upper surface
b Use the appropriate wrench to tighten the The gasket TOP mark must be facing up
crankshaft pulley nut to the specified torque
b Align the cylinder body dowels and the cylinder
Kgm IbH head dowel holes
CRANKSHAFT PULLEY NUT TORQUE 440 50 3181 362
4B SERIES
6B SERIES 440 50 3181 362 TOP
MARK
FRONT
SOCKET
WRENCH
c Carefully place the cylinder head on the cylinder
body
d Tighten the cylinder head bolt as follows
4 Tappet Chamber Cover 1 As cylinder head bolts have two kinds of length
install them at the proper location The shorter
a Apply liquid gasket to the tappet chamber cover ones 4 cyl series 4 bolts 6 cyl series 6
gasket bolts must be used at the injection pump side
b Install the tappet chamber cover and tighten the 2 Follow the numerical sequence shown in the
bolts to the specified torque Kgm lbH
TAPPET CHAMBER COVER 26 05 188 36
BOLT TORQUE
FRONT
TAPPET CHAMBER
COVER TORQUE Water Pump
3 The cylinder head bolt tightening method vary
depending on the gasket type to be Refer to the Coolant Pump sectioll ill this manual for
details of the water pump
Engines Generators
ASSEMBLY
For laminated steel type gasket
14 ROCKER ARM
Apply molybdenum disulfide grease to the ASSEMBLY
cylinder head bolt threads and setting faces
Use the Angular Tightening Method
kgmlbft
1st step 2nd step 3rd step 1 CYLINDER
HEAD
Bolt Torque 70 506 90O5 651 36 90o3
For sandwich gasket
Apply engine oil to the cylinder head bolt
threads and setting faces
kgmlbft
1st step 2nd step
New bolt
95o5 68636
Bolt Torque 70 506
Reused bolt
115o5 831 36
7 Rocker Arm and Rocker Arm Shaft
1 Check that the rocker arm shaft bracket lower
surface oil port is free from obstruction
2 Install the rocker arm shaft with the bracket to
the cylinder head
3 Tighten the rocker arm bracket bolts to the
specified torque a little at a time in the numeri
cal order shown in the 4 Lubricate the rocker arm and the rocker arm
shaft with engine oil 8 TAPPET
kgmlbftl CHAMBER
Rocker Arm Shaft Bracket COVER
31 05 224 36
Bolt Torque
2 3 7
ROCKER ARM
ASSEMBLY
4 4 BRACKETS NUMBERS INDICATE SUGGESTED ASSEMBLY SEQUENCE
2 3 5 Adjust the valve clearance
Refer to MAINTENANCE for the valve clearance
ROCKER ARM SHAFT adjustment procedure
THE ROCKER ARM MUST
BE INSTALLED WITH THE
OIL PARTS FACING UP 3 ROCKER ARMS
Engines INDICATE SUGGESTED ASSEMBLY SEQUENCE
ASSEMBLY
1 Cylinder Head Cover
3 Oil Filter Assembly
1 Check that the rocker arms the rocker arm
1 Before the installation set the special gaskets
shafts and the valve springs are thoroughly
which are included within the repair kit with the
lubricated with engine oil two oil filter mounting bolts
If required relubricate these parts 2 Apply a coat of LOCTITE 271 on the bolt
2 Place the cylinder head cover gasket on the threads to seal the bolts from the crankcase
as illustrated
cylinder head cover
3 Install the oil filter assembly and tighten the
Check the head cover gasket for looseness bolts securely
3 Tighten the cylinder head cover bolts to the kgmlbtt
specified torque a little at a time in the sequ Oil Filter Assembly
ence shown in the illustration Mounting Bolt Torque
6 cn kgmlbtt
Cylinder Head Cover Bolt
21 05 152 36
Torque
4 cn kgmlbtt 4 Injection Nozzle
Cylinder Head Cover Bolt Install the injection nozzles with the injection nozzle
11 05 79 36
Torque gaskets
Be carefull not to damage the nozzle tips
19 02 137 15
6 CYLINDER
CYLINDER HEAD
NOZZLE COVERS
GASKET
5 Fuel Injection Pipe and Fuel Leak Off Pipe
4 CYLINDER
1 Install the fuel injection pipes and tighten
the bolts to the specified torque
kgmlbtt
2 Starter Injection Pipe Torque 31 02 224 15 I
Install the starter to the flywheel housing and tighten
the bolts to the specified torque 2 Carefully position and set the clips CD
It is very important that each clip be positioned
kgmlbttl
correctly
Starter Fixing Bolts
84 607 An improperly positioned clip will result in
Torque
objectionable fuel pulsing noise and injection
pipe BELT 3 Install the fuel leak off pipes
Adjust the drive belt to MAINTENANCE for the drive belt Engines Generators
ASSEMBLY
6 Fuel Pipe Feed Pump to Fuel Filter 16 Alternator Fuel Pipe Fuel Filter to Injection Pump
a Put the alternator in position Install the adjusting
8 Fuel Return Pipe bolt in position to hold the alternator in position
Install the fuel pipes and tighten the fuel pipe joint b Put the belt in position on the pulley Move the
bolts to the specified torque alternator away from the engine to make an
adjustment to the belt
Take care not to interchange the check valves and
joint bolts c Tighten the bolts
d Make sure the tension of the belt is correct about
Kgm lbft 12 deflection at the center with pressure
I FUEL PIPE JOINT BOLTTORQUE 17 01 123 07
9 Intake Pipe MARINE TRANSMISSION
Install the intake pipe and tighten the intake pipe 1 Assemble the damper plate to the flywheel
flange bolts to the specified torque 2 Reinstall the marine transmission and fill with
ATF Dextron III
Kgm lbfI
INTAKE PIPE FLANGE BOLT TORQUE 17 01 123 07 NOTE Some such as the Borg Warner Velvet
1 Olnstall the Thermostat and Thermostat Housing Drive require oil coolers Oil coolers should be cleaned
a Inspect the thermostat housing and the housing pressure tested and repainted at engine overhaul The
gasket Apply some sealant to the gasket when transmission oil cooler hoses should also be inspected
reassembling Refer to the text on Heat Exchangers
b Install the temperature switch and sender and 3 Fill the engine cooling system with antifreeze
reconnect their wires mixture and the engine oil sump with lube the Oil and Water Sender and Switch
AP1 spec CF or the Starter Motor The engine should be test run under
load prior to
reinstalling At this time readjust the the Breaker Panel and the Preheat clearances on the hot engine
Solenoid
Allow the engine to cool to room temperature and the Engine Electrical harness torque the cylinder head bolts and
recheck the
15 Mount the complete Exhaust Manifold and the valve clearances See ENGINE ADJUSTMENTS
Expansion Tank to the Cylinder Head
MANIFOLDHEAT EXCHANGER 1 Mount the generator back end assembly with its
The exhaust manifold which was disassembled from the control panel Reconnect all DC wiring and
cylinder head should be inspected before reassembly reconnect all AC Remove the exhaust elbows from the lower surface
of the manifold Clean and inspect for cracks and
defects Replace as needed A CAUTION Check al AC and DC wiring
b Remove the exhaust nipples elbows and plugs from connections to WESTERBEKE wiring schematics
the manifold and heat exchanger and diagrams
c Remove water connectors from the ends of the
manifold Be sure to note the proper location and
arrangement of each for proper alignment 2 Fill the engine cooling system with antifreeze
mixture and the engine oil sump with lube oil
d Examine all parts for defects corrosion and wear AP1 spec CF or CG4
and replace as needed The engine should be test run under load prior to
e Flush out the manifolds interior with a liquid cleaner reinstalling At this time readjust the valve
and rinse thoroughly with fresh water clearances on the hot engine
fUse a pipe cleaner to clear the passage that Allow the engine to cool to room temperature and re
connects the coolant recovery tank tubing torque the cylinder head bolts and recheck the
g Flush out the coolant recovery tank and its valve ENGINE ADJUSTMENTS
connecting tube
h Replace the heat exchanger new hose connections and clamps for the cool
ing system
Engines Generators
TUNING OPERATION 10Check that the engine oil is continuously circu
lating from the oil pump to the valve rockers
After reassembly the engine must be tuned This will through the cylinder head
ensure that the engine operates at its If there is no oil circulation or if the oil circulation
sluggish stop the engine and make the Mount the engine on a test bench repairs or Connect the electrical wiring Refer to
the WIRING Reinstall the cylinder head cover
DIAGRAM
11lncrease the engine speed to 1500 rpm to do the
3 Connect the air intake line to the air cleaner engine warmingup operation
4 Connect the exhaust pipe 12Check the engine for oil fuel coolant and air
5 Manually operate the fuel feed pump to feed fuel intake leakage
to the engine 13 Check for abnormal noise and odor
6 Bleed the fuel lines of air 14Check for abnormal electrical charging
7 Crank the engine with the starter nonignition 15 Check the engine fastening parts for looseness
operation for about twenty seconds This will
prelubricate the engine internal components 16 When the engine coolant temperature reaches
75C 167F or more increase the engine speed
S Start the engine and allow it to run at 750 to SOO to 2000 rpm and allow it to run for twenty
rpm for five minutes seconds
9 Remove the cylinder head cover while the engine This will give the engine the essential runin
is running operating time
17Adjust the engine operation speed to the
specified value
1S Stop the engine to complete the tuning
procedure
Refer to the following pages for details of These sections also include Wiring Dagrams
Torque Diagrams Generator Data and a detailed Section
Engines Generators
LUBRICATING SYSTEM
OIL SYSTEM FLOW DIAGRAM
Full flow filter Oil pressure
r and oil filter I Starter
I
ypass
n I
warning light
switch
Battery
I J TURBO ONLY
11 f 1
I
valve V
LJ I
I IValve opening
pressu re 1 kgcm 1
OLIt h
i I
Ini 8 Oiling
pump 5 iet
6BD1T only
r
I I
I Partial
I I Valve opening Oil
I filter I pressure 45kgcm relief Pisto
I I
L J valve
J
Oil pan
OIL PUMP Visually inspect the disassembled
parts for
THIS GEAR TYPE OIL excessive wear and damage
PUMP IS DRIVEN BY
THE CAMSHAFT OIL Oil Pump Drive Gear
PUMP DRIVE
Use a feeler gauge to measure the clearance between
the oil pump cover oil pump case inside surface and
NUMBERS INDICATE
the drive gear
SUGGESTED ORDER If the clearance exceeds the specified limit the drive
OF DISASSEMBLY gear andor the oil pump cover must be replaced
mmin
Limit
Oil Pump Cover and Oil Pump
018 00071
Drive Gear GEAR
DRIVE SHAFT OIL PUMP COVER FEELER GAUGE
GEAR
6 DRIVEN GEAR
SHAFT SUCTION PIPE Make the necessary adjustments repairs and
parts
replacements if excessive wear or damage is Engines Generators
LUBRICATING SYSTEM
Cartridge SpinOn Type
Removal
Remover and Installer Filter Wrench
1 Loosen the used oil filter by turning it wise with the filter wrench
STRAIGHTEDGE 2 Discard the used oil filter
Installation
FEELER GAUGE 1 Wipe the oil filter mounting face with a clean rag
This will allow the new oil filter to seat properly
Oil Pump Driven Gear
2 Lightly oil the Oring
Use a feeler gauge to measure the clearance between
3 Turn in the new oil filter until the sealing face is fit
the oil pump case cover inside surface and the driven
gear ted against the Oring
4 Use the filter wrench to turn in the oil filter an addi
If the clearance exceeds the specified limit the driven
tional 34 of a turn or one turn
gear or the oil pump cover must be replaced
5 Check the engine oil level and replenish to the spec
mmin
ified level if required
Limit
6 Start the engine and check for oil leakage from the
Oil Pump Body and Driven oil filter
Gear Clearance
1 ELEMENT
OIL COOLER
NUMBERS INDICATE THE
ORDER OF ASSEMBLY
SPIN DN OIL FILTER
INSPECT AND MAKE ALL
DRING NECESSARY REPAIRS AND
Install the oil cooler element to the oil cooler and
tighten the cooler element fixing nuts to the speci
fied torque
kgmlbtt
Oil Cooler Element
26 05 188 36
Fixing Nut Torque
DRAIN
CONTAINER u
CHANGING THE OIL
Engines Generators
COOLING SYSTEM
1 COOLANT PUMP NUMBERS INDICATE
PULLEY ORDER OF DISASSEMBLY
2 COVER AND GASKET
COOLANT PUMP
SNAP RING
3 Snap Ring
Use a pair of snap ring pliers to remove the snap
1 Impeller ring
Use the remover to remove the impeller 4 Spindle Bearing and Spacer
Use a bench press and a suitable remover to
REMOVER remove the spindle bearing and spacer
PUMP
BODY
VISE
Use a bench press and a suitable rod to remove the
pulley center
5 Seal Unit Washer and Seal
Use a suitable remover to remove the seal unit the
PULLEY CENTER
washer and the seal
Engines Generators
COOLING SYSTEM
INSPECTION AND REPAIR ASSEMBLY
Make the necessary adjustments repairs and parts 7 Spindle Bearing and Spacer
replacements if excessive wear or damage is
discovered during inspection Lubricate the bearing with multipurpose grease
Use a bench press to install the spindle the bearing
and the spacer
REMOVING THE BEARINGS
AND SPACER
SMALLER BEARING
LARGE BEARING
6 Bearing Replacement
8 Snap Ring
Removal
Use a pair of snap ring pliers to install the snap
Use a bench press to remove two bearings and the ring
spacer
9 Pulley Center
Installation Use a bench press and a bar to install the pulley
Use a bench press to install two bearings and the center
spacer
PRESS BAR
PULLEY Use a micrometer to check the fitness at the three
points shown in the mmin
Shaft to Pulley Center 002 006
Fitness 00008 00024 10 Seal Unit Washer and Seal
Shaft to Impeller 007 011 1 Apply a thin coat of liquid gasket to the seal
Fitness
Fitness 00028 00043 unit outer periphery before Pulley Center to Pulley 014 00055
Fitness or less 2 Use a bench press and a bar to install the seal
unit into the pump body
SHAFT IMPELLER
PULLEY CENTER
PULLEY
TAKING Engines Generators
COOLING SYSTEM
11 Impeller HEAT EXCHANGER
1 Use a bench press to install the impeller to the The heat exchanger should be inspected and serviced
spindle during an engine overhaul
2 Use a feeler gauge to measure the clearance 1 Disconnect the hoses and remove the hoses fittings
between the impeller and the pump body drain plug and zinc anode Also remove the end
fittings and gaskets
mmin
2 Inspect the tube casing for wear and dents if at all
Clearance between suspect replace the heat exchanger
0308 Impeller and Pump Body 3 Clean out any zinc debris and pressure test the
coolant and raw water passages
BENCH PRESS 4 When reassembling install new gaskets and Orings
Apply some lubricant to the new gaskets and to the
fittings as you install them
5 Install a new zinc anode
FEELER GAUGE t
Note All of the above can be accomplished by sending the
heat exchanger to a heat exchanger service shop They will
also service transmission and engine oil coolers
12 Pulley I
6 Repaint the assembled heat exchanger with
Install the pulley and tighten the pulley bolts to the WESTERBEKE heat resistant spray enamel
specified torque
kgmlbft
I Pulley Fixing Bolts Torque I
INSTALLING
THE PULLEY
THERMOSTAT
ZINC ANODE
