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53017 Rev2 20.0 33.0ede eder 65a Technical Man




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MANUAL
65AFOUR
MARINE AND 200KW EDER
NET GENERATORS
3285 and 255KW EDE DNET
ARINE GENERATORS
PUBLICATION 053017
SECOND EDITION
APRIL 2009
WESTERBEKE
WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
WEBSITE CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines and some of
its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
gasses contain carbon Monoxide an odorless and
colorless gas carbon Monoxide is poisonous and can and death Symptoms ofCarbon 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 IMMEOIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been Inspected and WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine also recommends installing DETECTORS in the quarters
of your vessel They are inexpensive and at your local marine store
Engines Generators
SAFETY PREVENT BURNS FIRE
Read this safety numual carefuily Most accidents are
caused by failure to follow fundamental rules and precau A WARNING FiltJ can caUBB injury 01 deathl
tWns Know when dangerous condiJions exist and take the
necessary precautitJns to protect yourself your personnel Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructWns are in compliance with pump or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard Approved
flame
arrester removed Backfire can cause severe injury or
death
A WARNING lID not touch AC eltNtricaJ Do not operate with the air removed
willie tJIJfIiOtlIs mnning 01 wilen connected to sholtJ Backfire can cause severe injury or death
LetIIaI milage Is PItJSBIIt at tIrtJstJ connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will bum
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions fm fuel vapors can couse
Injury 01 datIr
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not COMect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
tIansfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING lID not touch hot BOgin palls 01 Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
BIhaust srsItJm compoOtlnis Amnning engine gets spill DO NOT allow any smoking open flames or other
sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
Always check the engine coolant level at the coolant fuel system
recovery tank
Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
I A WARNING StBam can couse injury 01 death Be certain fuel line fittings are adequately tightened and
free of leaks
In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this WESTERBEKE
Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas
111 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
at 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 Igmted by electrIcal nausea or death
arcing or by lit tobacco prodUCts Shut off all electrIcal
equipment in the vicinity to prevent electrIcal arcIng dur
Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust 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 toxic as
Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monOXIde
bums or sparks that could cause an explosion Remove
gas is present in diesel exhaust fumes Some of the
wristwatch rings and any other jewelry before handlIng
symptoms or signs of carbon monoxide inhalation or
the battery poisoning are
Always turn the battery charger off before disconnecting Vomiting Inability to think coherently
the battery connections Remove the negatIve lead first
Dizziness Throbbing in temples
and reconnect it last whenservicing the battery Muscular twitching
ACID Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING Sulfuric acid in batteries can cause
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
y WESTERBEKE
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that
INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their recommenda
Make sure all attaching hardware is properly tightened
tions when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 15 East 26th Street
be caught in these rotating parts New York NY 10010
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARIIIING High nIl IBvels can cau hBaring National Fire Protection Association
oss1 II Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARIIIING Do not WIlde In machlnory whsn YIIU arB
mtmI1IIIt lIT physicallt IncapacltalBd by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
PI Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
v WESJERBEKE
EngInes Generstors
TABLE OF CONTENTS
Testing for Overhaul Valves 41
Engine Compression 2 Rocker Arm 43
Engine 3 Timing 44
General Description 8 Camshaft 45
Cylinder Block 8 Idler Gear 46
Half Floating Head Cover 8 Balancing Shaft 47
Cylinder Head 8 Rod 48
Piston and Piston Rings 9 Crankshaft 50
Dynamic Balancer 9 Crankpin 51
Governor 10 Cylinder 53
Disassembly Procedures 11 Oil Pump 53
Generator 11 Servicing Specifi catIons Radiator Models II Engine 61
Propulsion Engines II I TImmg
nJectton 61
Preparation for Disassembly 11 Valve Clearance 62
Remove Interior Components II Oil PressureOil Change 63
Remote StopStart Panel lla Fuel System Assembly Procedures 12 Injectors 65
Surface Preparation 12 Injection Pump 65
Gasket Information 12 Glow Plugs 65
Engine Assembly 13 Raw Water Pump Heat Exchanger 13 Wiring Diagram 52952 EDE Marine Transmissions 13
Wiring Diagram 54469 EDER 67a
Radiators 13 Wiring Diagram 31944 65AFour 67b
Engine Tuning 13 65AFour Engine 14 33Kw EOE Cylinder Head and Valves 14 285Kw EDER 68b
Cylinder Head Gasket 16 Generator 69
Governor Housing Assembly 18 Torque Injection Pump 19 Special Tools Thermostat 20 Generator
Information 83
Injection Nozzle 20 Terminal Board Connections 84
Fuel Camshaft and Governor Weight 23 Electronic Regulator 85
Injection Pump Assembly 24 Generator Servicing 87
Water PumpOil Cooler 26 Generator Chart 88
Gear 27 EDE Testing the Voltage 89
Oil Screw and Strainer 29 Internal Wiring Schematic Piston and Connecting Rod 29 Changing Hertz and Voltage
Flywheel and Crankshaft 31 AC Output 92
Flywheel Housing 32 Generator Parts Breakdown Crankshaft 33 Metric Equivalent 95
Starter Motor Service 34 Metric Conversion Chart Service 37 Index Engine 40
Cylinder Head 40
WESTERBEKE
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD ENGINE COMPRESSION
Cause of Low Compression Check the compression pressure To do this warm the engine
remove all fuel injectorsor glow plugs disconnect the the time at which an engine should be overhauled shutoff solenoid wire and install
a compression adapter in
is determined by various conditions such as lowered engine the injector hole or glow plug hole Connect a output decreased compression
pressure and increased tester on the adapter and crank the engine with the starter
fuel and oil consumption The lowered engine power output motor until the pressure reaches a maximum value Repeat
is not necessarily due to trouble with the engine itself but is this process for each cylinder Look for cylinders caused by injector nozzle
wear or injection pump dramatically lower compression than the average of the
wear The decrease in compression pressure is caused by others
many factors It is therefore necessary to determine a cause
or causes on the basis of data produced by periodic COMPRESSION PRESSURE Faclary and maintenance Oil analysis on a seasonal
basis at 250 RPM 626 PSI
is a good means of monitoring engine internal wear When 44 by worn cylinders or piston rings the following
432 MPa
symptoms will occur
ALLOWABLE LIMIT
1 Low engine power output
al250 RPM 472 PSI
2 Increased fuel consumption 332 Kglcm
3 Increased oil consumption 326 MPa
4 Hard engine starting If a weak cylinder is flanked by healthy cylinders the
5 Noisy engine operation problem is either valve or Check the valve
These symptoms often appear together Symptoms 2 and 4 elearances for the weak cylinder adjust as needed and test
can result also from excessive fuel injection improper again If the cylinder is still low apply a small amount of oil
injection timing and wear of the injectors They are caused into the cylinder to seal the rings and repeat the test If the