Disassemble and inspect both halves of the thermostat ALSO SERVES AS A
housing looking for cracks and replace if DRAIN FOR RAW WATER
necessary Install a new thermostat and THE THERMOSTAT HOUSINGS F O
CRACKS OR DAMAGE INSTALL A NEW
b
THERMOSTAT AND GASKET i
j
TO REMOVE HEAT REPLACE GASKET
1 DRIVE BELT
Adjustment
1 Inspect the cooling fan drive belt for cracking and
other damage Replace if suspect
2 Check the drive belt tension by exerting a force of
10kg 22 Ib midway between the pulley and the
alternator pulley
3 Adjust the belt tension by loosing the alternator
THE GASKET IS GROOVED mounting bolt and adjusting bolt and pivoting the
AND FITS AROUND THE alternator
OUTER EDGE OF THE
THERMOSTAT Be sure to retighten the bolts after adjusting the belt
tension
Engin s Generators
WESTERBEKE RAW WATER PUMP
COMPLETE OVERHAULPUMP REMOVED FROM INSPECTION
1 Remove the six screws and lock washers and the sealing Inspect all parts for wear and corrosion It is also
Oring Inspect the Oring for reuse recommended that Orings gaskets and seals be Inspect the impeller for cracks or
stiffness and replace
if necessary PARTS LIST
2 Remove the impeller key Key Part Name Part Number Quantity
3 Remove the lock nut and withdraw the drive gear from Pump Housing 44344
the pump shaft and remove the key Insert a metal rod 2 Shan 43510
019 in diameter thru the hole in the shaft to prevent it 3 Impeller 43506
from turning while removing the lock nut 4 Cam 43503
5 Cover 43509
4 Using snap pliers remove the snap ring
6 Gear 43511
S Press out the shaft and bearing assembly from the pump 7
ORing 43567
housing Using an arbor press support the bearings inner 8 Key 43675 2
race and press the shaft out of the bearings 9 Bearing 35972 2
6 Remove the Orings from the shaft 10 Seal 43566 1
11 ORing 43568
7 Remove the shaft seal from the housingNote the seal
12 Snap Ring 43569
face position in the housing so as to reinstall the new
13 ORing 43570 1
seal correctly
14 Cap Screw 43673 6
8 Remove the cam screw and sealing washer and withdraw 15 Nut 45691 1
the cam from the housing 16 Lockwasher 317BO 6
17 ORlng 44183
18 Screw 19 Washer
32869 1
Reassemble the pump in the reverse order Cap Screw 43674 1
Apply a small amount of petroleum jelly on the lip of the
shaft seal and on the shaft itself when installing assembly into the pump housing CAREFULLY MESH THE PUMPS GEAR
WITH THE TIMING GEAR
When installing the pump cam inside the housing apply a WHEN amount of Permatex 1 to the inner surface of the cam
and to the securing screw threads Remove any excess 6
USE PERMATEX 1 ON
THE SCREW THREADS
AND THE INNER CAM
INSPECT HOUSING FOR CRACKS
AT REASSEMBLY APPLY A LIGHT
COAT OF SILICONE OR PETROLEUM
JELLY TO THE INNER SURFACE
OF THE HOUSING
Engines Generators
TURBOCHARGER
mmin
6 Cyl Limit
Rotor Shaft Radial Play TIR 0215 00085
4 If the measured value exceeds the specified limit
replace the shaft
MAGNET
BASE
TURBO CHARGER
TO OIL SUMP
Rotor Shaft Axial Play Measurement
Turbocharger Mounting Flange Gasket
1 Install a dial indicator on the turbine housing as illu
trated Carefully position the gasket with the edged side
facing up
2 Use the dial indicator to measure the rotor shaft
axial play with moving the shaft push and
pull Read the total indicator reading TIR
mmin
Limit
Rotor Shaft Axial Play TIR 011 00043
3 If the measured value exceeds the specified limit Turbocharger
the shaft must be replaced Semitighten the turbocharger mounting nuts
The nuts will be fully tightened after installation of
the oil pipes
kgmlbft
Turbocharger Mounting
Nut Torque
PULL
PUSH AND
PUSH AND
Shaft Radial Play Measurement
Oil Drain Pipe
1 Turn over the turbocharger with the turbine exhaust
inlet flange facing up 1 Remove the exhaust manifold distance tube
immediately beneath the 2 Install a dial indicator to measure the rotor shaft
radial play This will make it easier to install the oil drain
pipe
3 Use the dial indicator to measure play Read
the TIR 2 Install the oil drain pipe and tighten the oil drain
mmin pipe flange nuts to the specified torque
4 Cyl Limit kgmlbft
Rotor Shaft Radial Play TIR 019 00075 Oil Drain Pipe Torque 38 07 275 51 I
3 Reinstall the exhaust manifold distance tube
Engines Generators
FIXING BOLTS
Oil Feed Pipe kgmlbft
1 Prelubricate the turbocharger with engine oil Turbo Adaptor Fixing
53 10 383 72
through the oil port shown in the illustration Bolt Torque
2 Install the oil feed pipe and tighten the pipe
flange bolts to the specified torque
kgmlbft
CHECKING
Oil Feed Pipe Flange 1 Check the air intake duct connections for air lea
26 05 188 36 kage
Bolt Torque
2 Check the intake manifold connections for air lea
kage
3 Check the exhaust duct connections for smoke lea
kage
4 Check the turbocharger mounting nuts for loose
ness
5 Check the oil feed pipe for oil leakage
6 Check the oil return pipe joints for oil leakage
Kgm IbIt
lOlL RETURN PIPE BOLTS TORQUE 21 05 152 36
Turbo Adapter 6 cyl
1 Use a screw driver to insert the gas sealing ring
to the turbocharger exhaust outlet port
2 Tighten the turbo adaptor fixing bolts to the
specified torque
GAS SEALING RING
Engines Generators
ENGINE TIMING ADJUSTMENT 4 Hold the fuel control lever at the fully open No I piston to the top dead
center on the compression 5 Slowly tum the crankshaft pulley clockwise and at the
stroke Tum the crankshaft pulley clockwise viewed at same time feed fuel to the injection pump by slowly
engine front and align the mark on the crankshaft pulley pumping the feed pump When the fuel stops to flow out
with the TOC mark from No I delivery valve holder stop turning the crank
shaft pulley and pumping This is the beginning of fuel
Remove the access cover at the front of the injection pump
check the alignment between the pointer A on the
injection pump gear lock plate and the projected pointer B on 4 CYL SHOWN
the timing gear case If A and B are in alignment the timing
THE 6 CYL HAS EIGHT
is set correctly TIMING NOTCH LINES
If they are in alignment No1 cylinder is at the TOC on PUNCHED ON THE GEAR
the compression stroke If it is in misalignment recheck by CASE AND THE TOC
MARK ON THE CRANK
turning the crankshaft pulley one more tum to repeat the to make sure that it is in
alignment
TIMING GEAR
CASE
PUllEY MARK
6 Notice which injection timing mark is aligned with the
pulley mark The timing mark in alignment with the
pulley mark indicates the degrees before TOC the start
of fuel the crankshaft position for the start of fuel injection 7 Blowout the remaining fuel fromthe delivery valve
holder Check that there is no fuel being delivered from
1 Tum the crankshaft pulley viewed from
the priming pump
the engine front about 30
2 Remove No I high pressure injection line INJECTION TIMING BCTC 4 CYL 14
4 CYL TURBO 12
VALVE
HOLDER INJECTION TIMING BlDC 6 CYL 12
6 CYL TURBO 12
SPRING
mij DELIVERY
VALVE
3 Remove the injection pump No1 delivery valve holder
delivery valve and spring and reinstall the delivery valve
holder back into the pump
DELIVERY VALVE HOLDER TIGHTENING TORQUE
39 44 Nm 4 45 Kgm289 325 ftIb
Engines Generators
ENGINE PROCEDURES
1 Align the pulley mark and the specified timing mark
Refer to the injection timing Loosen the four injection pump attachment nuts LOOSEN FOUR NUTS
3 To advance the timing pivot the injection pump at the 80TH SIDES
pump drive shaft away from the engine
To retard the timing pivot the injection pump at the
pump drive shaft toward the engine
NOTE A 1mm misalignment between the timing marks
on the crankshaft pulley will correspond to about 2 in
crank angle
4 Recheck the timing following procedures 1 through 5
5 Tighten the four injection pump attachment nuts
6 Again remove No1 delivery valve holder and reinstall
the delivery valve spring and the valve holder
DELIVERY VALVE HOLDER TIGHTENING TORQUE
39 44 Nm 4 45 Kgm289 325 ftIb
7 Reinstall the No1 high pressure injection line
TIMING GEAR
CASE
Engines Generators
ENGINE ENGINE COMPRESSION OIL PRESSURE
Make certain the oil level dipstick is at the correct level The engines oil pressure during operation is indicated
and the air intake filter is clean The battery and starter motor by the oil pressure gauge on the instrument panel During
must also be in good condition normal operation the oil pressure will range between 40 and
60 psi 28 and 42 kgcm
1 Warm the engine to normal operating Move the control lever to a position for shutting off the NOTE A newly started cold engine call
have an oil pressure
fuel Disconnect the wires if a fuel shutdown solenoid reading up to 60 psi 42 kglcm2 A warmed engine can have
is used an oil pressure reading as low as 35 psi 25 kgIc171 2 These
3 Remove all the glow plugs from the engine and install readings will vary depending upon the temperature f the
engine and the rpm
the compression gaugeadapter combination to the
cylinder on which the compression is to be measured
Low Oil Pressure
The specified safe minimum oil pressure is 5 10 psi A
gradual loss of oil pressure usually indicates a worn bearings
For additional information on low oil pressure readings see
TESTING ENGINE COMPRESSION the ENGINE chart
Testing Oil Pressure
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 idle and read
the oil pressure gauge
OIL PRESSURE 50 psi at 1800 rpm
SENDER AND SWITCH TORQUE 9 13 fIlb 12 18 m kg
Oil pure at 1800 or 1500 rpm should maintain a reading
of 50 pSI
4 Close the raw water seacock Crank the engine and allow the gauge to reach a
maximum reading then record that reading PREHEAT SOLENOID
6 Repeat this process for each cylinder
COMPRESSION PRESSURE 441 psi 310 Kgem at 200 rpm
ALLOWABLE LIMIT 370PSI 260 Kgem
MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS 20A BREAKER
2844 psi 20 Kgem
NOTE lfthe readings are below the limit the engine needs an
overhaul
7 Reinstall the glow plugs and reset the fuel shutoff to the
run position
S Open the raw water seacock low compression is found detemline the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole Allow the oil to the pressure gauge and repeat the above test If reading rises dramatically the fault is with the
rings If the compression valve does not rise the problem is
with the valves
A slight rise in compression would indicate a problem with I
both the rings and the valves Oil PRESSURE
SWITCH
Engines Generators
ENGINE CLEARANCE The cylinder head bolts have been tightened with
the Angular Tightening Method shown ill this manual it is not necessary to retighten the cylinder
head SCREW
bolts before adjustng the valve clearances VALVE
shows six cylinder model 0076 IN 040MM
Cylinder No 1 2 3 4 5 6
Valve arrangement I E I E I E I E I E I E
When No1 cylinder
is at TDC in the 00 0 0 0 0
compression stroke
When NO6 cylinder
is at TOC in the 0 0 0 0 00 4 Loosen each valve clearance adjusting screw as shown in
compression stroke the
5 Insert a 040mm 0016 in feeler gauge between the
1 In order to bring No1 or No6 six cyl No4 piston rocker arm and valve stem end
four cyl to the top dead center in the compression 6 Turn the valve clearance adjusting screw until a slight
stroke align the TDC mark and the crankshaft pulley drag can be felt on the feeler gauge
mark 7 Tighten the locknut
Chart shows four cylinder model LOCKNUT TORQUE 188 36 Hlb 26 05 kgm
Cylinder No 1 2 3 4 8 Rotate the crankshaft 360
Valve arrangement I E I E I E I E 9 Realign the crankshaft pulley TDC notched line with the
When No1 cylinder timing pointer
is at TOC in the 0 0 0 0 10 Adjust the clearances for the remaining valves as shown
compression stroke
in the When NO6 cylinder
is at TOC in the 0 0 0 0
compression stroke
2 Do the adjustment on the circle marked valves in the
above table where No1 piston is in the TDC in the
compression stroke After these steps do the adjustments
on the double circle marked valves where the No6 NO1 CYLINDER IS AT TOC IN COMPRESSION STROKE
piston six cyl No4 piston four cyl is on TDC in the
compression stroke
3 After adjusting the valves with piston No1 at TDC
rotate the crankshaft 360 again aligning the TDC mark
and the pulley mark This brings piston No6 or No4 to
TDC then adjust the remaining valves
FRONT
NO1 CYLINDER IS AT
TOC IN COMPRESSION
STROKE FRONT
NO4 CYLINDER IS AT
TOC IN COMPRESSION
STROKE
Engines Generators
FUEL SYSTEM
FUEL INJECTION PUMP Changing the Fuel Filter
The fuel injection pump is a very important component 1 Shut the fuel supply off
of the diesel engine requiring the utmost care in handling 2 Slip a plastic bag over the fuel filter to prevent
If the fuel injection pump requires servicing remove it and fuel spillage then loosen the fuel filter turning
take it to an authorized fuel injection pump service facility with a filter wrench
Do not attemJt to disassemble and repair it
3 Using a rag wipe clean the sealing face on the
housing bracket so the new filter can be seated
properly
4 Lightly oil the sealing Oring on the new filter To
reinstall turn the filter assembly carefully until the Oring contacts the
sealing
surface of the housing bracket Turn 23 further
o I I 0
with the filter wrench
3RG Pump No NOTE The cartridge contains fuel Take care not to pill it
NpPE SA95 LICENCE BOSCH
during disassembly
5 Open the fuel supply The filter will fill with fuel
number Check for leaks
6 Run the engine to make certain there are no leaks
PLATE AND PRODUCT SERIAL
NUMBER
1 Injection pump adjustment and repair should be
made by the nearest DKKC Diesel Kiki Co Ltd or
ROBERT BOSCH Authorized Service Outlet
2 When you ask such authoriged service outlet the
adjustment or repair the Plate and
LIGHTLY WIPE
Product Serial Number will give them a necessary WITH CLEAN FUEL
clue to get technical data distributed by the manu
facturers previously TO LlFTPUMP
Without this data the Service Outlet will be unable FUEL
to effectively service your injection pump
If you are unable to locate the data applicable to
your injection pump please contact your PREFILL
WESTERBEKE dealer WITH FRESH FUEL
FUEL INJECTORS
FEED PUMP Poor fuel quality contaminants and loss of positive fuel
KNOB pressure to the injection pump can result in injector
faults Fuel injectors must be serviced in a clean room
environment
Before removing the old injector clean the area around
the base of the injector to help prevent any rust or
debris from falling down into the injector hole If the
injector will not lift out easily and is held in by carbon
buildup or the like work the injector sidetoside with
the aid of the socket wrench to free it and then lift it