also by defective electrical devices such as the battery compression comes up the rings are starter and glow plugs Therefore it is
desirable to Abnormally high readings on all cylinders indicate heavy
judge the optimum engine overhaul time by the lowered carbon accumulation a condition that might be pressure caused by worn
cylinders and pistons by high pressures and noise
plus increased oil consumption Satisfactory combustion is NOTE In case of severe vibrations and detonation noise the
obtained only under sufficient compression pressure If an cause may be fuel injector problems see FUEL lacks compression pressure
incomplete combustion Poor fuel quality contaminants and loss ofpositive fuel
of fuel will take place even if other parts of the engine are pressure to the injection pump will result in properly To determine
the period of it is important to measure the engine regularly At the same time the engine speed at TESTING ENGINE
which the measurement of compression pressure is made be checked because the compression pressure varies
with engine rpm The engine rpm can be measured at the
front end of the pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken it decreases gradually with the progress of wear
of these parts
When decrease of compression pressure reaches the repair
limit the engine must be overhauled When reinstalling the glow use antiseize engine requires overhaul
when oil consumption is high 343 to 392 Nm
blowby evident and compression valves are at minimum or Nozzle holder 35 to 40 kgfm
below 253 to 2B9 ftIbs
t96 to 245 Nm
Tightening torque Over1low pipe nut 20 to 25 kgfm
145 to tBt ftlbs
490 to 6B6 Nm
Nozzle holder assembly 50 to 70 kglm
362 to 506 ftlbs
Engines Generators
ENGINE following chart describes certain problems relating to engine service the probable causes of these problems
and the to overcome these problemsThis chart may be of assistance in determining the need for an PROBLEM
PROBABLE CAUSE HARO STARTING LOW CRANKING SPEEO
1 Engine oil viscosily 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
6 Defective main drive section 6 Check clutch for OEFECTIVE 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 Replace gasket
f Piston ring seized f 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
5 Governor spring out of POSITION 5 Correct spring
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 Airtrapped 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 aireleaner 1 Clean or replace air cleaner
WESTERBEKE
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT cnI 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 Retig hten bolts
4 Loose drain plug 4 Retighten plug
5 Looseoil pipe connector 5 Retighten oil connections
6 Broken rocker cover gasket 6 Replace gasket
7 Loose rocker cover attaching bolts 7 Relighten 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 Oelective 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 EXHAUSr
3 Moving parts nearly seized or excessively worn 3 Repair or replace
4 Poor compression 4 See LOW COMPRESSION HARO STARTING
5 Improper valve timing 5 Adjust
6 Improper valve clearance 6Adjust
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 Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST cant WHITISH OR PURPLISH
cant
d Worn valve stem and valve guide d Replace
e Low engine oil viscosity e Replace
f Excessive oil pressure I 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 ROO 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 Rebare cylinder to oversize and replace piston
2 Worn piston pin 2 Replace piston
3 Piston seized 3 Replace piston and rebore cylinder
4 Piston seized and ring worn or damaged 4 Replace piston and rings
VALVE MECHANISM
1 Worn camshaft 1 Replace
2 EXcessive valve clearance 2 Adjust
3 Worn timing gear 3 OPERATION INJECTION PUMP SYSTEM
1 Uneven injection 1 Adjust injection or replace parts
2 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
MJI WESTERBEKE
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE ENGINE KNOCKS WITHOUT
MUCH SMOKE
1 Main engine troubles
aOverheated cylinder a See OVERHEATING LOW OUTPUT
bCarbon deposits in cylinder b Clean
2 Too early injection timing 2 Correct
3 Too high injection pressure 3 Correct
4 Improper luel 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 Fuellilter clogged 1 Clean or
SOUND 2 Fuel pipe sucks air 2 Retighten pipe jOints or replace pipe
3 Water mixed in fuel 3 Replace 1 Vbelt slackening or slippery with oil 1
Adjust replace or clean
2 Damaged water pump 2 Replace
3 Lack of coolant 3 Add
4 Low oil level or poor oil quality 4 Add or change
5 Knocking 5 See KNOCKING
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 mallunction 2 Overhaul oil pump
3 Clogged oil cooler 3 Repair
4 Diesel dilution of the oil 4 Injection pump repair
HIGH OIL PRESSURE 1 Wrong type of oil 1 Replace
2 Relief valve defective 2 Replace
RAW WATER IN CYLINDERS 1 Fail of syphon valve or exhaust system 1 Clean out inspect exhaust system MIXING WITH 1
Injection pump broken 1 Rebuild replace
LUBE OIL
2 Injection pumps plunger is worn 2 Replace
3 Deficient nozzle injection 3 Replace nozzle
WATER MIXING WITH 1 Delective head gasket 1 Replace
LUBE OIL 2 Cylinder head flawed 2 Replace
Engines Generators
ENGINE Problem Probable Cause Exhaust smoking problems 1 Blue smoke
1 Incorrect grade of engine oil
1a Crankcase is overfilled with engine oil oil is blowing out
through the exhaust
2 White smoke 2 Engine is running cold
28 Faulty injector or incorrect injector timing
3 Black smoke 3 Improper grade of fuel
3a Fuel burn incomplete due to high back pressure in exhaust or
insufficient air for proper combustion Check for restrictions in
exhaust system check air intake
3blmproperly timed injectors or valves or poor compression
3 lack of air check air intake and air filter Check for proper
ventilation
3d Overload
LCD QISPLAYS
No LCD Display 1 Check battery 1 Battery on
2 20 amp breaker off 2 Turn breaker on
Oil Pressure 1 Oil level lowoil leak 1 Check oil level add oil and repair leaks
2 Lack of oil pressure 2 Test oil pressure If OK test oil pressure sendor inspect oil
filter inspect oil pump
3 Ground connection 3 Check ground connection
4 Faulty control module 4 Inspect all the plug Temperature 1 Check system coolant level 1 Add coolant Check for
leaks
2 Check water pump drive belt 2 Adjust belt tension replace belt
3 Faulty Temp sensor 3 Check 4 Ground Connection 4 Check ground circuit
5 Faulty control module 5 Check plug Temperature 1 Check sea water flow 1 Inspect thru hull fitling hose and
strainer Correct as needed
2 Faulty exhaust temp switch 2 TesVreplace
3 Ground Connection 3 Check ground circuit
4 Faulty control module 4 Check plug connections
5 Sea water pump 5 Inspect Voltage 1 Check alternator drive belt 1 Adjust if worn
2 Check charge voltage 2 Check excitation alternator
3 Check battery connections 3 Check and cables from battery to engine
4 Faulty control module 4 Check plug Voltage 1 Check AC voltage output 1 Adjust generator for cause
2 Faulty control module 2 Check plug Frequency 1 Check engine speed 1 Adjust
2 Check fuel supply 2 Inspect filters Test fuel pump operation
3 Amperage load 3 Check load with amprobe
LED Display 1 Compartment ambient temperature 1 Ventilate tum pink too high
WESTERBEKE
Engines Generators
I GENERAL DESCRIPTION
CYLINDER BLOCK
This engine employs separate type crankcases
the crankcase 1 with combustion parts and the
crankcase 2 which supports the crankcase 1 and
reduces noise
Since it is a hanger type you can easily assem
ble and disassemble it The cylinder is a linerless
type which enables good cooling operation less
strain and good abrasion resistance
HALFFLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 05 mm or so off the cylinder head This
arrangement helps reduce noise coming from the
cylinder head
CYLINDER
HEAD COVER
RUBBER
PACKING
UOIL HEAD
This engine employs a three valve system two
inlet valves and double ports and one exhaust
valve which produces good inlet inertia to
improve combustion efficiency and It also employs a new chamber with multiple Besides the conventional cross port system it
employs the forced cooling method to eliminate heat distortion thus and reliable Englnes
Generators
GENERAL AND PISTON RINGS
This engine employs the ETVCS VERSIONII
so that the improved combustion surface at the
top of the piston enables more complete com
bustion efficiency than the conventional models TOP RING I I
The profile and the offset of the piston are
optimized to reduce piston slap The oil jet at
the small end of the connecting rod reduces the
G r I
heat load of the piston
Three rings are installed in grooves in the
piston The top ring is made of nitrizing steel to
OILRING
get more reliability than the chrome plated ring
PISTON
It is a keystone type ring to provide heavy load At the Sliding part a
special piston ring which is conformable to the
cylinder wall is employed The second ring on the peripheral surface and it an undercut ring to prevent
the holding of oil DEPRESSION
The oil ring 3 has chamfered contact faces
and an expander ring which increase the
pressure of the oil ring against the Several grooves are cut on the topland to
help heat dissipate and to prevent BALANCER
Engines are sure to vibrate due to the PISTON of the pistons engines are much less prone to than four
cylinder engines However
any engine has many moving parts in addition
to its pistons and cannot be completely free
from vibration
The four cylinder engine is fitted with
BALANCER weight on the crankcase to absorb the
second inertia mentioned above and v WESTERBEKE
Engines Generators
FORK LEVER
GENERAL DESCRIPTION 2
GOVERNOR
This mechanism maintains engine speed at a
constant level even under fluctuating loads and
provides stable idling and regulates maximum
engine speed by controlling the fuel injection
rate
This engine uses a mechanical governor that
controls the fuel injection rate at all speed SPRING PIN ranges from idling to maximum speed by
GOVERNOR SPRING 4
utilizing the balance between the flyweights
SPEEO centrifugal force and spring tension LEVER
A governor shaft for monitoring engine speed
is independent of the injection pump shaft and FORK LEVER 1 7
rotates at twice the speed of conventional types
providing better response to load fluctuation and
delivering greater engine output IDLE ADJUSTING
FLYWEIGH1l1
At Start
The stop solenoid energized to run type is
NOLOAD
powered to release the stop lever
As no centrifugal force is applied to the ROTATION
flyweight 1 low tension of the start spring 2
OUTPUT LIMITING BOLT
permits the control rack to move to the starting
position supplying the amount of fuel required to
start the engine
At Idling
Turn the speed control lever 3 clockwise to TORQUE LIMITING BOLT
idle the engine It tensions the governor spring
SPEEO CONTROL LEVER 131Hl
4 to pull the fork lever 2
When the fork lever 2 is pulled it moves the
torque spring pin 6 and fork lever 1 7 in the
direction of the arrow A to restrain the weight
In combination with the start spring tension it
is balanced with the centrifugal force of the
flywheel weight to maintain idling
CONTROL RACK
At rated speed with full load and overload
As the speed control lever is changed from the middle
speed to high speed the governor spring to compress the torque spring and move the
fork lever 1 in the direction of the arrow A
The fork lever 2 moves until it reaches the bolt to keep rated rotation and rated output
When the engine is overloaded the engine decreases and the centrifugal force of flywheel To stop engine
weight decreases Then the torque spring moves the When the stop solenoid is turned off the spring
fork lever 1 in the direction of arrow A tension of the solenoid is released the rod extrudes and
The control rack moves in the direction that increases the stop lever moves the control rack in the direction of
fuel supply to increase the output It is balanced with the the arrow B which stops the force of the flywheel weight to produce low
To stop the engine manually move the external stop
speed output torque output lever to the left
9Y WESTERBEKE
Engines Generators
DISASSEMBLY PROPULSION ENGINE
Unplug and disconnect the electrical connections on the out Unplug the instrument panel wiring harness Drain the
side and inside of the control box to allow for the removal of transmission fluid and the transmission oil cooler hoses
the control box off the AC generator end NOTE Properly Detach the oil cooler hoses and unholt the or mark all connections to ensure
proper reconnecting from the the air hose between the control box and the engine NOTE Label any lines hoses or cables as you
separate them
intake box Separate the exhaust hose at the water and disconnect the fuel supply and return lines the engine oil and the coolant from
the engine If the transmission is not being rebuilt it should be support and then unbolt the generator backend
inspected Flush out and pressure test the oil cooler and
from the engine replace the coolant hoses Inspect and lubricate the gear generator information
will be found in the linkage and the propeller shaft coupling Clean and section of this manual
the transmission and change the transmission fluid
For transmission service and maintenance refer to the
COOLANT DRAIN
19MM HEX PLUG units Operators mannal To rebuild a transmission
contact the transmission manufacturer for the location of
DAMPER
MODELS
Drain the coolant using the petcock found at the base IT uDAMPER
of the radiator Unbolt the radiator from the side support PLATE FOR WEAR AND
brackets and lower the mounting frames Remove the BROKEN and set aside for the DC
charging alternator Remove the four
bolts securing the fan to the fresh water pump pulley
PREPlUtAilIN FOR remove the fan and pulley Unbolt the fan guard and Clean or wash the engine it
Do not remove or disassemble the parts that require no
disassembly
When disconnecting sensor wires label and tape the ends
Perform disassembly in a proper order using proper tools
Keep disassembled parts in order Apply oil when
necessary Take special care to keep the fuel system parts
from intrusion of dust and dirt
Parts must be restored to their respective components from
which they were removed at disassembly This means that all
parts must be set aside separately in groups each marked for
its component so that the same combination or set can be
reproduced at assembly
Pay attention to marks on assemblies components and
parts for their positions or directions Put on marks if
necessary to aid assembly
Carefully check each part or component for any sign of
faulty condition during removal or cleaning The part will
RADIATOR tell you how it acted or what was abnormal about it more
WESTERBEKE
Engines Genersors
DISASSEMBLY EXTERIOR the separated from the
engine begin the following step by step procedure the exterior parts
NOTE Mount the engine securely on a suitable engine stand
1 Remove the start motor drive belt and the alternator 9 Remove the exhaust components from the exhaust
Label the wires and cables manifold
2 Witb the hoses disconnected remove the thermostat a Remove the exhaust elbow if applicable from the
housing and housing gasket leaving the temperature lower surface of the manifold Clean and inspect for
sender and switch in place if applicable cracks and defects Replace as needed
3 Remove the magnetic pickup from the bell housing b Remove the exhaust nipples elbows and plugs from
Generators only the manifold
4 Remove the Hywheel heD housing and the circuit c Remove the water connectors from the ends of the
solenoid mounting bracket manifold Be sure to note the proper location and
Remove the engIne back plate arrangement of each for proper alignment
S Remove the oU filter oU cooler oU hoses and mounting d Examine aU parts for defects corrosion and wear
bracket Make note of the hose arrangements and replace as needed
6 Remove the transmission damper plate from the e Flush out the coolant recovery tank and clear its hose
engIne Hywheel Marine Engines passage Set aside to reinstaD on the boat
7 Remove the engIne mounted raw water pump 10 Remove the coolant circulating pump Refer to
complete with its adapter mounting plate See RAW COOlANT PUMP ASSEMBLY