The injector seats in the cylinder head on a FUEL FEED PUMP sealing washer This washer should be
removed with
CLEAN WITH DIESEL FUEL the injector and replaced with a new washer when the
new injector is installed
The fuel injectors should be pressure tested after 750
operating hours
INJECTION STARTING
PRESSURE 181 Mpa 2630 psi
Fuel Feed Pump
The fuel feed pump is an integral part of the injection HOLDDOWN NUTS TORQUE 19 02 kgm 135 15 fHb
pump The fuel strainer in the pump should be serviced
Refer to the 59
FUEL SECTION
5 NOZZLE
HOLDER
PUSH RO 4 Injection Nozzle
NOZZLE HOLDER There must be no oil on the contact surfaces of the
CAP NUT injection nozzle and the injection nozzle holder
Clean these contact surfaces with diesel fuel before
CAP NUT GASKET
The nozzle dowel pin must be aligned with the
NUMBERS INDICATE dowel hole in the nozzle holder body
THE ORDER OF
DISASSEMBLY
NOZZLE
ADJUSTING ALIGN THE DOWEL
SCREW WITH THE HOLE
5 Retaining Nut
kgmlbft
PUSH ROD Nozzle Retining Nut
SPRING 7 1
Torque
6 RETAINING NUT
Nozzle INJECTOR
Remove the nozzle assembly from the nozzle body
1 TORQUE WRENCH
Keep the parts separately to maintain the proper
needle valve to body Push Rod Spring
Check the push rod spring for wear weakness and cor INJECTION TESTING
rosion 1 Using the nozzle tester check the spray pattern and
injection starting pressure of nozzle and if it
exceeds the limit adjust or replace the nozzle When
Nozzle Holder Push Rod using nozzle tester take the following precautions
1 Check the nozzle holder push rod curvature
2 Check the nozzle holder push rod and needle valve
contact surfaces for excessive wear and poor con
A CAUTION The spray injected from the nozzle is
tact
of such velocity that it may penetrate deeply into
the skin of fingers and hands destroying tissue If
Injection Nozzle it enters the bloodstream it may cause blood
poisoning
1 Check the injection nozzle needle valve the valve
seat and the injection nozzle hole for carbon depos
its NOZZLE INJECTION
TESTER
If carbon deposits are present the injection nozzle
and the needle valve must be replaced
2 Hold the nozzle body vertically
Pull the needle valve about onethird of the way out
of the nozzle body
Release the needle valve
Check that the needle valve falls back into the noz
zle body as far as the valve seat
If the needle valve does not fall back into the nozzle
body as far as the valve seat the injection nozzle alf the diesel fuel of the nozzle tester is discolored
and the needle valve must be replaced replace it At the same time clean or replace the
fuel filter
b Set the nozzle tester in a clean place where there
3 Injection Pipe Connector is no dust or dirt
kgmlbft c Mount the nozzle holder on the nozzle tester
Nozzle Connector Torque 55 05 388 36 I d Use the fuel at the approximate temperature of
68F 20C
Engines Generators
FUEL SECTION
e Operate the hand lever of nozzle tester several GLOW PLUGS
times to bleed the air in the nozzle line then move
the hand lever at intervals of one stroke per second The glow plugs are wired through the preheat solenoid
while reading the injection starting pressure When PREHEAT is pressed at the control panel this
solenoid should click on and the glow plug should
Injection Starting Pressure Adjustment begin to get hot
The Injection nozzle injection starting pressure can be Inspection
adjusted after the screw is installed
To inspect the plug remove the electrical terminal con
INJECTION STARTING PRESSURE 2630 psi 181 MPa 185 Kgem nections then unscrew or unclamp each plug from the
cylinder head Thoroughly clean each plugs tip W
threads with a soft brush and cleaning solution to
remove all the carbon and oil deposits While cleaning
examine the tip for wear and burn erosion if it has
eroded too much replace the plug
Testing
GOOD BAD BAD An accurate way to test glow plugs is with an ohmmeter
Touch one prod to the glow plugs wire connection and
the other to the body of the glow plug as shown A
good glow plug will have a 04 06 ohm resistance
Spray Condition Check During Injection Nozzle Testing This method can be used with the plug in or out of the
Operation engine You can also use an ammeter to test the power
1 Tighten the cap nut drain 5 6 amps per plug
2 Check the injection nozzle starting pressure
3 Check the injection nozzle spray condition
Nozzle Holder Cap Nut
A WARNING These glow plugs will become very hot
to the touch Be careful not to burn your fingers when
kgmlbtt
testing the plugs
Cap Nut Torque 45 05 325 36 I
TESTING A GLOW PLUG
WITH AN OHMMETER
Kgm IbII TESTING A GLOW PLUG
INJECTION HOLDDOWN NUTS TORQUE 19 02 13715 USING A TEST LIGHT
GLOW PLUGS
FROM PREHEAT
TERMINAL
Reinstall the plugs in the engine and test them again
The plugs should get very hot at the terminal end
within 20 to 25 seconds If the plugs dont heat up
quickly check for a short circuit When reinstalling the
glow plugs use antiseize compound on the threads
A WARNING Do not keep a glow plug on for more
than 30 seconds
Kgm IbII
I GLOW PLUG TIGHTENING TORQUE TORQUE 27 195
Engines Generators
METER NOTE Current model tachometers use a coarse adjustment
dial to set the tachometer to the crankshaft pulley IpI11S The
The meter used in propulsion engine instru
calibrating screw is then usedfor fine tuning
ment panels contains two separate electrical circuits with a
common ground One circuit operates the hour meter and the
other the tachometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the back of the instrument JUMPER WIRE
The tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage 130148 DC
The following are procedures to follow when COARSE
TERMINAL
a fault in either of the two circuits in a
TACH INP
Hour meter Inoperative CALIBRATION AC VOLTAGE
Check for the proper DC voltage between and TACHOMETER CHECK New Voltage present meter
is defective repair or replace NOTE In a new installation having new instrument panels
the tachometer may 170t always be correctly calibrated to the
2 Voltage not present trace and electrical con
engines rpm This calibration should be checked in all new
nections for fault Jump 12 volts DC to meter
telminal to verify the operation
1 Warm up the engine to nonnal operating Inoperative Remove any specks on the crankshaft pulley
with a clean
Check for the proper AC voltage between tachometer input cloth and place a piece of suitable reflecting tape on the
tenninal and tell11inal with the engine running pulley to facilitate use of a photoelectric type Voltage present attempt
adjusting meter through calibra 2 Start and idle the engine
tion access hole No results repair or replace meter 3 Aim the light of the tachometer onto the reflecting tape to
2 AC voltage not present check for proper alternator DC confinn the engine speed Check the instrument panel
output voltage tachometer reading Adjust the tachometer in the panel by
using the instrument coarse adjustment to calibrate the
3 Check for AC voltage at tach telminal on alternator to
instrument reading to the closest RPM that the photo tach
ground
is showing Then use the fine calibration adjustment to
4 Check electrical connections from tachometer input ter bring the instrument to the exact reading as the photo tach
minal to alternator Sticking
1 Check for proper AC voltage between tach inp
tenninal and telminal
2 Check for good ground connection between meter
terminal and Check that altemator is well grounded to engine block at
alternator pivot Inaccurate
a With a handheld tach on tile front of the crankshaft
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in tl1e rear of
the tachometer Zero tile tach and bring it to the rpm
indicated by the strobe or hand tach Verify tile rpm at
idle and at high speed and adjust the tach as needed
Engines Generators
WESTERBEKE 51A MANDO ALTERNATOR
DISASSEMBLY AND TESTING
A WARNING A failed alternator can become very
hot Do not touch until the alternator has cooled down
REAR HOUSING
A WARNING Before starting the engine make
certain that everyone is clear of moving parts Keep
away from sheaves and belts during test procedures
A WARNING Multimeters and DC Circuits
DC and AC circuits are ofter mixed together in marine
applications Always disconnect shore power cords
isolate DC and AC converters and shut down generators
before performing DC testing No AC tests should be
made without proper knowledge of AC EXCITER
TERMINAL R
TACHOMETER
TERMINAL SENSING
TERMINAL S
GROUND REFER TO THE
TERMINAL E WIRING DIAGRAMS FOR THE ABOVE
WIRING HARNESS CONNECTIONS
JUMPER B
TESTING THE EXCITATION CIRCUIT
TESTING THE OUTPUT CIRCUIT 1 Connect the positive voltmeter lead to the excitation
1 Connect the positive voltmeter lead to the output terminal R on the alternator and the negative lead to
terminal B and connect the negative lead to the ground the ground terminal E on the alternator
terminal E on the alternator 2 Turn the ignition switch to the on positiul and note the
2 Wiggle the engine wiring harness while observing the voltmeter reading The reading should be 13 to 25
voltmeter The meter should indicate the approximate volts see battery voltage and should not vary If no reading is 3 If the
reading is between 75 and 11 volts the
obtained or if the reading varies check the alternator rotor field circuit probably is shorted or grounded
output circuit for loose or dirty connections or Disassemble the alternator and test the rotor as
damaged wiring described under CLEAN AND TEST ALTERNATOR
COMPONENTS in this section
NOTE Prior to any altemator testing impect the entire
altemator system wiring for defects Check all conllections 4 If the reading is between 60 and 70 volts the rotor
for tightness and clealliiness particularly battery cable field circuit probably is open Remove the regulator
clamps and battery tenninals Inspect the altemator drive and inspect it for worn brushes or dirty slip rings
belt for excessive wear and replace if necessary Also adjust Replace the brushes if they are less than 1I4in 6 mm
for proper belt tension long If the brushes and slip rings are in good condi
tion disassemble the alternator and test the rotor as
outlined under CLEAN AND TEST ALTERNATOR
COMPONENTS in this section
WESTERBEKE
Engines Generators
MANDO ALTERNATOR SERVICE
e Remove the regulator THE EXCITER LEAD
f Temporarily reinstall Jumper Al and all associated
nuts Leave Jumper B installed
g Remove the plastic plug from the side of the
regulator
h Connect a jumper between the top brush lead
and the ground
JUMPER A
5 If no reading is obtained an open exists in the REGULATOR U L
lead or in the excitation circuit of COVER
the regulator Disconnect the lead from exc terminal R
Connect the positive voltmeter lead to the excitation SENSING OUTPUT
lead and the negative voltmeter lead to ground terminal TERMINAL TERMINAL
E If the voltmeter now indicates an approximate battery
voltage the voltage regulator is defective and must be
GROUND
replaced If no voltage is indicated check the excitation
circuit for loose or dirty connections or damaged wiring
TEST VOLTAGE REGULATOR
Perform this test to determine if the voltage regulator is CONNECT
operating correctly using a 0 20 volt DC voltmeter JUMPER WIRE
NOTE The battery must be fully charged to obtain a proper
BRUSHES
voltage reading in this test If necessary charge the battery
with a battery chargeror allow the engine to run a sufficient
length of time to fully charge the battery before taking a REGULATOR
reading
1 Connect the positive voltmeter lead to the positive
battery terminal and the negative voltmeter lead to
the negative terminal
2 Start the engine and run it at fast idle until the engine
reaches its normal operating temperature Adjust the PLASTIC PLUG
TOP LEAD
engine speed to 1500 2000 rpm and observe the FROM BRUSH
voltmeter for the highest reading The reading should
be between 137 and 147 volts
3 If the reading is high check for a loose or dirty i Repeat steps 1 and 2
alternator ground lead connection If the connection is NOTE Do lot let Ihe Itage exceed 16 10111
good the voltage regulator is faulty and must be
j If a voltmeter reading of 145 volts or above is
replaced Be sure to disconnect the battery cables before
now obtained the voltage regulator is faulty and
attempting to remove the alternator
must be replaced If the voltmeter reading is below
4 If the reading is low 145 volts inspect the brushes and slip rings for
a Stop the engine and remove the alternator wiring wear dirt or damage If the hrushes and slip rings
connections are good the alternator is fault internally
b Remove the Phillips cover screw from the regulator Disassemble the alternator and test the components
cover see as outlined in this section
c Remove the nut from the output terminal and the
nut from the sensing terminal and remove Jumper
d Remove another nut from the sensing terminal and
the nut from the excitation terminal
Engines Generators
MANDO ALTERNATOR SERVICE
REMOVE ALTERNATOR 10 Place an oversized Vbelt around the pulley and fasten
the pulley in a vise
1 Disconnect the negati ve battery ground cable
11 Use a 78 in box wrench to loosen and remove the
2 Disconnect the wiring leads pulley nut
3 Loosen the screws Holding the alternator rotate it 12 Remove the pulley nut lockwasher pulley fan and
toward the engine and lift the belt off the pulley spacer
4 Remove the screws and washers and remove the TERMINAL
NUTS
PHILLIPS FAN
SCREWS PUllEY AND FAN
COMPONENTS
A CAUTION DO NOT insert screwdriver blades
OUTPUT more than 116 in 16 mm Damage to the stator
TERMINAL winding could result from deeper NOTE Score the stator and
the front alld rear housings so
the llnit may be reassembled correctly
13 Remove the four throughbolts and carefully pry the
DISASSEMBLE ALTERNATOR front housing away from the rear housing using two
screwdri verso
1 Remove the terminal nuts to remove the jumper see
REAR HOUSING
2 Remove the remaining terminal nuts
3 Remove the capacitor
4 Remove the Phillips screw from the regulator cover
SCREW DRIVER
5 Remove the cover
6 Remove the nut from the terminal
7 Remove the jumper
8 Remove the terminal insulators
9 Remove the two Phillips screws and remove the 14 Carefully push the rotor assembly out of the front
assembl y housing and rear housing
NOTE If he bearing is removed from he hOllsing nell
bearing mltst be installed
IS After removing the three bearing locking screws care
fully press the front bearing out of the housing Press
REMOVAL against the inner race of the bearing
WESTERBEKE
Engines Generators