WATER PUMP for parts breakdown Marine Engines and 11 Remove the air intake silencer and the intake
Generators only manifold
8 Remove the engine heat exchanger If possible leave 12 Prepare to disassemble the main engine
one end of each hose connected to the part being
removed Marine Engines and Generators only
WESTERBEKE
Engines Generators
ASSEMBLY PROCEDURES
GENERAl INFORMATION
Surface Preparation
Thoroughly remove all substances deposited on the gasket
application surfaces using a gasket scraper or wire brush
Check to ensure that the surfaces to which the silicone gasket GREASE
is to be applied is flat Make sure that there are no oils
greases and foreign substances deposited on the application
surfaces Do not forget to remove the old sealant that
remains in the bolt holes INTERNAL SNAP RING EXTERNAL SNAP RING
ASSEMBLY
Wash all parts except for oil seals Orings rubber sheets
etc with cleaning solvent and dry them with air pressure
Always use tools that are in good condition and be sure
you understand how to use them before performing any
job PLACE THE SHARP EDGE
Use only good quality lubricants Be sure to apply a coat AGAINST THE DIRECTION
aFFORCE
of oil grease or sealant to parts as specified
Be sure to use a torque wrench to tighten parts for which When reassembling external or internal snap rings position
torques are specified them so that the sharp edge faces against the direction from
When the engine is assembled new gaskets and Orings which force is applied
must be installed
GASKET aware of these common problems that can occur during The engine has several areas where forminplace RTV
assembly silicone gaskets are used such as LOCTITE 598 or GE
Insufticlent Lubrication Heavily oil sliding and RTV 100 To ensure that the gasket fully serves its purpose
reciprocating parts lightly oil head bolts and other fasteners it is necessary to observe some precaution when applying the
except those that penetrate into the water jacket These gasket Bead size continuity and location are very important
fasteners should be sealed with Pennatex No Z or the Too thin a bead could cause leaks and too thick a bead could
hightech equivalent be squeezed out of location causing blocking or narrowing of
Reversed orientation Most gaskets many bolt washers and the fluid feed lines To eliminate the possibility of leaks from
all thermostats are asymmetrical a joint it is necessary to apply the gasket evenly without a
break while observing the correct bead damage Run fasteners down in sequences and in three stepsIZ 23 and 111 torque The gasket material used
in the engine is a room are bolts and rocker arm shaft vulcanization RTV type and is supplied in a 140z The former are torqued as
indicated The gram The RTV hardens as it reacts with shaft fasteners should be brought down in very moisture in the
atmospheric air and can be used for sealing
small increments working from the center bolts out Gaskets both engine oil and coolant head gaskets might also be damaged they should be
positioned with great care
Engines Generators
ENGINE ASSEMBLY INSPECTION ENGINE TUNING rebuilding the engine the alternator should be cleaned
After reassembly the unit must be test run This will ensure
and inspected The housing can be wiped off with a solvent that the operates to its Fill
and the alternator tenninal studs should be cleaned with a the engine cooling system with an antifreeze mixture and the
wire brush Make certain the studs are tight and clean the engine oil sump with lube oil API of CF CG4
wiring connections that connect to the wiring harness CH4 or CI4 SEA 1540
Thrn the rotor pulley by hand It should turn smoothly 1 Mount the unit on a test stand aud make the needed
fuel elecrtical exhaust and coolant connections as
Depending on when the alternator was last serviced the
may need replacing If the alternator is at all suspect
send it to a service shop for testing and overhaul or refer to 2 Prelube the unit if not already done or disable the fuel
the more detailed alternator section in this manual and crank the unit to
allow the oil pump to prime the oil EXCHANGER MARINE 3 Start the unit and monitor for proper operation like oil
pressure water temperature DC charge etc
Install the heat exchanger replace the heat exchanger zinc
and attach new hoses with new clamps to the cooling system 4 Allow the unit to come up to normal to the COOllNG SECTION in this manual
for HEAT temperature and check the engine speed Propulsion
adjust engine idle speed for smoothest service
5 Check unit for any leakage of oil fuel or TRANSMISSION MARINE ENGINES Correct as needed
1 Assemble Ibe damper plate to the flywheel 6 Propulsion Check fuJI no load rpm
2 Reinstall Ibe marine transmission and fill with the 7 Load test the unit in gradual steps 114 112 34 and
full load
correct amount of fluid Do not overfill
8 After load test stop unit an allow to rest Check all
MOlE Some such as the Borg Warner Velvet fasteners and electrical connections to make sure they
Drive require oil coolers Oil coolers should be cleaned are tight and secure Check wire hose challing and
pressure tested and repainted at engine overhaul The protect as oil cooler hases should also be to the text on HEAT EXCHANGERS
Refer to the following pages for details of
These sections also include Wiring Diagrams Engine
Torque Diagrams Starter Motor and Raw Water Pump
The radiator cleaned flushed and pressure tested can be
assembled to the generator mounting rails The fan can be
assembled to the the engines flexible mounts Replace any that show
signs of wear rust or splits in the rubber isolators In a
complete overhaul all four should be Engines Generators
DISASSEMBLYI ASSEMBLY
Cylinder Head and Valves
Cylinder Head Cover and Nozzle Holder
1 Remove the injection pipes 1 and overflow pipes PIPE
2 Remove the glow plugs
3 Remove the nozzle holder assembly 4 and copper gaskets
4 Remove the heat seal
5 Remove the head cover
When Check to see that the cylinder head cover gasket is not
defective
Be sure to replace the heat seal
TIghten the head cover mounting bolts to specified torque
Mount the return fuel check valve with the I mark in the
direction of flow back to the taok t
69 to 113 Nm
Cylinder head cover GLOW
07 to 115 kgfm
mounting screw
51 to 832 ItIbs
PIPE
226 to 363 Nm
Injection pipe retaining
23 to 37 kgfm
166 to 268 ItIbs NOZZLE
490 to 686 Nm
Tightening torque NOlzle holder assembly 50 to 70 kgfm
COPPER
362 to 506 ItIbs
GASKETS
196 to 245 Nm
Overflow pipe assembly
20 to 25 kgfm HEAT SEAL
retaining nut
145 to 181 ItIbs
196 to 245 Nm
Glow Plug 20 to 25 kgfm
145 to 181 ItIbs
HEAD COVER
Nozzle Heat Seal Service Removal Procedure
IMPORTANT
Use a plug phillips screwdriver that has a dia which is
bigger than the heat seal hole Approx 6 mm 14 in
1 Drive screw driver lightly into the heat seal hole
2 Turn screw driver three or four times each way
3 While turning the screw driver slowly pull the heat seal out
together with the injection nozzle gasket
If the heat seal drops repeat the above procedure Hmit seal
4 and injection nozzle gasket 3 must be changed when the
injection nozzle is removed for cleaning or for service
PHilLIPS
LIFTING EYE
INJECTION
CAUTION IF THERE IS REASON TO REMOVE THE NOZZLE
ENGINES LIFTING EYE 00 NOT ATTEMPT TO TAKE
OUT THIS STUO SIMPLY REMOVE THE NUT AND
THE BOTTOM BOLT THE STUD IS PERMANENTLY
ASSEMBLED THRU THE WATER JACKET GASKET 3
HEAT SEAL 4
Engines Generators
Rocker Arm and Push Rod
1 Remove the rocker arm 1 as a unit
2 Remove the push rods
3 Detach the bridge arm
When When putting the push rods onto the tappets check to see if
their ends are properly engaged with the tappet recess
IMPORTANT
After reassembling the rocker arm be sure to adjust the
valve clearance
490 to 559 Nm
Rocker arm bracket
Tightening torque 50 to 57 kgfm LVli PUSH RODS
screw
362 to 412 ftIbs
Cyfinder Head and Tappet
TAPPET
1 Loosen the hose clamp and remove the bypass hose
2 Disconnect the fuel pipe 3 first and then the fuel filter
3 Remove ttie IN EX Manifold
4 Remove the cylinder head screw in the order of 18 to 1 and
remove the cylinder head
5 Remove the cylinder head gasket
6 Remove the tappets from the crank case
When Replace the head gasket with a new one
Before installing the tappets apply engine oil thinly around
them
When mounting the gasket set it to the knock pin hole Take
care not to mount it reversely
The cylinder head should be free of scratches and dust
Take care for handling the gasket not to damage it
Install the cylinder head
Tighten the cylinder head screw gradually in the orderof 1 to
18 aiter applying engine oil
Be sure to adjust the valve clearance See the Valve 014 06 03 Om
Clearance 018 010 02 07 0
It is not necessary to retighten the cylinder head screw aiter 17
no no 00 00 15
running the engine for 30 minutes 0 oclo o d 08 0
0 0
IMPORTANT 0013 0 05 0 04 0 012 16
When replace the piston piston pin bush connecting rod
CYLINDER HEAD TIGHTENING
or crankpin bearing select the cylinder head gasket SEQUENCE
thickness to meet with the top clearance refer to the
Selecting Cylinder Head Gasket
NOTE
Mark the cylinder number to the tappets to prevent
981 to 1079 Nm
Cylinder head mounting
Tightening torque 100 to 110 kgfm
screw
723 to 796 ItIbs
Engines Generators
DISASSEMBLYI ASSEMBLY
a 2 Notches
b 1 Notch
Selecting Cylinder Head Gasket
c Without Notch
Replacing the Cylinder head Gasket
1 Make sure to note the notch a b or c of cylinder head
gasket
2 Replace the same notch a b or c as the original cylinder
head gasket
Selecting the Cylinder Head Gasket
Select the cylinder head gasket thickness to meet with the
top clearance when replacing the piston piston pin bush Flywheel Side
connecting rod or crankpin bearing
1 Measure the piston heads protrusion or recessing from the
crankcase cylinder face 4 spots per each piston average of MEASURING PISTON
four pistons using the dial Jauge as shown
2 Select the suitable cylinder head gasket refer to the table
below
Piston Heads protrusion or
Notch 01 Thickness of cylinder recessing from the level of
Cylinder head gasket crankcase cylinder face
Head average of 4 pistons
Gasket Before After
V3300E2B V3300TE2B
tightening tightening
PROTRUSION
007 to 027 to RECESS SPOTS
2 notches
090mm
00354 in
080mm
00315 in
0049 mm
00028 to
0151mm
00110 to II
00019 in 00059 in I
1 notch 100mm 090mm
0050 to
0149 mm
015 to
0051 mm
b 00394 in 00354 in 00020 to 00059 to
00058 in 00020 in
0150 to
wnhout
notch c
105mm
00413 in
095 mm
00374 in
020 mm
00059 to
00078 in
00510 Dmm
00019 to
a in 2 13
1 Remove the valve cap 1 and the valve spring collets 2
compressing the valve spring 4 with the valve spring retaine
3
1 Valve Cap
When J1 J1 2 Valve Spring Collet
3 Valve Spring Retainer
Install the intake valve spring with its smallpitch end
4 Valve Spring
downward at the head side
5 Valve Stem Seal
Wash the valve stem and valve guide hole and apply engine
6 Valve
oil 7 Arm Bridge
After installing the valve spring collets lightly tap the stem to
assure proper fit with a plastic hammer
LARGE PITCH
SMALL PITCH
t INSTALL WITH SMALL
10 PITCH END DOWN
Engines Generators
GOVERNOR
7 Slide off the governor connecting rod 7 from the rack pin of CONNECTING
injection pump assembly ROD 7
8 For convenient sake temporarily hook the start spring on the PIN 51
rack pin hole of the governor connecting rod
9 Remove the governor housing mounting screws
10 Detach the governor housing assembly 8 from the injection
pump unit
When When reassembling the inside parts put the oil on each inside
part slightly
After sliding on the governor connecting roa to the rack pin
tighten the nut with the specified torque with using the jig for
GOVERNOR
keeping the governor connecting rod horizontal See the CONNECTING ROD 71
Replacing Injection Pump Assembly
After tightening the nut hook the start spring on the rack pin
Check the movement of control rack of injection pump
assembly by the stop lever
NOTE
When installing the governor housing assembly to the
injection pump unit be careful not to damage Oring
When linking the governor connecting rod to the rack pin
of injection pump use the jig for keeping the governor
connecting rod horizontal Otherwise the control rack
may be stuck and causes to be difficult to start the engine GOVERNOR
or hunting of governor See the Replacing Injection HOUSING
ASSEMBLY 81
Pump Assembly
9B to 113 Nm
Governor housing
100 to 115 kgfm
mounting screw
723 to B32 torque
2B to 40 Nm
Antirotation nut 029 to 041 kgfm
21 to 30 ftlbs
ORING
0f CONNECTING ROD 7
START SPRING 6
Engines Generators
DISASSEMBLYI ASSEMBLY INJECTION PUMP
GEAR 5
4 Temporarily tighten the injection pump gear mounting nut by
hand
5 Fix the injection pump unit and tighten the injection pump gear
mounting nut to the specified torque
S Take off the fuel cam shaft lock screws 2 and tighten the
plugs 1 for plugging
7 Loose the injection pump unit mounting nuts 4 for aligning the injection timing
8 Moving the injection pump unit clockwise viewed from gear
case side align the injection timing marks S on the injection
pump unit and on the gear case
9 Tighten the injection pump unit mounting nut 4 to the
specified torque
10 Reconnect the lubricating oil pipe 3 and
replace the injection pump unit support and the
gear cover of the injection pump unit
11 Remove the flywheel lock
12 Check the injection timing See the Injection the injection timing is not within the repeat 7
to 12 again
736 to 834 Nm
Injection pump gear
75 to 85 kgfm
mounting nut
542 to 6t5 hIbs
TIghtening torque
177 to 206 Nm
Injection pump unit
t8 to 21 kgfm
mounting nut
130 to 152 hIbs
JI NUTS 4
Governor Housing Assembly
1 Remove the injection pump unit from the engine See the
Injection Pump Unit
2 Remove the governor lubricating pipe
3 Remove the stop solenoid
4 Detach the sight cover 3 from the injection pump unit
5 Unhook the start spring 4 from the rack pin 5 of injection
pump assembly
S Remove the nut
NOTE
Be careful not to drop the nut inside
Engines Generators
DISASSEMBLYI ASSEMBLY
Injection Pump Unit
Removing the fuel injection pump unit
1 Detach the gear cover for the fuel injection pump unit from the
gearcase
2 Place the piston of the 4th cylinder at the top dead center in
the compression stroke Lock the flywheel in place
IMPORTANT SUPPORT look for the align mark on the idle gear 2 Using a white
marking pen or the like put an align mark on the engaged
tooth of the idle gear This helps to reassemble these
gears in mesh later
NOTE
When the already existing align marks align with each
other there is no need to put another align mark
3 Unscrew the two plugs 1 off the injection pump unit
4 Tighten the upper fuel cam shaft lock screw until it comes into
contact with the fuel cam shaft Make sure the cam shaft does
not move any longer
5 Tighten the lower fuel cam shaft lock screw 2 until it comes
into contact with the fuel cam shaft
NOTE
Never overtighten the lock screws when they have come
into contact with the cam shaft Otherwise the injection
pump unit itself may get damaged
Use of a socket set screw dog point type in
recommended for best results Such screw can be
constructed as shown in figure a
6 loosen the injection pump gear mounting nut Using the
specific gear puller take out the gear 5
1 B
NOTE c
Be careful not to drop the key
7 Disconnect the lubricating oil pipe
8 Loosen the three injection pump unit mounting nut
9 Remove the injection pump unit support 6 and take out the A M8 x Pilch 125
injection pump unit B 5 mm dia 0 I 97 in dia
C 4 mm 0157 Pump Unit D 45 mm 1772 in
Reassembling the fuel injection pump unit E 10 mm 039 in Conspicuously Painted
1 Place the piston of the 4th cylinder at the top dead center in
the compression stroke Lock the flywheel in place
2 Place the injection pump gear 5 back into the gear case
position Make sure of aligning the align marks of the injection
pump gear 5 and the idle gear 2
3 install the injection pump unit to the injection pump gear 5
NOTE
When installing the injection pump unit to the injection
pump gear make sure that the key is fit in the keyway of
injection pump gear
WESTERBEKE
Engines Generators
DISASSEMBLYI Assembly
1 Remove the thermostat cover mounting screws and remove
THERMOSTAT
the thermostat cover
2 Remove the thermostat assembly