MANDO ALTERNATOR SERVICE
2 Inspect and test the diodetrio assembly
a Using a commercial diode tester a 12volt DC test
lamp or an ohmmeter check the resistance between
BEARING LOCKING each of the three diode terminals and the indicator
SCREWS light stud
light stud
FRONT BEARING
BEARING
DRIVER
DIODE TRIO ASSEMBLY
h Reverse the tester leads and repeat the resistance
FRONT
BEARING FRONT HOUSING checks
c A very low resistance should be indicated in one
16 Remove the rectifier assembly by removing the Phillips direction and a very high resistance should be indi
screw and lifting out the assembly cated in the other direction if the diodes are normal
d If any diode appears to be defective replace the
complete assembly Do not attempt to replace an
individual diode
3 Test the bridge as follows
a Using a commercial diode tester check for
continuity from each of three terminals to the
ouput RECTIFIER REMOVAL GROUND RECTIFIER
TERMINAL AND TEST ALTERNATOR COMPONENTS h Reverse the tester leads and repeat Step a
c Continuity should exist in only one direction and
1 Inspect and test the assembly The
all diodes should check alike
brush set may be reused if the brushes are 1I4 in
6 mm or longer The brushes must not be oil soaked d Perform the same continuity checks between the
cracked or grooved three terminals and strap ground terminal This
should show continuity in only one direction
Test for continuity between I and 2 and 3 and 4 using
through the diodes and all diodes should check
a test lamp or an ohmmeter These checks will indicate
alike
a good assembly replace the complete
assembly if necessary e If any diode appears to be defective replace the
rectifier TESTING BRUSH ASSEMBLY
Engines Generators
MANDO ALTERNATOR SERVICE
4 Clean and inspect the front and rear housings
a Inspect the rear housing for cracks or breaks in the
casting stripped threads or a damaged bearing bore
Replace the housing if any of these conditions exist
b Inspect the front housing for cracks stripped or
damaged threads in the adjusting ear or an outof LAMINATIONS
round bore in the mounting foot If possible
correct slightly damaged threads using a tap b Check the resistance from each lead 1 2 and 3 to
Replace the housing if necessary the laminations 4 There should be no continuity
c If the housings are to be reused clean them in if the insulation is good
solvent and dry with compressed air c Inspect the stator windings for signs of Clean and inspect the rotor shaft bearings
A discolored winding should be replaced
NOTE Do not use a solvent on the rear rotor bearing d If a winding shows a high resistance or an open
since it is serviced as a unit with the rotor circuit between any two of the three winding
terminals or indicates poor insulation between the
a The bearings should be wiped clean with a lintfree windings and the laminations the stator must b
cloth containing a moderale amount of commerc 1 replaced
solvent Do not immerse a bearing in solvent or
use pressurized solvent or air 8 Check the rotor assembly as follows
b Check the bearings for obvious damage looseness NOTE If slip rings need to be replaced you must
or rough rotation Replace a bearing if any doubt replace the entire rotor
exists as to its condition a Visually inspect for physical defects such as dam
NOTE If the rear rotor bearing needs replacement aged shaft threads worn or damaged bearing areas
replace the entire rotor burned or pitted slip rings or scuffed pole fingers
6 Inspect the belt pulley for rough or badly worn belt b Measure the winding resistance across the slip rings
grooves or keyway and for cracks or breaks Remove A Place the ohmmeter leads on the edges of the
minor burrs and correct minor surface damage replace slip rings not on the brush contact surfaces The
a badly worn or damaged pulley correct winding resistance at 70 80 F 21
27 C is 41 to 47 ohms
c Minor burning or pitting of the slip ring surfaces
FRONT
can be removed using a crocus cloth Thoroughly
HOUSING J FRONT wipe the slip rings clean after polishing removing
BEARING all grit and dust
d Check for a grounded slip ring or rotor winding by
measuring the resistance from each slip ring to the
rotor body or pole finger B An open circuit should
EAR HOUSING be indicated in both cases for a good rotor
e If the windings are defecti ve or physical damage
cannot be corrected replace the rotor assembly
9 Use a commercial capacitor checker to test the
capacitor for capacity shorts leakage and series
resistance
L OSF
7 Test the stator windings as follows S
a Using an ohmmeter or test lamp check for F
continuity between all three leads 1 2 and 3
A low ohm reading or lit test lamp should be E
observed
INTERNAL CIRCUIT WIRING
Engines Generators
MANDO ALTERNATOR SERVICE
2 Place the rotor pulley end up on the bed of an arbor
press on two steel blocks
3 Press the front housing and bearing assembly down
onto the rotor shaft Press against the bearings inner
race only using a sleeve driver Take care to insure that
POLE FINGERS the rotor leads clear the steel blocks
SLEEVE DRIVER
FRONT HOUSING AND
BEARING ASSEMBLY
SLIP RINGS
ROTOR
INSTALLING THE FRONT HOUSING ON THE ROTOR ALTERNATOR 4 Install the rectifier assembly into the rear
housing
1 Carefully press the front bearing into the front housing
5 Insert the Phillips screw and tighten it
pushing against the bearings outer race using a bearing
driver Lock the bearing in place with screws
TORQUE 25 35 bin 28 40 Nm
BEARING RECTIFIER
DRIVER ASSEMBLY
FRONT BEARING
OUTER
FRONT HOUSING
RACE
6 Assemble the front and rear housings as follows
a Put the stator winding in the front housing with the
FRONT BEARING ASSEMBLY stator leads away from the front housing and the
notches in the stator laminations aligned with the
four throughbolt holes in the housing
b Align the scribe marks you made in the stator and
front and rear housings during disassembly
BEARING LOCKING c Slip the rear housing into place over the rotor shaft
SCREWS Align the mounting holes and put the stator leads
through the holes at the top of the rear housing
d Install the four bolts and tighten them
TORQUE 35 65 Ibft 40 73 Nm
NOTE If the front housing is lIeH the throughholt
FRONT BEARING Vill not be tapped
ASSEMBLING THE BEARINGS
Engines Generators
MANDO ALTERNATOR SERVICE
7 Install the spacer and the fan Then push the pulley INSTALL ALTERNATOR
lockwasher and nut onto the shaft Turn the nut a few
1 Install the alternator screws and washers
turns
8 Place an oversized Vbelt around the pulley and fasten 2 Connect the wiring leads
the pulley in a vise 3 Put the belt on the alternator crankshaft and coolant
pump pulleys
4 Adjust the alternator belts tension see DRIVE BELT
ADJUSTMENT under ENGINE OVERSIZED
VBELT MANDO ALTERNATOR Battery Voltage 12 Volt
Maximum Speed 13500 RPM
Cut in Speed Max 2000 RPM at exc
Max 1500 RPM at L2
Reg Set Voltage 147 Volts
Ambient Temp 20C 100C
Ground Negative
INSTALLING THE PULLEY AND THE FAN NUT
9 Use a torque wrench to the tighten the nut
TORQUE 35 50 Ibft 47 68 Nm
10 Carefully install the assembly on the
rear housing with the two mounting screws
11 Install the small terminal Install the large terminal Install the jumper
14 Install the nut on the terminal
15 Install the assembly cover
16 Install the Phillips screw for the assembly cover
TORQUE 25 351bft 28 51 Nm
17 Install the Install the terminal nuts
19 Install the jumper
20 Install the last terminal nut
Engines Generators
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 condi
BaHery 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 cOlToded 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
b 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 Open field circuit b Inspect and test frame and field assembly
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 RlPAIR 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 a
fastener 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
j 33
30 31 32 15 1fIJ
2223
1 SOLENOID ASSEMBLY 10 7 Jb
2 CLUTCH DRIVE
35
ASSEMBL Y 6 0
3 BRUSH HOLDER 2
ASSEMBLY 21
4 BRUSH GROUNDED
5 BRUSH INSULATED
6 DE HOUSING 18
BUSHING 21 SHIFT LEVER SCREW
7 BRUSH SPRING 34
22 SHIFT LEVER WASHER
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 Ii 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
STARTER of Frame Field and Brush Holder Group
Figure 5
Remove or 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 29 INSULATED BRUSH
4 BRUSH GROUNDED
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 Housing bolts 36 and 37
2 Armature support bracket 16
Important
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
TWO MAY BE USED GROUP
6 from the drive housing 18 unless replacement
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
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 DIA
6
22MM
087 IN DlA
OPEN
TUBE
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 torn 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 I 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 12voIt starters and approxi
mately175 ohms for 24voIt starters
h 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
MOTOR
winding circuit Either condition is cause for
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
h 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
h 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 armature 13 as follows Figure 11
NOTE Ball bearings which are removed from the Install or Connect
armature must be replaced with new bearings The h 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 armature 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
h New CE andor DE bearings 8 andor 9 to the
a From inside the drive housing 18 drive out the
armature 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 armature shaft
h 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 removed from 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
ACCESS
PIECE OF FLAT METAL STOCK ABOUT 5MM OR 316 IN CENTER HOLE
SUPPORT
THICK AND 55 MM OR 2 114 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
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
I 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 l0 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
a 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
8 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 Vshaped 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
142 MM
056 IN
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 513 and 14
handling Do not overflex tlJe 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
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 Ibin
socket
c Push the spring fully onto the post and release the free
end to engage the notch in the brush socket
INSULATED BRUSH
INSULATION
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
a The Oring can easily be damaged during installa
assembly
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 13 Ibin 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 25 lbin 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 Ibin
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
b The nut on the terminal of the solenoid assembly to
and release the brush springs to contact the ends of
11 Nm 100 Ibin
the brushes
5 Oring 20
Engines Generators
STARTER MOTOR
STARTER INSTALLATION CE FRAME
Testing After Repair Dr 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 battery cable
is disconnected at the battery 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 FRAME AND
a Solenoid battery B terminal nut to 18 Nm 13 lbft FIELD
ASSEMBLY
b Solenoid switch S terminal nut to 18 Nm
16Ibin FIGURE 15 ALIGNING TIMING MARKS
STARTER 12 Volt models have these NoLoad Test AMPS
RPM
VOLTS
Minimum Maximum Minimum Maximum
10 125 190 3000 5600
All 24 Volt models have these NoLoad Test AMPS
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 52 59 10 017019 12 14 10 076 081
24 100 125 20 016 020 12 14 20 115 165
Engines Generators
WIRING DIAGRAM
44780
ALTRNUOR 2np 12A
ALleRNATOR 2y A
J
tl 01 III OIlG
IVIO
110111
II SWICH 11
AVI OSSUR
I LlII
122 VOC III Ill
L 0 1 ttl
II 11111
STABlER MOTOR LU
14 1111
114 VIO
I I
10
IEO 114 Rn
uBllI
au Is
IlIH
III 11
YO YlO OI 0 tit 0
L YIOj r LD
It Jfu MOV JUMPER IMEI CTIG
SOID RMOT PIEl
2 GIQUID TlNIIAl or IHUT SOlUOID 01 24Y SYSUN OIl
1821
m WI INHAT
SWITCH
Tl122
lBI5
TBIl
1BI2 START
SWITCH
T8IO
TlI2S
T824
STCP
SWITCH
HOUR VOLT tI1I
METER
I METER
Engines Generators
WIRING SCHEMATIC
44780
BATTERY 12lVOC
CIRCUIT
BREAKER STARTER
l J I STARTER I
grg SOLENOIOJ
GtOWPLUGS
I PItEHEATi
SOLENOI
AL HRNAlOR
KISURT
IIZRUN
7 01 L PRSS lK TEWP WATER TEW
51 TeM 511 reH WI reM
r STO
sneH KZRUN RlAr
I IUODZ
PREHEAT START
S TeH WI TeH IIISTART RElAY
r r 1
l J L J
Oil 8YPASS SIITCH
AUI 0 SIITCH
Oil PRSS TIIJ TBI 1112l TBZ TlIS TIIl TIll TBZ TIIl5 WATER HM SIIDI
TIlltO
STOP
SWI TeH
OIL PRESS GAUGE
PREHEAT START
SWI TeH 5 TeH
IND LIGHT
r
TfPIAl REWOTE STARTSTOP ANfl
VOL H4 T R
NOl
o REMOTE COfIICTOR PINS
Engines Generators
REMOTE INSTRUMENT PANEL
44329 STOP SWITCH
REMOTE
PANEL
CONTROL REAR VIEW
PREHEAT
SWI TCH
PREHEAT
START SWI TCH
STOP
SWITCH
t16 REDVL
116 REDWHT
116 WHT
110 RED
PREHEAT
START
SWITCH
SWITCH
0 116 WHTRED
MALE CABLE
CONNECTOR
114 RED REAR VIEW
114 RED
116 VElRED
PN 44336
Engines Generators
WIRING DIAGRAM
MARINE ENGINES 44781
ALTERNATOR 24V 42A ALTERNATOR 0 51A
00 OIL PRESSURE
ll1ill
SWITCH
USED IlMllU
1224 VDC
NOTE S
I THI ODUCT IS IRoHeTEO BY WAfrlUAt IIST CIRCUIT IIRtAlR LOCATED IIEAR THE S1
STARTER exCESSIVE CURIIIH ll CAUSE THE BR ItR TO JRI AND THE NGIN IlL
SHUT DOWN tHE lIun liE SURE THAT THE INSTIIUIINT ANEL WilliNG AND S2
116 AilE IItSTALLED TO PRVl1T CONTACT IIETEEN ElECHtlCAl DEVICES ANO SEAWATER
2 AN ONOFr SWITCH SHOULD liE INSTAlLEO 8ETwEEN THE UTTERl AND STARTER TO
DISCONNECT THE IIATTE N AN OHRGENCT AND WHl1 tEAYING THE aOAT A SWCH
TH A CONTINUOUS UTIli OF I1S AMS AT 12 VDC LL SRYE THIS FUNCTION THIS PZ
STCH SHOULD NOT eE UseD TO MAI OR 8REAII THE CIRCUIT
1 THE PltrIll IIE AT LUG Z IS UNtSED AND SHOULD II INSULATED ITAIN PANEl ONLT
THE GAY ItE AT PLUG 1 IS UNUHD AND SHOULD Itt INSULATED ADMltAl PANEl ONU
CONNECT THE CIItCUIT IIIAKER AND RESISTOR RE TO THE fItMINAl FOR I l VOLr
ADMIRAL
SUTOIS ONLY FOR l4 VOLT SlSTENS REMOVE THE CIRCUIT 8REUER AND CONNECT 01
RESISTOR RE TO THE 114 LT 8tU RES AND THEN GAOUND THE 1 TAWINAL PANEL
WTR TaP
OAUOI
110 RED
Hr 11il01
Engines Generators
WIRING SCHEMATIC
MARINE ENGINES 44781
START
SOl STARTER
Al TERNATOR
12Y CB
OPTIONAL ALTERNATORS
I I IT 8lU I
lot PI Hit
PRESTOLITE 72 AMP ALT
VOL 90 AMP ALT
PREHEAT
SWI TCH
ORN ORN
CASE GN
DISCONNECT JUMPER FOR
USE WITH TWO LESTEK 135 160 190 AMP ALT
Ih12UIII
Engines Generators
ENGINE Starting Starter Inoperative 90
Starter Operates but engine does not turn over 91
Engine turns over but does not start though fuel
is being delivered to the injection pump 92
Engine turns over but does not start 93
Unstable Low Idling Power Fuel Consumption Oil Consumption 10 1
Overheating l 02
White Exhaust Smoke l 03
Dark Exhaust Smoke l 04
Oil Pressure Does Not Rise 105
Abnormal Engine Noise l 06
NOTE Use this section to quickly diagnose and repair engine failures
Each chart has three headings arrangedfrom lefi to right
1 Check Point 2 Trouble Cause 3 Remedy
Engines Generators
ENGINE HARD STARTING
1 STARTER INOPERATIVE
Checkpoint Trouble Cause Remedy
NG NG
Transmission neutral switch Defective neutral switch Replace the neutral switch
if so equipped
I J
Loose battery cable terminals Clean andor retighten the bat
Battery I
Poor connections due to rusting tery cable NG NG
Battery discharged or weak Recharge or replace the battery
NG NG
Drive belt loose or broken r Adjust or replace the drive belt
I NG Defective starter switch or NG Replace the starter switch or
Starter switch r r
the starter relay
starter relay
Defective magnetic switch or Repair or replace the magnetic
Starter motor
starter relay
r switch
Starter motor I Defective starter motor Repair or replace the starter motor
Engines Generators
ENGINE HARD STARTING
2 STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER
Checkpoint Trouble Cause Remedy
Loose battery cable terminals
NG Clean andor retighten the bat
Battery
Poor connections due to rusting tery cable NG
Battery discharged or weak Recharge or replace the battery
NG NG
Drive belt loose or broken Adjust or replace the drive belt
NG NG
Starter motor r Defective pinion gear r Replace the pinion gear
NG Defective magnetic switch
NG Repair or replace the magnetic
t switch
NG Brush wear NG Replace the brush andor the
Weak brush spring
t brush spring
NG Piston crank bearing seizure NG Repair or replace the related
Engine r t
or other damage parts
Engines Generators
ENGINE HARD STARTING
3 ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
Checkpoint Trouble Cause Remedy
Continued from the previous page
OK I
Injection nozzle injection starting
NG NG Adjust or replace the injection
Injection nozzle pressure too low r
nozzle
Improper spray condition
Defective fuel injection nozzle
Injection pump resulting in fuel drippage after
fuel injection
NG Replace the delivery valve
NG Defective injection pump control Repair or replace the injection
rack operation pump control rack
NG Injection pump plunger worn or Replace the injection pump
stuck plunger assembly
Injection pump VE pump Injection pump drive shaft seizure Replace the injection pump drive
or other damage shaft
NG Injection pump governor spring Replace the injection pump
seizure governor spring
Engines Generators
ENGINE HARD STARTING
4 ENGINE TURNS OVER BUT DOES NOT START
Checkpoint Trouble Cause Remedy
Defective engine stop mechanism Replace the engine stop
Engine stop mechanism NG Defective fuel cut solenoid
valve Replace the fuel cut solenoid
VE pump valve
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
Fuel Fuel tank is empty NG Fill the fuel tank
Repair or replace the fuel lines
Fuel piping NG Clogged or damaged fuel lines
Loose fuel line connections
NG Retighten the fuel line
Fuel filter Fuel filter overflow valve does
not close
Repair or replace the fuel filter
overflow valve
NG Replace the fuel filter element or
Clogged fuel filter element
the fuel filter cartridge
Fuel system
NG Air in the fuel system Bleed the air from the fuel system
Continued on the next page
Engines Generators
ENGINE UNSTABLE LOW IDLING Checkpoint Trouble Cause
Remedy
Low idling NG Low idling improperly adjusted
r Adjust the low idling
Throttle control system Throttle control system
improperly adjusted
r Adjust the throttle control
system
NG NG
Fuel system r Fuel system leakage or blockage r Repair or replace the fuel system
NG NG
Air in the fuel system r Bleed the air from the fuel system
NG NG
Water particles in the fuel system t Change the fuel
Fuel filter Clogged fuel filter element
NG Replace the fuel filter element or
the fuel filter cartridge
Continued on the next page
Engines Generators
ENGINE UNSTABLE LOW IDLING Checkpoint Trouble Cause
Remedy
Continued from the previous page
OK I
Injection pump NG Defective governor lever operation
NG Repair or replace the governor
lever
NG Regulator valve improperly
NG Adjust or replace the regulator
adjusted VE pump only valve
NG NG
Broken plunger spring Replace the plunger spring
NG
Worn plunger Replace the plunger assembly
NG NG
Worn camshaft Inline pump only Replace the camshaft
Worn roller tappet Inline pump
Replace the roller tappet
only
NG NG
Worn cam disc VE pump only Replace the cam disc
Valve clearance Valve clearance improperly
Adjust the valve clearance
Engines Generators
ENGINE INSUFFICIENT POWER
Checkpoint Trouble Cause Remedy
Air cleaner Clogged air cleaner element r
Clean or replace the air cleaner
element
Fuel Water particles in the fuel r Replace the fuel
NG NG
Fuel filter r Clogged inlet filter screen r Clean filter screen
Fuel feed pump Defective fuel feed pump r
Repair or replace the fuel feed
pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
Injection nozzle injection starting
NG NG Adjust or replace the injection
pressure too low r
nozzle
Improper spray condition
Fuel injection pipes Fuel injection pipes damaged or NG Replace the fuel injection pipes
obstructed
Continued on the next page
Engines Generators
ENGINE INSUFFICIENT POWER
Checkpoint Trouble Cause from the previous page
OK I
Injection pump Defective delivery valve Replace the delivery valve
Defective timer MG Repair or replace the timer
NG NG Adjust or replace the control
Improper control lever operation lever
Adjust the injection timing
Defective injection timing Repair or replace the injection
pump timer
Weak governor spring Replace the governor spring
NG Worn plunger Replace the plunger assembly
NG Worn camshaft inline pump only Replace the camshaft
Continued on the next page
Engines Generators
ENGINE INSUFFICIENT POWER
Checkpoint Trouble Cause from the previous page
OK I
NG NG
Injection pump Worn roller tappet t Replace the roller tappet
Exhaust gas leakage from the
Turbocharger exhaust system Repair or replace the related
parts
Air leakage from the intake system
NG NG
Defective turbocharger assembly r Replace the turbocharger assembly
Blown out cylinder head gasket
Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
NG Valve clearance improperly NG
Valve clearance r Adjust the valve clearance
adjusted
NG NG
Valve spring r Valve spring weak or broken Replace the valve spring
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
Full load adjusting screw seal Open and improperly set
adjusting screw seal NG Adjust and reseal the adjusting
screw
Engines Generators
ENGINE EXCESSIVE FUEL CONSUMPTION
Checkpoint Trouble Cause Remedy
Repair or replace the fuel system
Fuel system Fuel leakage t related parts
OK I
Air cleaner Clogged air cleaner element t
Clean or replace the air cleaner
element
OK I
Low idling speed
NG NG
t Poorly adjusted low idle speed r Adjust the low idle speed
OK I
Injection nozzle injection starting
Injection nozzle pressure too low r
Adjust or replace the injection
nozzle
Improper spray condition
OK I
Fuel injection timing Fuel injection timing improperly
adjusted
t Adjust the fuel injection timing
OK I
Defective delivery valve result
Injection pump ing fuel drippage after fuel t Replace the delivery valve
injection
OK I
Air leakage from the turbocharger NG Repair the turbocharger intake
Turbocharger t
intake side side
Continued on the next page
Engines Generators
ENGINE EXCESSIVE FUEL CONSUMPTION
Checkpoint Trouble Cause from the previous page
OK I
NG NG
Turbocharger r Defective turbocharger assembly r Replace the turbocharger assembly
OK I
Valve clearance Valve clearance improperly
adjusted
r Adjust the valve OK I
Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure Piston ring sticking or broken I Replace the related parts
Improper seating between the
valve and the valve seat
OK I
NG NG
Valve spring Valve spring weak or broken r Replace the valve spring
Engines Generators
ENGINE EXCESSIVE OIL CONSUMPTION
Checkpoint Trouble Cause Remedy
Engine oil
NG Engine oil unsuitable NG Replace the engine oil
f
Too much engine oil Correct the engine oil volume
OK I
Oil seal and gasket
Oil leakage from the oil seal
andor the gasket
NG Replace the oil seal andor the
gasket
OK I
NG NG
Air breather f Clogged air breather r Clean the air breather
OK I
Defective valve seals
Inlet and exhaust valves NG NG Replace the valve seals the
Valve seals
t Worn valve stems and valve r valves and the valve guides
guides
OK I
I Piston rings
Piston rings worn broken or
improperly installed
Replace the piston rings or
properly install
OK I
NG Cylinder lines scored or NG
Cylinder liners f
worn
r Replace the cylinder Engines Generators
ENGINE OVERHEATING
Checkpoint Trouble Cause Remedy
NG Insufficient antifreeze NG Replenish the antifreeze
Cooling water I r
Insufficient raw water Correct raw water flow
OK I
NG Drive belt loose or cracked NG
Drive belt causing slippage r Replace the drive belt
OK I
Raw water pump Impeller or bearings r raw water pump
OK I
Water pump Defective water pump r Repair or replace the water pump
OK I
Cylinder head and cylinder body NG Defective sealing cap resulting in NG
f t Replace the sealing cap
sealing cap water leakage
OK I
NG NG
Thermostat I Defective thermostat r Replace the OK I
Cooling system clogged by Clean the foreign material from
Cooling system
foreign material the cooling system
OK I
Fuel injection timing f
Fuel injection timing improperly
adjusted
NG Adjust the fuel injection timing
Engines Generators
ENGINE WHITE EXHAUST SMOKE
Checkpoint Trouble Cause Remedy
NG NG
Fuel r Water particles in the fuel r Replace the fuel
OK I
Fuel injection timing r Retarded fuel injection timing Adjust the fuel injection timing
OK I Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure r Piston ring sticking or broken r Replace the related parts
Improper seating between the
valve and the valve seat
OK I
Turbocharger Defective turbocharger Replace the OK I
Defective valve seals
Inlet and exhaust valves
Valve seals NG Worn valves stems and valve
Replace the valve seals the
valves and the valve guides
guides
OK I
Piston rings Piston rings worn broken or NG Replace the piston rings or
improperly installed properly install
OK I
Cylinder lines scored or
Cylinder liners Replace the cylinder liners
worn
Engines Generators
ENGINE DARK EXHAUST SMOKE
Checkpoint Trouble Cause Remedy
Air cleaner r Clogged air cleaner element NG Clean or replace the air cleaner
element
Injection nozzle injection starting
Injection nozzle NG pressure too low
NG Adjust or replace the injection
nozzle
Improper spray condition
Fuel injection timing NG Fuel injection timing improperly
adjusted
r Adjust the fuel injection timing
Defective delivery valve resulting
Injection pump
NG in fuel drippage after
NG Replace the delivery valve
fuel NG NG
Excessive injection volume r Adjust the injection volume
Engines Generators
ENGINE OIL PRESSURE DOES NOT RISE
Checkpoint Trouble Cause Remedy
Engine oil r
NG Improper viscosity engine oil
Too much engine oil NG Replace the engine oil
Correct the engine oil volume
Defective oil pressure gauge Repair or replace the oil
Oil pressure gauge or sendor
Oil pressure indicator light
or sendor NG pressure gauge or sendor
Oil filter Clogged oil filter element Replace the oil filter element or
the oil filter cartridge
Relief valve and bypass valve
Relief valve sticking andor weak
bypass valve spring
NG Replace the relief valve andor
the bypass valve spring
NG NG
Oil pump Clogged oil pump strainer Clean the oil pump strainer
NG NG Replace the oil pump related
Worn oil pump related parts parts
Rocker arm shaft Worn rocker arm bushing
r Replace the rocker arm bushing
NG Replace the camshaft and the
Camshaft Worn camshaft and camshaft
bearing
camshaft bearings
NG NG Replace the crankshaft andor
Crankshaft and bearings r Worn crankshaft and bearings f
the bearings
Engines Generators
ENGINE ABNORMAL ENGINE NOISE
1 Engine Knocking
Checkpoint Trouble Cause Remedy
Check to see that the engine has been thoroughly warmed up befoe beginning the Fuel
Fuel unsuitable NG Replace the fuel
OK I
Fuel injection timing NG Fuel injection timing improperly
adjusted
e Adjust the fuel injection timing
OK I
Injection nozzle NG Improper injection nozzle starting
pressure and spray condition
Adjust or replace the injection
nozzle
OK I
Compression pressure r
Blown out head gasket
Broken piston ring NG Replace the head gasket or the
piston ring
2 Exhaust Leakage Noise
Tighten the exhaust hose
Exhaust System r Loosely connected exhaust or
broken exhaust hose NG connections
Replace the exhaust hose
OK I
Replace the washers
Injection nozzles andor glow Loose injection nozzles andor NG
Tighten the injection nozzles
plugs glow plugs
andor the glow plugs
I I
Continued on the next page
Engines Generators
ENGINE ABNORMAL ENGINE NOISE
2 Exhaust Leakage Noise
Checkpoint Trouble Cause Remedy
Continued from the previous page
OK I
NG Loosely connected exhaust mani NG Tighten the exhaust manifold
Exhaust manifold r r
fold andor glow plugs OK I
NG NG
Cylinder head gasket r Damaged cylinder head gasket r Replace the cylinder head gasket
3 Continuous Noise
NG NG
Drive belt r Loosen drive belt r Readjust the drive belt tension
1 I
OK I
Raw water pump Impeller or bearings f raw water pump
OK I
Water pump bearing Worn or damaged water pump
bearing
r Replace the water pump bearing
OK j
Alternator Defective alternator NG Repair or replace the alternator
OK I
Valve clearance improperly
Valve clearance
adjusted
r Adjust the valve Engines Generators
ENGINE ABNORMAL ENGINE NOISE
4 Slapping Noise
Checkpoint Trouble Cause Remedy
I NG NG
Valve clearance improperly
Valve clearance r
adjusted
Adjust the valve OK I
NG NG
Rocker arm Damaged rocker arm r Replace the rocker arm
OK I
NG NG
Flywheel Loose flywheel bolts r Retighten the flywheel bolts
OK I
Crankshaft and thrust bearings r Worn or damaged crankshaft
andor thrust bearings
Replace the crankshaft andor