When Apply a liquid gasket Three Bond 1215 or equivalent only at
the thermostat cover side of the gasket
Install the thermostai with its bleed hole facing towards
the discharge opening of the thermostat housing
ReAssemble and Test
Turn the cover back into place and tighten the three
screws Do nol overtightenl Tighten the hose and close the drains Top off the coolant and run the
HOUSING COVER engine CHeck for normal temperature and for any leaks
around the thermostat THERMOSTAT
ASSEMBLY
TEMPERATURE
Nozzle SENSOR
Nozzle Holder
1 Secure the nozzle retaining nut 7 with a vise
2 Remove thehozzle holder 1 and take out parts inside
When reassembling ADJUSTING
Assemble the nozzle in clean fuel oil
Install the push rod 4 noting its direction
After assembling the nozzle be sure to adjust the fuel injection
pressure ROO 4
343 to 392 Nm
NOZZLE
Nozzle holder 35 to 40 kgfm
HOLDER PIECE
253 to 289 Ibs
PIECE
t96 to 245 torque Overflow pipe nut 20 to 25 kgfm
145 to 181 Ibs NUT 7
490 to 686 Nm
Nozzle holder assembly 50 to 70 kgfm
362 to 506 Ibs
Engines Generators
DISASSEMBLYI Fork Lever Assembly
1 Pull off the governor fork lever shaft 1 with the extra screw
Dia 4 mm Pitch 07 mm Length more than 25 mm
2 Unhook the governor spring 3 at the governor fork lever 4
side
3 Remove the governor fork lever assembly from the governor
housing 5
When After reassembling the governor housing assembly check the
movement of the governor fork lever assembly the speed
GOVERNOR
control lever and the stop lever
NOTE
When assembling the inside parts put the oil on each
Inside part slightly
Be careful not to deform the start spring
Boost Arms III equipped Boost Remove the boost actuator 1
2 Remove the circlip 2 4
3 Remove the boost arms 3 and the boost spring 4 from the
pin fi
392 to 451 torque Boost actuator 40 to 46 kgfm
289 to 333 ftIbs
HOUSING 5
GOVERNOR
FORK LEVER 4
J 1 FORK
LEVER
I ClIP 2 t SHAFT
r
BOIOST ARMS 3
nrRnlnT SPRING 4 GOVERNOR SPRING
PIN 5
PIN 5
REMOVING THE CRCLIP BOOST
ARMS AND SPRING
WESTERBEKE
Engines Generators
SPEED CONTROL
LEVER 1
1 Remove the speed contra lever 1 and the return spring
2 Remove the governor lever assembly 3 from the governor
housing
3 Remove the start spring 4 and the stop spring
Stop Lever
1 Remove the stop lever 1 and the return spring
2 Remove the stop lever shaft
RETURN
SPEED CONTROL SPRING
LEVER 1
STOP SPRING
WESTERBEICE
Engines Generators
DISASSEMBLYI ASSEMBLY
Fuel Camshaft and Governor Weight
1 Separate the governor housing assembly from the injection
pump unit See the Injection Pump Unit
2 Remove the governor sleeve
3 Remove the injection pump assembly
4 Remove the cover
5 Remove the fuel camshaft lock screws
6 Fix the fuel camshaft with open end wrench 4 and remove
the governor weight mounting nut and the governor weight 5
7 Loosen the fuel camshaft stopper mounting screws and
remove the fuel camshaft stopper 6
8 Pull out the fuel camshaft 7 and bearings 8 together
9 After removing the bearings circlip 9 press out the
bearings
NOTE
Do not use the fuel camshaft lock bolts when removing
the governor weight mounting nut Otherwise the lock
bolts or injection pump housing might get damage
When Press the bearings into the fuel camshaft
Set the circlip at the gear sides bearing
Install the fuel camshaft and bearings to the injection pump
housing
Attach the fuel camshaft stopper and tighten the fuel camshaft
stopper mounting screws with the specified torque
Attach the governor weight to the fuel camshaft and tighten the
governor weight mounting nut with specified torque
23510 275 Nm COVER
Injection pump
24 10 2B kgfm
mounting screw
174 to 203 torque
17710206 Nm
Injection pump
IB 10 21 kgfm
mounting nut
13010152 ftIbs
GOVERNOR
WEIGHT 5
BEARINGS B
WESTERBEKE
Engines Generators
Fuel Camshaft and Governor Weight Continued
When Fix the fuel camshaft with lock bolts as the key way of fuel
camshaft 10 is upward
Install the injection pump assembly to the injection pump
housing
Attach the Oring and the cover and tighten the cover
mounting screws
Install the governor sleeve to the fuel camshaft CAMSHAFT
Check the movement of the governor sleeve
NOTE
Be careful not to damage the Oring
Be careful the direction of the governor sleeve
When reassembling inner parts oil each
part slightly
79 to 93 Nm
Fuel camshaft stopper
080 to 095 kgfm KEY
mounting screw
58 to 69 nIbs WAY 10
Tightening torque
628 to 726 Nm
Governor weight
64 to 74 kgfm
mounting nut
463 to 535 nlbs
Replacing Injection Pump Assembly IIf necessary
The Injection pump can be replaced with the crankshaft in
whatever position
1 Disconnect all injection pipes
2 Disconnect the fuel pipe 2 and fuel overflow pipe
3 Disconnect the connector 3 from the stop solenoid Then
remove the stop solenoid
4 Detach the sight cover 5 from the injection pump unit
5 Unhook the starter spring 6 and remove the control rod nut
6 Slide off the governor connecting rod 7 from the rock pin of
injection pump assembly
7 Remove the injection pump mounting screws and nuts and
take out the injection pump assembly
NOTE
Be careful not to drop the antirotation nut
Be careful not to deform the start spring
When taking out the injection pump assembly be careful CONNECTING ROD 7lm1
not to hit it against the governor connecting rod
When Install the new injection pump according to the installing
STARTER SPRING 6
procedure
GOVERNOR
ROD 7
WESTERBEKE
Engines Generators
Procedure of Injection Pump Assembly
1 Install the fuel injection pump assembly 1 in its unit 2 and
hook the governor connecting rod to the rack pin of the fuel
injection pump assembly
2 Place the service jig 3 in the stop solenoid mounting hole of
the fuel injection pump unit
3 Make sure the permanent magnet at the tip of the service jig is
attracted to the governor connecting rod 4 To do this turn
the jig a little clockwise and and look into the
fuel injection pump unit sight hole to see if the governor
connecting rod 4 moves right and left Slightly tighten the antirotation nut of the governor connecting
5 Holding down the service jig 3 by hand tighten up the anti
rotation nut 5 to the specified torque
6 Hook the start spring 6 to the rack Procedure Continued I
1 Move the stop lever 1 and visually check to see if the fuel
injection pump control rack comes smoothly back to the start
position by the counter force of the start spring
2 If the control rack fails to move back smoothly remove the
start spring and the antirotation nut take the above steps
from 2 of the former page again
3 Finally fit the sight cover and the stop solenoid back into place
28 to 40 Nm
Antirotation nut 029 to 041 kgfm JIG
21 to 30 ftlbs
235 to 275 Nm
Injection torque 24 to 28 kgfm
mounting screw CONNECTING
174 to 203 ftIbs
177 to 206 Nm
Injection pump
18 to 21 kgfm
mounting nut
130 to 152 ftlbs
START SPRING
RACK PIN
SLIDING
POINT
Engines Generators
DISASSEMBLYI ASSEMBLY
ORIVE PULLEY
Alternator Drive Pulley
1 Lock the flywheel in place CRANKSHAFT
2 Remove the crankshaft screw SCREW
3 Draw out the drive pulley
When 2550 to 2746 Nm
Tightening torque Crankshaft screw 260 to 280 kgfm
1881 to 2025 Drive Fan Pulley RADIATOR MODELS
1 Lock the flywheel in place
2 Remove the crankshaft screw
3 Draw out the drive fan pulley
01 WATER PUMP
Water Pump and Oil Cooler
Water Pump
1 Remove the pipe band and the water pipe
2 Remove the water pump
When When mounting the water pump take care not to forget
mounting the Oring and not to let it out of Cooler
1 Remove the water pipe
2 Remove the oil filter cartridge 2 and the oil cooler joint screw WATER PIPE
3 Remove the oil cooler
392 to 441 torque Oil cooler joint screw 40 to 45 kgfm
289 to 325 ftlbs OIL FILTER
COOLER
Englne Generators
Case
Gear Case Cover
1 Remove the gear case cover
When Confirm that the liquid gasket coating surface is free of water
dust and oil in order to maintain sealing effect
Carefully apply the adhesive evenly Refer to the illustration
NOTE
When mounting the parts take care to
fit them to the mating parts
Assemble the parts within ten minutes
Apply a liquid gasket Three Bond 12170 to the gear case
cover
235 to 275 Nm
Gear case cover