the thrust bearings
OK I
Crankshaft and connecting rod NG Worn or damaged crankshaft Replace the crankshaft andor
bearings
r andor connecting rod bearings the connecting rod bearings
OK I
Connecting rod bushing and Worn or damaged connecting rod Replace the connecting rod
piston pin
r bushing and piston pin bushing andor the piston pin
OK I
Worn or damaged piston and
Piston and cylinder liner NG cylinder liner Replace the piston and the cylin
der liner
Foreign material in the cylinder
Engines Generators
TORQUE DATA 4208
Kgm lbIt GEAR CASE
FUEL SYSTEM
I 1902
13715
18836
l
1701
16010 12307
2605
1886
FLYWHEEL
HOUSING 0602
2105
15236
2605
1105
OIL COOLER
For steel 70 95 05
asbestos 506 686 36 New bolt
sandwich 70 115 05 R
gasket 506 831 36 eused bolt
For lamnated
steel sheet 7090 05 900 3 o
506651 36 o
gasket
Apply MOS2 grease
MANIFOLDS CYLINDER HEAD
Engines Generators
TORQUE DATA
Kgm lbfl
PISTON
460 3 g
5310
38372
6 CYL
223t22
FUEL FILTER
I 60t5
FLYWHEEL
26O5
26O5
2411 18836
173572 0
aiij
I lol
t r
21O5
BODY 6 CYL SHOWN
WESTERBEKE
Engines Generators
TORQUE DATA
i I
26O5
lSS36
Kgm IbIt
ft 31O5
W22436
THERMOSTAT
ASSEMBLY
ROCKER ARM
15
CAMSHAFT
1157105
Lubricate with engine oil
Engines Generators
THE BE GENERATOR
SINGLE AND THREE PHASE EMERGENCY
STOP
GENERATOR generator is a fourpole brushless selfexcited requires only the driving force of the engine to produce
AC output The copper and laminated iron in the exciter stator
are responsible for the selfexciting feature of this magnetic field produced causes an AC voltage to be
induced into the related excitor rotor windings during located in the exciter rotor rectify this voltage to DC
and supply it to the windings of the rotating field This creates
an field which rotates through the windings
of the main stator inducing an AC voltage which is supplied
to a load An AC voltage is produced in the of the main stator and is in tum supplied to a
voltage regulator The regulator produces a DC voltage to
excite the exciter stator windings enabling the to produce a rated AC output The voltage regulator SWITCH
senses AC voltage output and adjusts DC excitation to the
exciter stator winding according to amperage load the
generator is furnishing To maintain a constant voltage output
OPERATION A CAUTION Prior to performing any or more of these generators may be run in parallel by
make certain that the generator is shut down adding a parallel device The parallel device is added are off and the unit is at
room the electrical terminal box to ensure equal output of
generator voltage Contact your WESTERBEKE dealer or
the WESTERBEKE factory for information on parallel Use compressed air to clean the generators extclior Do
use liquids or water Do not use compressed air on any
interior components as this could result in short circuits
AUTOMATIC
VOLTAGE
REGULATOR
PARALLELING DEVICE
NOT SHOWN
TERMINAL
LATOR
AC TERMINAL
Engines Gsnerators
VOLTAGE REGULATOR voltage regulator is an advanced design which AC alternator performance It is equipped with
complete protection circuitry to guard against that could be detrimental to the AC alternator
green L
yellow L
i Amp
g Slab
ill Volt
VOLTAGE REGULATOR DIAGRAM
AmpHertz
These two adjustments arc used in onjunction with the two
protection circuits in the voltage regulator that are potentiometer is used to adjust output voltage At proper by the illumination of a colored
LED operating speed the output voltage should be held at
1 from a noload condition to a full rated generator output
1 Delayed overload protection yellow LED
and from power factor 10 08 with engine drive speed 2 Low speed protection red up to 6
Both systems have an intervention threshold which can be
Prior to starting the engine tum the VOLT and STAB adjusted using the respective Each of the two
trimmers using a mini phillips screwdriver fully in a circuits are able to cause an adequate reduction in clockwise Minimum direction
until you feel them voltage to safeguard the excitor windings and prevent their
hit their stops the AMP and HER1Z trimmers completely clockwise The overload
protection system has a delay which in the same manner temporary overloading of the generator during times
such as
With the alternator running at noload at normal speed and motor startup or other similar load surge demands The
with VOLT adjust at minimum it is possible that output regulator also has a third LED green that glows will oscillate Slowly rotate the
VOLT adjust clock generator operation to indicate correct operation of the
wise The voltage output of the alternator will increase and regulator with the Increase the voltage to the desired value In only the green
LED will stay potentiometer permits variation of the to generator load changes so as to and obtain a minimum recovery time to
the normal voltage output
In order to adjust the regulator stability the alternator must be
running at noload and the output must be the STAB adjust slowly clockwise until the to fluctuate At this point rotate the STAB until the voltage is
stable within 1 or 2
tenths of a volt
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
o 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 com
monly used on easystarting loads such as washing
o When the generator is run at 1500 RPM the AC voltage
output frequency is 50 or where loads are applied after the motor is
started such as small power tools Because they require 5 to Therefore to change the generators frequency the
7 times as much current to start as to run their use should be generators drive engines speed must be changed Along with
avoided whenever possible if the electric motor is to be a reconfiguring of the AC output connections at the by a small generator
Capacitor and repulsion a regulator board voltage output adjustment must also be
induction motors require from 2 to 4 times as much current made See ELECTRONIC GOVERNOR in the manual
to start as to run The current required to start any motor
varies with the load connected to it An electric motor con
nected to an air compressor for example will require more A CAUTION Prior to any cleaning or than a motor to which no load is
connected make certain aI switches are off and the generator is
In general the current required to start liSVolt motors connected at room medium starting loads will be approximately as follows
MOTOR SIZE AMPS FOR AMPS FOR Generator Maintenance
STARTING
HP RUNNING
AMPERES AMPERES o Maintaining reasonable cleanliness is important
16 32 64 to 224 Connections of terminal boards and rectifiers may become
14 46 92 to 322 corroded and insulation surfaces may start conducting if
13 52 104 to 72S salts dust engine exhaust carbon etc are allowed to
12 72 144 to 292 build up Clogged ventilation openings may cause
34 102 204 to 40S excessive heating and reduced life of windings
1 13 26 to 52 o For unusually severe conditions thin
coatings should be sprayed or brushed
NOTE In the above table the maximum Amps for Starting is over all surfaces to reduce rusting and corrosion Typical
more for some small motors than for larger ones The reason materials suggested are Daubert Chemical Co Non
for this is that the hardest starting types splitphase are not Rust AC41O and Ashland Tectyle 506 or in larger sizes
o In addition to periodic cleaning the generator should be
Because the heavy surge of current needed for starting inspected for a tightness of all connections b is required fOf only
an instant the generator will not of overheated terminals and c loose or damaged wires
be damaged if it can bring the motor up to speed in a few o The drive discs on single bearing generators should be
seconds If difficulty is experienced in starting motors tum checked periodically jf possible for tightness of screws
off all other electrical loads and if possible reduce the load and for any evidence of incipient cracking failure Discs
on the electric motor should not be allowed to become rusty because rust may
accelerate cracking The bolts which fasten the drive disc
Required Operating Speed to the generator shaft must be hardened steel SAE grade
Run the generator first with no load applied then at half the 8 identified by 6 radial marks one at each of the 6
generators capacity and finally loaded to its full capacity as comers of the on the generators data plate The output voltage
o The rear armature bearing is lubricated and sealed no
should be checked periodically to ensure proper operation of maintenance is required However if the bearing becomes
the generating plant and the appliances it supplies If an AC noisy or have it or ampere meter is not installed to monitor voltage
and load check it with a portable meter and amp probe o Examine bearing at periodic intervals No side movement
of shaft should be detected when force is applied if side
NOTE When the vessel in which the generator is installed motion is detectable bearings are wearing or wear on
contains AC equipment of I20 volts only it is recommended shaft of bearing socket outside bearing has the generators AC
tenninal block be configured to pro Repair must be made quickly or major components will
vide one 120 volt AC hot leg for the vessels distribution rub and cause major damage to This will ensure good motor starting
response from the o Compressed air can be used to clean the
exterior Do not use compressed air on internal
Engines Generators
GENERATOR AC VOLTAGE VOLTAGE frame ground wire whitegreen must be when changing the AC output configuration L1 o
of the AC terminal block For making connections to the AC
terminal block use terminal ends for 114 inch studs that will
accept multi strand copper wire sized for the amperage rating
from the hot lead connection The frame ground wire is white L2
or white with a green strip It connects between the neutral
stud and the generator Frequency L3 0 N L3
9 10 II 911
1 Frequency is a direct result of speed
1800 rpm 60 hertz 1500 rpm 50 hertz 12
2 To change generator frequency SERIES Y PARALLEL Y
4BOV60 Hz 20BV60 Hz
Configure the AC terminal block for the desired voltage 190V50 Hz
3BOV50 Hz
frequency as shown Ensure that the case ground wire is
connected to the correct terminal block neutral ground
stud
NOTE The whitegreen ground wire may be removed in those L1 0 L1
1 12 where the AC circuit has a separate neutral and
ground circuit This will prevent the unit from being a ground
source in the vessel
L2 0 L2
IMPORTANT 45 67
When changing from 50Hz to 60Hz the and nominal vottage will increase by 20
but the current does not change from the 50Hz value L3 0 L3
Should voltage stay at 50Hz then the output power
89 10 1 1
may be increased by 5 due to improved is accomlished by resetting the AVR froom 60Hzto 50Hz the voltage and power
values must decrease by 20 ot the 60Hz value SERIES DELTA
240V60 Hz
2 PARALLEL DELTA
120V60 Hz
220V50 Hz 1100V50 Hz
NOTE IF WIRING FOR 50 Hz THE 60 Hz JUMPER
MUST BE REMOVED FROM THE REGULATOR
SINGLE PHASE
L1 lL2
4 7 1 10
8 1 1
DOUBLE DELTA
120240V60 Hz
110220V50 Hz
Engines Generators
INTERNAL WIRING DIAGRAM
12 WIRE 3 PHASE I GROUND
I A EXCITER STATOR I
I
1 I 0 STATOR
C I1 EXCITER
ROTOR FIELD I 6
I I 2
I C
I 1
hPD
f1 I I
BLUE
I DIODES I
L
I 7 6 5
J 2 11
FUSE L
a RED
23 FOR SENSING 100140V 12 WIRE 3 PHASE
12 FOR SENSING 200280V SHOWING PARALLEL Y
THE PO PARALLEL DEVICE
YEllOW IS OPTIONAL UP TO 320 KVA
THE LINK P ACTIVATES OR
DEACTIVATES THE PARALLELING
DEVICE IF IT IS PRESENT
Engines Generators
ELECTRONIC GOVERNOR TO ElECTlIONIC
system is composed of three basic components
1n IIUl
1 Controller Mounted in the instrument panel TOTERMIN N
IOARD It UltACJ BlACK
2 Sensor Installed on the bellhousing over the 2
Y
flywheel ring gear
IUClWH
3 Actuator Mounted at the front of the engine and TO SENSD SHIELDEDll
TtGOVERNOR
attached with linkage to the throttle arm of the CAllLE
WHIR
injection pump VIOlET VIOlET
TO LINEAR ACT UATOfi
OlET VIOLET
TERMINAL BOARD 3
CONTROLLER
REFER TO WIRING DIAGRAMS
PN30300B 12V
PNj39747 24V
INSPECTION AND ADJUSTMENT
The controller has two adjustment pods You need a
mini screw driver to adjust these One is speed and the
gain These are noted on the drawing of the controller
When you press the preheat switch the actuator linkage
attached to the throttle arm of the injection pump should
move outward towards the injection pump and return
back into the actuator in a quick motion
SENSOR Start the engine The speed should be in the low idle
PN039172
range 600700 rpm If the engine speed is higher than
this idle range shut the engine down Check the linkage
LINEAR between the actuator and throttle arm The throttle arm
ACTUATOR
PN303007 12V
stop should be about touching the open idle stop screw
PN3974624V boss Adjust the linkage to position the throttle ADJUSTMENT The
controller has an adjustment screw for speed
1 Speed This adjustment is used to raise or lower the adjustment Turn this screw outward counter clockwise
engines speed to the desired hertz a few turns Restart the engine
2 Gain This adjustment affects the reaction time of
the actuator to the load changes NOTE If there is any oscillating of the actuator linkage
producing hunting adjust the gain towards zero 0 until
NOTE A high gain adjustment can induce an oscillating this hunting is removed
of the actuator producing a hunting mode In such
Increase the engine speed slowly with the speed
caseslessen the gain adjustment adjusting screw turning it inward clockwise In some
instances this screw may need to be turned 610 before an increase in engine speed is
noted Bring the
engine speed to 1800 rpm 60 Hz 1500 rpm 50 Hz
1 With no power to the governor adjust the GAIN to Momentarily push the actuator linkage towards the
900 oclock actuator and release The actuator should quickly regain
2 Start the engine and adjust the speed by turning the proper speed If there is any hunting adjust the gain
speed pot clockwise to desired speed towards zero 0 until this hunting is removed
When the gain is adjusted you may need to readjust the
NOTE Controllers are factory adjusted to minimum rpm speed at no load shut the generator down
However for safety one should be capable of disabling
Push the DC exciter circuit breaker in Start the
the engine if an overspeed should exist generator
3 At noload turn the GAIN potentiometer clockwise Check speed Hertz set at 60 Hz
until the engine begins to hunt if the engine does Load the generator
not hunt physically upset the governor linkage
If the governor is slow to react and maintain 60 Hertz
4 Turn the GAIN potentiometer adjust the gain clockwise Again you may need to adjust
until stable the speed at no load
NOTE The controller operates on I2VDC The voltage You will find the governor will maintain 60 05 Hertz
range is 20 96VDC 12VDC 144VDC voltage right up to the full rated amperage output for the
generator
varies above or below these ranges the controller will
not operate and the engine will run in an idle mode until
proper voltage is supplied to the 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 Pu rple lead to black 4 Replace controller if battery voltage is not present at bOth
leads
b Second pu rple to black
5 Pertorm 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 actuatcr lead
actuator connection
b Battery voltage at both actuator b Broken actuator lead
connections
c Battery voltage at one actuator lead c Replace the actuator
but not the fully extends when PREHEAT 1 Check controller Lift one of the purple
is depressed and stays extended actuator leads from the terminal block
Depress PREHEAT
a Actuator fully extends a Short in lead to actuator
b Actuator does not fully extend and b Replace controller
connections
NOTE Release PREHEAT and reconnect
the purple hunts oscillates and 1 Linkage between actuator and throttle 1 running binding
2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the Controller
controller
3 Inadequate DC power supply to
controller complete the following tests
Connect a DC voltmeter across the
plus and negative leads at the
controller terminal block
Lift both purple leads from the
terminal block
Connect one purple lead to the
C plus terminal and the other to tie
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
BE NOTE AC GENERATOR MUST
BE PERFORMED WITH THE ENGINE OPERA TIN AT 60 HZ
FAULT PROBABLE CAUSE
NO AC VOLTAGE OUTPUT AT NO LOAO 1 Short or open in the 4 Open in exciter
main stator winding stator winding
2 Shorted poziresistor 5 Open in rotating
on exciter rotor field winding
3 Four or more shorted or
open diodes on exciter VOLTAGE PROOUCEO AT 1 Blown 6 AMP fuse 3 Shorted or open main
NO LOAO 15 20 VOLTS AC auxiliary circuit feed to AVR stator auxiliary winding
2 Faulty voltage regulator 4 AC circuit breaker tripped
LOW AC VOLTAGE OUTPUT AT 1 Reset voltage 3 Open or shorted exciter
NO LOAO 60 100 VAC rotor winding
2 Open or shorted diodes in
exciter rotor 1 to 3 diodes 4 Faulty voltage AC OUTPUT VOLTAGE 1 Reset voltage VAC OR HIGHER
2 Faulty voltage VOLTAGE OUTPUT 1 STB pod on regulator 2 Faulty voltage SPEED STEADY needs
VOLTAGE DROP UNDER LOAD 1 Diodes on exciter rotor
60 100 VOLTS AC breaking down when load is
applied inductive 13 diodes
Engines Generators
GENERATOR MAINTENANCE
A CAUTION Prior to performing any maintenance
make certain that the generatoe is shutdown switches
are off and the unit is at room CLEANING
Use compressed air to clean the exterior of the 3 Remove the seager rings with snap
generator Do not use liquids or water Do not use ring pliers
compressed air on interior components as this could 4 Remove the bearings with a proper
cause short circuits bearing puller
Rotation Diode Bridge
COVER 1 Disconnect the five wires of the
rotating diode bridge
REAR PANElFRONT COVER 2 Remove the blocking bolt and
PANEL pulling gently remove the
SIDE PANELS
diode bridge
aIL I
TERMINAL BOARD AVR COMPONENT
DIODE BRIDGE
B
r c SPACERS
REAR OO
SEAL HUBLlU DIODE 10
DIODE
BRIDGE COUPLING HUB BRIDGE
ARMATURE BEARING ROTOR AND FAN
REASSEMBLY
DISASSEMBLY 1 Heat the bearing with a special
magnetic device and using insulated
If it becomes necessary to disassemble
gloves assemble the bearings to
the statorrotor assembly use the following
the shaft
text as a guide
1 Insert a suitable puller which can be
easily made and remove the exciter 2 Put the seager rings back into place
Thoroughly clean the shaft and
2 Extract the rotor using a hoist with
spread a thin layer of Permabond
soft ropes of sufficient strength
or similar product over the shaft seat
Carefully remove the rotor and place
it on the prepared work area It may
be necessary to remove the front
cover to extract the rotor due to the
diameter of the fan
SNAP RING 3 Reassemble the exciter carefully
PLIERS making sure the diode connecting
cables are turned toward the outside
4 Install the rotor and completely
ROTORFAN ASSEMBLY reassemble the generator with all
the covers back in place
WESTERBEKE
Engines GeneratDr
45 BED GENERATOR GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle marine engine
Vertical inline overhead valve water cooled General Closed system with bleed points
direct injection 70 hp 1800 rpm and
60 hp 1500 rmp Fuel No2 diesel oil cetane rating of 45 or Naturally
aspirated
Fuel Injection Pump BOSCH Model A type Integral with injection pump
Fuel Injection Timing WBTDC
Nozzle Stroke 402 x 465 inches 1020 x 1180 mm
Fuel Filter Full flow Displacernent 262 cubic inches 43 liter
on Order 1 3 4 2
Air cleaner Replaceable paper Liner Type Dry
Air Flow 123 of Rotation Clockwise when viewed from the front engine Torque 210 ftIb 1500
rpm Fuel Consumption 35 US gph 132 Iph
Corn pression Ratio inches rnrn Height 336 inches 855 mm
ELECTRICAL SYSTEM
wout transmission Width 306 inches 778 mm Starting Battery 12 Volt negative ground
Length 625 inches 1588 mm
Battery Capacity 750 900 Cold Cranking Amps CCA
Weight dry 1585 Ibs 719 kgs
DC Charging Alternator 51 Amp rated TUNEUP Starting Aid Glow
Pressure 441 psi 31 kgcm at 200 rpm Starter 12 Volt 329 KW
Limit of difference Not to exceed 2844 psi 200 kgcm DC Cranking Current 400 CCA
Injector Pressure 2133 psi 150 Seat Angle Intake 45
LUBRICATION SYSTEM
Exhaust 45 General Gear typepressure Clearance Intake and exhaust
Oil Filter Full flow paper element spinon type
engine cold 0016 inches 040 mm
Sump Capacity 145 US qts 138 Speed 50 Hz 1500 rpm not including filter
60 Hz 1800 rpm
Operating Oil Pressure 25 85 psi
engine hot
GENERATOR DATA
Oil Grade API Specification Power 1800 1500 rpm
SAE 30 10W30 15W40
45KW 35KW
Design Brushless four pole revolving field EXHAUST SYSTEM
power takeoff
Exhaust Elbow 45 All units adjustable to 50 or 60 Hertz
Exhaust Hose Size 4 10 1016 mm hose
Phase Three phase Single phase units Factor 08
ENGINE AIR 12 lead reconnectable Combustion Air 1230 cfm
Voltage Regulation standard 1 no load to full load Note The pressure differential between the outside of the engine
Class H as defined by NEMA MGI65 ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mrn at full open throttle measure with a Direct drive centrifugal Rise Within NEMA MGI2240
definition full load
COOLING SYSTEM
Meets CE requirements General Fresh watercooled block Level
controlled with heat Output 60 Hertz 50 Hertz
LL LN LL LN Operating Temperature 170 190 F 77 88 Star 480 277
400 230 Fresh Water Pump Centrifugal type metal impeller Star 208 120 230
Series Delta 240 120 230 115 Raw Water Pump Positive displacement rubber Delta
130 110 eng ined riven
Zig Zag 400 230 330 190 Coolant Fresh regulator is adjustable 5
System Capacity 17 US qts 161 liters
3 Phase amperage calculation x 1732 x PF
Engines Generators
55 BED GENERATOR SECTION
GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle turbocharged General Closed system with bleed points
marine engine Vertical inline overhead valve
water cooled direct injection 90 hp 1800 rpm Fuel No2 diesel oil cetane rating of 45 or higher
and 80 hp 1500 rpm Fuel Injection Pump BOSCH Model A type Turbo charged
Fuel Injection TIming 12 BTDC
Govemor Integral with injection pump Nozzle Stroke 402 x 465
inches 1020 x 1180 mm Fuel Filter on engine Full flow Displacement 202 cubic inches 43 liter
Air cleaner Replaceable paper Order 1 3 4 2 AirFlow
190 cfm62 of Rotation Clockwise when viewed from the front engine Torque max 280 ftIb 1500 rpm
Fuel Consumption 48 US gph 182 Ratio 171
ELECTRICAL inches mm Height 336 inches 855 mm Starting Battery 12 Volt negative ground
wout soung guard Width 306 inches 778 mm
Length 625 inches 1588 mm Battery Capacity 750 900 Cold Cranking Amps CCA
Weight dry 16471bs 746 kgs DC Charging Altemator 51 Amp rated beltdriven
Starting Aid Glow plugs
TUNEUP Starter 12 Volt 29 Pressure 441 psi 31 kgcm at 200 rpm
DC Noload Current 2 of rated amps
Limit of difference Not to exceed 2844 psi 200 kgcm
DC Cranking Current 450 amps engine Pressure 2630 psi 185 Seat Angle Intake 45
LUBRICATION SYSTEM
Exhaust 45
General Gear typepressure Clearance Intake and cold 0016 inches 040 mm
Oil Filter Full flow paper element spinon type
Engine Speed 50 Hz 1800 rpm Sump Capacity 145 US qts 138 liters
60 hz 1800 rpm not including filter
Operating Oil Pressure 250 85 psi
GENERATOR DATA engine Power 1800 1500 rpm Oil Grade
API Specification SAE 30 10W30
15W40
Design Brushless four pole revolving field COOLING SYSTEM
power takeoff
General Fresh watercooled block All units adjustable to 50 or 60 Hertz
controlled with heat Three phase Single phase units available Operating Temperature 170 190 F 77 88 C
Power Factor 08 Fresh Water Pump Centrifugal type metal impeller
12 lead reconnectable Raw Water Pump Positive displacement rubber Regulation
Standard 1 no load to full load Class H as defined by NEMA MGI65
Coolant Fresh Water
System Capacity 17 US qts 161 Direct drive centrifugal Rise Within NEMA MGI2240 defination full load
EXHAUST Level Meets CE requirements Exhaust Elbow 45 elbow
VDltage Output 60 Hertz 50 Hertz Exhaust Hose Size 4 10 1016 mm LL
LN LL LN
Series Star 480 277 400 230 ENGINE AIR Star 208 120
230 127
Series Delta 240 120 230 115 Combustion Air 160 cfm
Parallel Delta 130 110
Zig Zag Note The pressure differential between the outside of the engine
compart
400 230 330 190
ment versus the inside of the engine compartment should not exceed 2
Voltage regulator is adjustable 5 inches of water 51 mm at full open throttle measure with a manometer
3 Phase amperage calculation x 1732 x PJ
Engines Generators
65 BED GENERATOR GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle Vertical inline General Closed system with bleed points
overhead valve fresh water cooled direct
injection marine engine 100 hp 1800 rpm Fuel No2 diesel oil cetane rating of 45 or higher
and 85 hp 1500 rpm Fuel Injection Pump BOSCH Model A type Naturally aspirated
Fuel Injection Timing Integral with injection pump Nozzle
Stroke 413 x 492 inches 1050 x 1250 mm Fuel Filter on engine Full flow Displacement
396 cubic inches 65 liter Air cleaner Replaceable paper Order 153624
Air Flow 170 cfm62 Liner Type Dry
engine of Rotation Clockwise when viewed from the front Fuel Consumption 49 US gph 185 Iph
Engine Torque 313 ftIb 1500 rpm ELECTRICAL Ratio 171
Starting Battery 12 Volt negative inches mm Height 342 inches 868 mm
Battery Capacity 750 900 Cold Cranking Amps CCA
wout transmission Width 306 inches 778 mm
Length 749 inches 1903 mm DC Charging Alternator 51 Am prated belt d riven
Weight dry 19371bs 878 kgs Starting Aid Glow plugs
Starter 12 Volt 29 KW actuated shift
TUNEUP DC Noload Current 2 of rated Pressure 441 psi 31 kgem at 200 rpm
DC Cranking Current 450 CCA
Limit of difference Not to exceed 2844 psi 200 Pressure 2631 psi 185 kfcm
LUBRICATION SYSTEM
Valve Seat Angle Intake 45
General Gear typepressure circulation
Exhaust 45
Valve Clearance Oil Filter Full flow paper element spinon
type
Intake and cold 0016 inches 040 mm Sump Capacity 145 US qts 138 Speed
not including filter
50 Hz 1500 rpm
60 Hz 1800 rpm Operating Oil Pressure 28 85 psi
engine hot
GENERATOR DATA Oil Grade API Specification CG4
SAE 30 lOW3D Power 1800 1500 Brushless four pole revolving field
COOLING SYSTEM
power takeoff General Fresh watercooled block
controlled with heat exchanger
All units adjustable to 50 or 60 Hertz
Operating Temperature 170 190 F 77 88 C
Phase Three phase Single phase units available
Fresh Water Pump Centrifugal type metal impeller Factor 08
Raw Water Pump Positive displacement rubber 12 lead
Regulation Standard 1 no load to full load
Coolant Fresh Class H as defined by NEMA MGI65 System Capacity 25 US qts 237
Direct drive centrifugal blower
EXHAUST Rise Within NEMA MGI2240 defination full load
Exhaust Elbow 45 Level Meets CE requirements
Exhaust Hose Size 4 ID 1016 mm hose
Voltage Output 60 Hertz 50 LL LN LL LN
Series Star 480 277 400 230 ENGINE AIR Star 208 120
230 127 Combustion Air 170 cfm
Series Delta 240 120 230 115
Parallel Delta 130 110 Note The pressure differential between the outside of the
engine compart
Zig Zag 400 230 330 190 ment versus the inside of the engine compartment should not
exceed 2
Voltage regulator is adjustable 5 inches of water 51 mm at full open throttle measure with a
manometer
3 Phase amperage calculation x 1732 x PF
Engines Generators
95 BED GENERATOR GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle turbocharged General Closed system with bleed points
marine engine Vertical inline overhead valve
fresh water cooled direct injection145 hp Fuel No2 diesel oil cetane rating of 45 or higher
1800 and 125 hp 1500 rpm Fuel Injection Pump BOSCH Model A type Turbocharged
Fuel Injection Timing 12 BTDC
Governor Integral with injection pump Noule Stroke 413 x 492 inches
1050 x 1250 mm Fuel Filter Full flow Displacement 396 cubic inches 65 liter on
Liner Type Dry Air cleaner Replaceable paper Order 153624
AirFlow 240 cfm 62 cmm
engine of Rotation Clockwise when viewed from the front
Fuel Consumption 72 US gph 273 Iph
Engine Torque max 423 ftIb 1800 Ratio 171 ELECTRICAL
inches mm Height 342 inches 867 mm Starting Battery 12 Volt H negative ground
wout transmission Width 306 inches 778 mm Battery Capacity 750 900 Cold Cranking Amps CCA
Length 750 inches 1903 mm
DC Charging Alternator 51 Amp rated dry 2100 Ibs 952 kgs
Starting Aid Glow plugs
TUNEUP Starter 12 Volt 29 KWactuated Pressure 441 psi 31 kgcm at 200 rpm
DC Noload Current 2 of rated amps
Limit of difference Not to exceed 2844 psi 200 kgcm DC Cranking Current 450 CCA
Injector Pressure 2631 psi 185 Seat Angle Intake 45 COOLING
SYSTEM
Exhaust 45 General Fresh watercooled block Clearance Intake and exhaust
controlled with heat cold 0016 inches 040 mm
Operating Temperature 170 190 F 77 88 C
Engine Speed 50 Hz 1500 rpm Fresh Water Pump Centrifugal type metal impeller
beltdriven
60 Hz 1800 rpm
Raw Water Pump Positive displacement rubber impeller
engined riven
GENERATOR DATA
Coolant Fresh Power 1800 1500 rpm System Capacity 25 US qts 2371 liters
95KW 80KW
Design Brushless four pole revolving field EXHAUST SYSTEM