Tightening torque 24 to 28 kgfm
mounting screw
174 to 203 hIbs LIUIUIU Valve
1 Remove the relief valve retaining screw
2 Remove the relief valve 2 the spring 3 and the packing
686 to 784 Nm
Relief valve retaining
Tightening torque 70 to BO kgfm
screw
506 to 579 Gear and Camshaft
1 Remove three set screws of the idle gear and draw out the idle RELIEF
gear 1 2 VALVE 2
2 Remove two set screws of the camshaft stopper and draw out
the camshaft SPRING 3
When Set the crankshaft at the top dead center of No 1 and 4 PACKING
cylinder and the camshaft key to the top position and align the
INJECTION RETAINING
marks of idle gear 1 and idle gear 2 to assemble them PUMP GEAR 1 SCREW
Refer to the illustration
Mount the injection pump gear 1 after installing the gear
case
235 to 275 Nm
CamShaft set screw 24 to 28 kgfm
174 to 203 torque
235 to 275 Nm
Idle gear mounting iIDLE GEAR 1
24 to 28 kgfm
screw
174 to 203 Ibs
CRANK
WESTERBEKE GEAR
Engines Generators
Gear 1 and Idle Gear 2 For Balancer Modell
1 Remove the idle gear mounting screws o
MOUNTING
2 Draw out the idle gear 2 and 3 SCREWS
When When install the idle gear 2 and 3 be sure to place the 4th
cylinder piston at the top dead center in compression then
align all mating marks on each gear to assemble the tifTling
gears set the idle gear last
Idle gear mounting 235 to 275 Nm
Tightening torque 24 to 28 kgfm
screw
174 to 203 ftlbs
CRANK
GEAR
Camshaft and Balancer Shaft For Balancer Model
1 Remove the camshaft set screws and draw out the camshaft
2 Remove the balancer shaft 1 set screws and draw out the
balancer shaft 1 BALANCER
SHAFT 1
3 Remove the balancer shaft 2 set screws and draw out the
balancer shaft 2
When BALANCER
When install the balancer shaft 1 and 2 be sure to place the 2
4th cylinder piston at the top dead center in compression then
align all mating marks on each gear to assemble the timing v
gears set the idle gear last
235 to 275 Nm
Camshaft set screw 24 to 28 kgfm
174 to 203 torque
235 to 275 Nm o
Balancer shaft set screw 24 to 28 kgfm
174 to 203 Itlbs
Plate Gear Case
1 Remove the three plate mounting screws Detach the plate o
When Apply Three Bond 12170 adhesive or equivalent over the
shaded zones on both sides of the gasket that will be
sandwiched between the crankcase and plate
Be sure to fix the Orings GEAR
CASE
235 to 275 Nm torque Plate mounting screw 24 to 28 kgfm
174 to 203 ftlbs
LIQUID
Ingfnes Generators
OIL PAN
Oil Pan and Oil Strainer
1 Unscrew the oil pan mounting screws and remove the oil pan
2 Unscrew the oil strainer mounting screw and remove the oil
strainer 2
When Install the oil strainer using care not to damage the Oring
Apply liquid gasket Three Bond 1217D to the oil pan as
shown LIQUID
Confirm that the liquid gasket coating surface is free of water GASKET
dust and oil in order to maintain sealing effect o
Carefully apply the adhesive evenly
NOTE
When mounting the parts take care to
fit them to the mating parts
Assemble the parts within ten minutes
To avoid uneven tightening tighten mounting screws in
diagonal order from the center
After cleaning the oil strainer install it
Attach the oil pan with its central drain plug facing toward
the air suction side
OIL AND CONNECTING Rod Cap
1 Remove the connecting rod screws 1 from connecting rod
2 Remove the connecting rod caps
When Align the marks a with each other Face the marks toward
the injection pump
Apply engine oil to the connecting rod screws and lightly screw CONNECTING
ROD SCREWS 1
it in by hand then tighten it to the specified torque
If the connecting rod screw wont be screwed in smoothly
WRENCH
clean the threads
If the connecting rod screw is still hard to screw in replace it
When using the existing crank pin bearing again put tally
marks on the crank pin bearing and the connecting rod in order
to keep their Fit the crank pin bearing in place its centrally groove side
toward the connecting rod and the nongrooved side toward
the cap
785 to 834 torque Connecting rod screw 80 to 85 kgfm
579 to 615 ftIbs
ALIGN a
WESTERBEKE
Engines Generators
DISASSEMBLYI ASSEMBLY
Pistons
1 Turn the flywheel and set a piston to the top dead center
2 Pull out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer
When Before inserting the piston into the cylinder apply enough
engine oil to the cylinder
When inserting the piston into the cylinder face the mark on
the connecting rod to the injection pump
IMPORTANT
Do not change the combination of cylinder and piston
Make sure of the position of each piston by marking For
example mark 1 on the No1 position
When inserting the piston into the cylinder place the gap
of the compression ring 1 on the opposite side of the A
combustion chamber and stagger the gaps of the 8 Second Rlnll
compression ring 2 and oil ring marking a right angle from C 011 Ring Gap e
the gap of the compression ring 1 D Piston Pin Hole
a 079 red 45 j
Carefully insert the pistons using a piston ring
compressor 1 Otherwise their chromeplated section
may be scratched causing trouble inside the Ring and Connecting Rod
1 Remove the piston rings using a piston ring tool
2 Put the fan shaped concave 8 on the piston as shown
3 Remove the piston pin 1 and separate the connecting rod
7 from the piston
When Be sure to fix the crankpin bearing and the connecting rod are
same ID colors
When installing the ring assemble the rings sa that the
manufactures mark 12 near the gap faces the top of the
piston
When installing the oil ring onto the piston place the expander
joint 10 on the opposite side of the oil ring gap
Apply engine oil to the piston pin
When installing the piston pin immerse the piston in 80C
CONCAVE
176 of oil for 10 to 15 minutes and insert the piston pin to the
piston
Assemble the piston to the connecting rod with the aligning the A Connecting Rod 10 Color
direction of the fan shaped concave 8 of piston head and the
mark 9 of connecting rod
The end faces of the oil ring are plated with hard chrome In
Blue or without color
B Crankpin Bearing 10 Color
Blue or without cOlor
0
Oil RING
putting the piston into the cylinder be careful not to get the oil GAP
ring scratched by the cylinder Use the piston ring fitter to rn y
tighten up the oil ring If the rings planting is scratched it may
d II t bl MARK THE SAME NUMBER ON
get st uck on th e cy IIn er wa causing a serious rou e THE CONNECTING ROD AS THE
PISTON SO AS NOT TO CHANGE
THE COMBINATION
MTGS MAR 12
y WESTERBEKE
Engines Generators
DISASSEMBLYI and Crankshaft
Flywheel
1 Install the flywheel lock so that the flywheel does
not turn
NOTE
Do not use an impact wench Serious damage will occur
2 Detach the flywheel screws
3 Remove the flywheel
When Apply ergine oil to the flywheel screws
Before fitting the flywheel and the crankshaft together wipe
oil dust and other foreign substances off their mating faces
The flywheel and the crankshaft are fitting together in just one
position Make sure they are tightly fit and drive the bolts
98110 1079 Nm
Tightening torque Flywheel screw 100 to 1 t 0 kgfm TOP MARK UP
723 to 796 Ibs
Bearing Case Cover
NOTE
Before check the side clearance of
crankshaft Also check it during reassembly
1 Remove the bearing case over mounting screws
2 Screw two removed screws into the screw hole 3 of bearing
case cover to remove it
When IMPORTANT TWO SCREW HOLES 3
In case of replacing the oil seal use caution when
installing the seal in the bearing case cover as not to
install it tilted The seal should be flush with the cover
Confirm that the liquid gasket coating surface is free of
water dust and oil in order to maintain sealing effect
Apply liquid gasket Three Bond 12170 to the bearing
case cover as shown
Before installing the bearing case cover I oil seal
assembly lube the seal and be careful not to damage the
seal while installing the assembly
Install the bearing case cover I oil seal assembly to
position the casting mark UP on it upward
Tighten the bearing case cover mounting screws with LIQUID
GASKET
even force on the diagonal line
NOTE
When mounting the parts take care to
fit them to the mating parts
Assemble the parts within ten minutes
235 to 275 Nm
Bearing case torque 24 to 28 kgfm