power takeoff Exhaust Elbow 45 All units adjustable to 50 or 60 Hertz
Exhaust Hose Size 4 ID 1016 mm hose
Phase Three phase Single phase units Factor 08
LUBRICATION SYSTEM
12 lead reconnectable General Gear typepressure
Oil Filter Full flow paper element spinon type
Voltage Regulation Standard 1 no load to full load
Class H as defined by NEMA MGI65 Sump Capacity 220 US qts 208
not including Direct drive centrifugal blower
Operating Oil Pressure 25 85 psi 35 42 Rise Within NEMA MGI2240 defination full load engine Level Meets CE
requirements Oil Grade API CG4
SAE 30 10W30 Output 60 Hertz 50 LL LN LL LN
Series Star 480 277 400 230 ENGINE AIR Star 208 120
230 127 Combustion Air 190 cfm
Series Delta 240 120 230 115
Parallel Delta 130 110 Engine Cooling 200 cfm
Zig Zag 400 230 330 190 Note The pressure differential between the outside of the engine
regulator is adjustable 5 ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a manometer
3 Phase amperage calculation x 1732 x PJ
Engines Generators
80N4 GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle marine engine General Closed system with bleed points
Vertical inline overhead valve water cooled
direct injection 80 hp 2500 rpm Fuel No2 diesel oil cetane rating 0145 or Naturally
aspirated Fuel Injection Pump BOSCH Model A type Integral with injection pump
Fuel Injection Timing WBmC
Bore Stroke Noule Multihole
402 x 465 inches 1020 x 1180 mm
Fuel Filter Full flow Displacement 262 cubic inches 43 liter
on Order 1 3 4 2
Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front
Air Flow 150 clm
Engine Torque 210 fHb 1500 rpm engine Ratio 171
Fuel Consumption 47 US gph inches mm Height 320 inches 813 mm
wout transmission Width 252 inches 645 mm ELECTRICAL SYSTEM
Length 472 inches 1168 mm
Starting Battery 12 Volt H negative dry 971 Ibs 4408 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
TUNEUP DC Charging Altemator 51 Amp rated beltdriven
Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Limit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 KW
Injector Pressure 2133 psi 150 kfcm DC Noload Cu rrent 2 01 rated amps
Valve Seat Angle Intake 45 DC Cranking Current 400 CCA
Exhaust 45
Valve Clearance Intake and exhaust LUBRICATION cold 0016
inches 040 mm
General Gear typepressure Speed Idle 600 900 rpm
Cruise 1800 2200 rpm Oil Filter Full flow paper element spinon type
Max 2400 2500 rpm Sump Capacity 145 US qts 138 liters
not including filter
COOLING SYSTEM Operating Oil Pressure 25 85 psi
General Fresh watercooled block engine hot
controlled with heat exchanger Oil Grade API Specification CF or Temperature 170 190 F 77 88 C
SAE 30 10W30 Water Pump Centrifugal type metal impeller beltdriven
Water Pump Positive displacement rubber impeller
General HURTH Standard Transmission
helical gears hydraulically operated multiple disc
Coolant Fresh Water Capacity 17 US qts 161
liters
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 0 elbow
Propeller 22x16 P2 blade or 22x14 P3 blade
using standard propeller should allow the engine to reach its full
Exhaust Hose Size 4 ID 1016 mm hose transmission rated rpm 2500 000 100 at full open throttle
while underway in forward gear
ENGINE AIR REQUIREMENTS Lubricating Fluid Dextran Air 150 cfm
Transmission Sump
Capacity Hurth 45 213 US qts 20 liters The pressure differential between the outside of the engine compart
ment versus the inside of the engine compartment should not exceed 2
inches 01 water 51 mm at full open throttle measure with a Engines
Generators
11 OT4 GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle turbocharged General Closed system with bleed points
marine engine Vertical inline overhead valve
water cooled direct injection 110 hp 2400 Fuel No2 diesel oil cetane rating of 45 or higher
rpm Fuel Injection Pump BOSCH Model A type Turbo charged
Fuel Injection Timing 12 0 Integral with injection pump Nozzle
Stroke 402 x 465 inches 1020 x 1180 mm Fuel Filter Full flow Displacement
on engine
202 cubic inches 43 Order Air cleaner Replaceable paper
element
1 3 4 2
Direction of Rotation Clockwise when viewed from the front AirFlow 230 cfm
engine Torque max 280 ftIb 1500 rpm
Fuel Consumption 61 US gph Ratio inches mm Height 320 inches 813 mm
ELECTRICAL SYSTEM
wout transmission Width 283 inches 719mm
Starting Battery 12 Volt negative ground
Length 472 inches 1168 mm
Battery Capacity 750 900 Cold Cranking Amps CCA
Weight dry 987 Ibs 4480 kgs
DC Charging Altemator 51 Amp rated beltdriven
TUNEUP Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Starter 12 Volt 3 IYV
Limit of difference Not to exceed 2844 psi 200 kgcm
DC Noload Current 2 of rated amps
Injector Pressure 2133 psi 150 kfcm
DC Cranking Current 400 CCA
Valve Seat Angle Intake 45 0
Exhaust 45 0
LUBRICATION SYSTEM
Valve Clearance Intake and cold 0016 inches 040 mm General Gear
typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon
type
Cruise 1800 2200 rpm Sump Capacity 145 US qts 138 liters
Max 2300 2400 rpm not including filter
Operating Oil Pressure 25 85 psi
COOLING SYSTEM engine hot
General Fresh watercooled block Oil Grade API Specification CF or CG4
controlled with heat exchanger SAE 30 10W30 Temperature 180 1900 F 77 88 0 C
Fresh Water Pump Centrifugal type metal impeller Water Pump Positive displacement rubber impeller
TRANSMISSION
General HURTH Standard Transmission Fresh Water
helical gears hydraulically operated multiple disc
System Capacity 17 US qts 161 liters clutch
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 0 elbow
Propeller 24x18 P2 blade or 24x16 P3 blade
Exhaust Hose Size 4 ID 1016 mm hose using standard propeller should allow the engine to reach its
full
transmission rated rpm 2400 000 100 at full open throttle
while underway in forward gear
Lubricating FIid Dextran 11
Transmission Sump
Capacity Hurth 45A 213 US qts 20 liters Air 230 cfm
Note The pressure differential between the outside of the engine compart
ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines Generators
120N6 GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle Vertical inline General Closed system with bleed points
overhead valve fresh water cooled direct
Fuel No2 diesel oil cetane rating of 45 or higher
injection marine engine 120 hp 2500 Fuel Injection Pump BOSCH
Model A type Inline
Naturally aspirated
Fuel Injection Timing Integral with injection pump
Nozzle Stroke 413 x 492 inches 1050 x 1250 mm
Fuel Filter Full flow Displacement 296 cubic inches 65 liter
on Order 1 53624
Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front
Air Flow 240 cfm
Engine Torque 298 ftIb 1500 rpm engine Ratio 171
Fuel Consumption 65 US gph 246 inches mm Height 325 inches 823 mm
wout transmission Width 252 inches 645 mm ELECTRICAL SYSTEM
Length 564 inches 141omm
Starting Battery 12 Volt negative ground
Weight dry 11751bs 5341 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
TUNEUP DC Charging Alternator 51 Amp rated beltdriven
Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Limit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 rW actuated Pressure
2631 psi 180 kfcm DC Noload Current 2 of rated amps
Valve Seat Angle Intake 45 DC Cranking Current 400 CCA
Exhaust 45
Valve Clearance Intake and exhaust LUBRICATION cold 0016
inches 040 mm
General Gear typepressure Speed Idle 600 900 rpm
Cnuise 1800 2200 rpm Oil Filter Full flow paper element spinon type
Max 2400 2500 rpm Sump Capacity 22 US qts 208 liters
not including filter
COOLING SYSTEM Operating Oil Pressure 25 85 psi 35 42 Fresh watercooled
block engine hot
controlled witil heat exchanger Oil Grade API Specification CF or Temperature 180 190 F 77 88 C
SAE3o 1OW3 15W40
Fresh Water Pump Centrifugal type metal impeller beltdriven
Water Pump Positive displacement rubber impeller
General HURTH Standard Transmission
helical gears hydraulically operated multiple disc
Coolant Fresh Water Capacity 25 US qts 237
liters
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 elbow
Propeller 22x16 P2 blade or 22x14 P3 blade
using standard propeller should allow the engine to reach its
Exhaust Hose Size 4 JD 1016 mm hose transmission full rated rpm 2500 000 100 at full open
throttle while underway in forward gear
ENGINE AIR REQUIREMENTS Lubricating Fluid Dextran Air 240 cfm
Transmission Sump
Capacity Hurth 45 213 US qts 20 liters The pressure differential between the outside of the engine compart
Hurth 63 42 US qts 40 liters versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines
Generators
170T6 GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle turbocharged General Closed system with bleed points
marine engine Vertical inline overhead valve
fresh water cooled direct injection 170 hp Fuel No2 diesel oil cetane rating of 45 or higher
2500 rpm Fuel Injection Pump BOSCH Model A type Turbocharged
Fuel Injection Timing 12 BTDC
Governor Integral with injection pump Nozzle Stroke 413 x 492
inches 1050 x 1250 mm Fuel Filter Full flow Displacement 423 cubic inches 65 liter
on Order 153624 Air cleaner Replaceable paper of Rotation
Clockwise when viewed from the front AirFlow 365 cfm
engine Torque max 423 ftIb 1800 rpm
Fuel Consumption 93 US gph 352 Ratio inches mm Height 335 inches 823mm
ELECTRICAL SYSTEM
wout transmission Width 280 inches 711 mm
Length 5Z5 inches 1410 mm Starting Battery 12 Volt H negative ground
Battery Capacity 750 900 Cold Cranking Amps CCA
Weight dry 12451bs 56523 kgs
DC Charging Altemator 51 Amp rated beltdriven
TUNEUP Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Starter 12 Volt 3 KW
Limit of difference Not to exceed 2844 psi 200 kgcm
DC Noload Current 2 of rated amps
Injector Pressure 2631 psi 185 kfcm
DC Cranking Current 400 CCA
Valve Seat Angle Intake 45
Exhaust 45
LUBRICATION SYSTEM
Valve Clearance Intake and cold 0016 inches 040 mm General Gear
typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon
type
Cruise 1800 2200 rpm Sump Capacity 22 US qts 208 liters
Max 2400 2500 rpm not including filter
Operating Oil Pressure 25 85 psi
COOLING SYSTEM engine hot
General Fresh watercooled block Oil Grade API Specification CF or CG4
controlled with heat exchanger SAE3o 1oW3o Temperature 180 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller beltdriven Water Pump Positive
displacement rubber impeller General HURTH Standard Transmission Casehard
ened helical gears hydraulically operated multiple
disc Fresh Water
System Capacity 25 US qts 237 liters Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
Propeller Shaft Right EXHAUST SYSTEM Propeller 24x18 P2 blade or
24x16 P3 blade
Exhaust Elbow 45 elbow using standard propeller should allow the engine to reach
transmission full rated rpm 2500 000 100 at full open
Exhaust Hose Size 4 10 1016 mm hose throttle while underway in forward gear
Lubricating Fluid Dextran II
Transmission Sump
Capacity Hurth 63 42 US qts 40 liters Air 365 cfm
Note The pressure differential between the outside of the engine compart
ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a 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 EQUIVALENTS
1 Degree of Latitude 60 Nm 111120 km
1 Minute of Latitude 1 Nm 1852 km
VOLUME
Cubic Inches in x 16387 Cubic Centimeters x 061 in
Imperial Pints IMP pt x 568 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 OC X 18 32
Degree Celsius OC OF 32 x 56
LIQUID WEIGHTS
Diesel Oil 1 US gallon 713 Ibs
Fresh Water 1 US gallon 833 Ibs
Gasoline 1 US gallon 61 Ibs
Salt Water 1 US gallon 856 Ibs
Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
c
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
25400 40 101600
03937
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
01524
03048
122 1 24
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

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
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 GALLONS
Gallons Liters Gallons Liters Liters Gallons Liters

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
SPECIAL TOOLS
CONNECTING ROD BUSHING CRANKSHAFT GEAR
INSTALLER 47020 REMOVER 47D
CRANKSHAFT PULLEY SOCKET
6 crL 54MM
CRANKSHAFT REAR OIL SEAL 4 crL 42MM
INSTALLER 47019
CYLINDER LINER INSTALLER
47015 COMPRESSION GAUGE
ADAPTER 47019
VALVE STEM OIL SEAL
INSTALLER 47014
CRANKSHAFT TAPER COMPRESSION GAUGE
BUSHING REMOVER
47017
CRANKSHAFT BEARING CYLINDER LINER REMOVER ANGLE
REMOVER AND INSTALLER 47D22
VALVE SPRING COMPRESSOR CYLINDER LINER NOTE Numbers in
italic are WESTERBEKE part
PISTON RING numbers Contact your WESTERBEKE dealerfor
COMPRESSOR
additiollal tools
Engines Generators
INDEX
AC Voltage Connections 115 17 34
Alternator 63 69 Instrument Panel Wiring 44329 86
66 Introduction 2
Disassembly 65 Lubricating System 047
Testing 63 Maintenance Generator 118
Angular Nut Bolt Tightening 8 Measurements 11
BE Generator 112 Metric Conversion data 129 Engine 57 Oil Cooler 048
Coolant Pump 049 Oil Flow Diagram 047
Cooler Oil 048 Oil Pump Head Torque 042 Pump Coolant 049
Diagram Wiring 47781 87 Pump Fuel Feed 59
Diagram Wiring 47780 84 Pump Fuel Injection 59
Engine Disassembly 10 14 Pump Oil 047
Drive Belt 51 Pump Raw Water 52
Electronic Governor 117 Raw Water Pump 52
Engine Adjustments 55 58 34
Engine Assembly 35 46 Camshaft Crankshaft Bearings 38 Connection Rod Cylinder Head Cover 040 Crankshaft
Exhaust Manifold 37 Cylinder Head 16
Flywheel Al Cylinder Liner 23
Injection Nozzle 045 Flywheel 34
Injection Pump 040 IdLer Gear 22
Oil Cooler 042 Piston 15 27
Oil Pan Piston Pin Rod Al Push Rod Piston 35 Rocker Ann 21
Rocker Arm 043 Tappet 20
Timing Gear Case 39 VaLve Guide 17
Valves 36 Valve Seat 18
Water Pump 042 Valve Spring 20
Engine Compression 57 170T6 128
Engine Index 89 A 89 108 120N6 127
Engine Tuning 046 110T6 126
Fuel Feed Pump 59 80N4 125
Fuel Section 60 95 BED 124
Generator BE 112 65 BED 123
Generator Information 114 55 BED 122
Generator Maintenance 120 45 BED 122
Glow Plug Test 61 Starter Motor 83
Heat Exchanger 51 Disassembly Pump 59 ELectrical Testing Nozzle 60 61 Timing 55 Parts
Engines Generators
62 Turbocharger 53
Testing for Overhaul 3 Valve Clearance Adjustment 51 Voltage Regulator Adjustments 113
Timing Injection 55 Wiring Instrument Panel 44329 86
Torque Data 109 111 Wiring Diagram 44780 84
Torque 9 Wiring Diagram 44781 87
Torque Cylinder Head 42 Wiring Diagram Internal BE Generator 119 Wiring Schematic 44780 Electronic Governor 118 Wiring
Schematic 44781 Engine Index 89 4 89 108
Engines Generators
Engines

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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.