mounting screw
174 to 203 Ibs
Engines Generators
Housing
1 Remove the flywheel housing
When Tighten the flywheel housing mounting screws with even force
on the diagonal line
Make sure the crank cases 1 and 2 are clean Install them in
position referring to the flywheel housings contoured face
775 to 902 Nm
Flywheel housing
Tightening torque 79 to 92 kgfm
mounting screw
571 to 665 Ibs
Crankcase 2
1 Remove the crankcase 2
When reassembling CRANKCASE 2
0 0 0 0
IMPORTANT 0 0 0
0l
SIT 1
Make sure the crankcase 1 and 2 are clean
J 0
Apply liquid gasket Three Bond 12170 to the crankcase
Sil
2 as shown o r9J
0
Tighten the crankcase 2 mounting screws with even force 1 fA
fn 0
on the diagonal line f 1
Confirm that the liquid gasket coating surface is free of fir 1 l b
0
water dust and oil in order to maintain sealing effect 0 0 0 0 0 0 0
0
Carefully apply the adhesive evenly co Jf
i5J
NOTE
When mounting the parts take care to
fit them to the mating parts
Assemble the parts within ten minutes
490 to 559 Nm
Crankcase 2 mounting
Tightening torque 50 to 57 kgfm
screw
362 to 412 1 and Crankcase 2
When Match the crankcase 1 and 2 referring to the flywheel
housings contoured face
Tighten the crankcase 2 mounting screws loosely
Tighten up the jig to the specified torque same as the flywheel
housing screw This helps to minimize the level difference
between the crankcase 1 and the crankcase 2 at the flywheel
CRANKCASE 1
side Possible gap must be 005 mm 00020 in or smaller
490 to 559 Nm
Crankcase 2 mounting
50 to 57 kgfm
screw
362 to 413 torque
775 to 902 Nm
Flywheel housing
79 to 92 kgfm
mounting screw
571 to 665 ftlbs GAP
FLYWHEEL
HOUSING
WESTERBEKE
Engines Generators
DISASSEMBLYI ASSEMBLY
Remove the main bearing case
2 Remove the crankshaft
When Reassemble the main bearing case having the same number
as the one engraved on the crankcase and set the casting
mark F W SIDE on the main bearing case facing towards
the flywheel side
Reassemble the thrust bearing 2 with the oil groove facing
outside into both side of the fourth main bearing case
Apply oil to the main bearing case screws and tighten them to
the specified torque
1373 to 1471 Nm
Main bearing torque 140 to 150 kgfm
screw
1013 to 1085 Ibs
EARING MAIN
CASE
THRUST BEARING 2
v WESTERBEKE
Engines Generators
STARTER MOTOR SERVICE
Disassembling Motor Gear Set of Packings
1 Disconnect the solenoid switch Front Bracket Through Screw
2 Remove the two through screws 9 and the Solenoid Switch Armature
two brush holder lock screws take out the Overrunning Clutch Yoke
rear end frame 13 and the brush holder
Internal Gear Brush Holder
3 Disconnect the armature 10 and the yoke
11 Remove also the ball 7 from the tip of Planetary Gear Rear End Frame
he armature Sail
4 Remove the set of packings 8 the four
planetary gears and another packing SOLENOID SWITCH
5 Take out the shaft assembly Take note of the
position of the lever
fii FOUR BAL7
PLANETARY
GEARS
GEAR
ASSEMBLY
FRONT
IMPORTANT BRACKET
Before disconnecting the yoke put tally marks on the
yoke and the front bracket ARMATURE 10
Take note of the positions of the set of packings and the
setup bolt
Apply grease to the gears bearings shafts sliding part
and ball
NOTE
Do not damage to the brush and commutator
When Apply grease DENSOCO No 50 or equivalent to the parts
indicated in the and Mica
1 Check the contact face of the commutator for wear and grind
the commutator with emery paper if it is slightly worn
2 Measure the commutator 00 with an outside micrometer at
several points
3 If the minimum 00 is less than the allowable limit replace the
armature
4 If the difference of the ODs exceeds the allowable limit
correct the commutator on a lathe to the factory Measure the mica undercut
6 If the undercut is less than the allowable limit correct it with a
saw blade and chamfer the segment edges
SEGMENTOEPTH OF MICA
32mm
Factory spec
12598 00
314 mm CORRECT INCORRECT
Allowable limit
12362 in
MICA
050 to 080 mm
Factory spec
00197 to 00315 in
Mica undercut
020 mm
Allowable limit
00079 in
yo WESTERBEKE
Engines Generators
STARTER MOTOR SERVICE
Brush Wear
1 If the contact face of the brush is dirty or dusty clean it with
emery paper
2 Measure the brush length A with vernier calipers
3 If the length is less than the allowable limit replace the yoke A BRUSH lENGTil
assembly and brush holder
180mm
Factory spec
07086 in
Brush length CA
t tO mm
Allowable limit
0433t Coil
1 Check the continuity across the commutator and armature coil
core with an ohmmeter
2 If it conducts replace the armature
3 Check the continuity across the segments of the commutator
with an ohmmeter
4 If it does not conduct replace the armature
Commutator
Infinity
Resistance Armature coil core INSPECTING THE ARMATURE COIL
Commutator segment Clutch
1 Inspect the pinion for wear or damage
2 If there is any defect replace the overrunning clutch assembly
3 Check that the pinion turns freely and smoothly in the
overrunning direction and does not siip in the cranking
direction
4 If the pinion slips or does not rotate in the both directions
replace the overrunning clutch INSPECTING THE OVERRUNING CLUTCH
Brush Holder
1 Check the continuity across the brush holder and the holder
support with an ohmmeter
2 lfit conducts replace the brush holder
Brush holder Infinity
support
Engines Generators
STARTER MOTOR SERVICE
Field Coil
1 Check the continuity across the lead 1 and brush 2 with an
ohmmeter
2 If it does not conduct replace the yoke assembly
3 Check the continuity across the brush 2 and yoke 3 with an
ohmmeter
4 If it conducts replace the yoke assembly
Lead 1 Brush 2 ol
Resistance
Brush 2 Yoke 3 Check the bearing for smooth rotation
2 If it does not rotate smoothly replace Measure the resistance across each lead of the stator coil with
an ohmmeter
2 If the measurement is not within factory replace
3 Check the continuity across each stator coil lead and core with
an ohmmeter
4 If infinity is not indicated replace it
I Resistance I Factory spec I Less than 10 n
Engines Generators
ALTERNATOR SERVICE
DESCRIPTION
The stator is connected to a threephase fullwave package which contains six diodes The the AC generated in the stator to a DC output for
60 AMP charging and to the regulator and the field of the integral is provided by the field diode or diode trio
package contained in the alternators produce a rated output of 50 or 51 amps
rated output is achieved at approximately 6000 alternator CASE GROUND
pm at an ambient temperature of 75F 238C are designed to operate in an ambient of 40 to 212F 40 to
REFER TO THE WIRING
DIAGRAM IN THIS
MANUAL FOR ALL
When rebuilding the engine the alternator should be cleaned WIRING inspected The housing can be wiped
off with a solvent
and the alternator temninal studs should be cleaned with a
wire brush Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness
Thm the rotor pulley by hand It should tum smoothly REAR
FRONT BRACKET 2
BRACKET ALTERNATOR
REMOVE 4 SCREWS
Front Bracket
1 Remove the 4 screws
2 Separate the fron bracket 1 and the rear bracket 2 from
each other
IMPORTANT
Put a tally line on the front bracket and the rear bracket for
reassembling them Hold the rotor base of the claw in a vise Loosen the lock nut
using a M24 box wrench
583 to 789 Nm
Tightening torque Pulley nul 595 to 805 kgfm
430 to 582 ftlbs
Rotor
1 Remove the 4 screws and detach the bearing retainer
2 Temporarily install the nut on the pulley screw and detach the
MOUNTING
rotor When the rotor is detached the 2 brushes are found to stretch
out of the shaft hole
TWO BRUSHES
Engins Generators
ALTERNATOR the Brush
1 Fit the brush with its sliding face in the clockwise direction
when viewed from front
IMPORTANT
TWO BRUSHES
Be sure to keep the 2 brushes deep in the brush holder
Otherwise the rotor and the rear section can not be filted
into position
Use a 4 mm hex wrench to push the brushes into place
Using a pinpointed 2 mm punch keep the brushes from
popping out
2 Match the tally line of the front section with that of the rear
section
WRENCH
3 Tighten the 4 screws and draw out the pinpointed punch out
of the brush holder
PUNCH
Bearing at Slip Ring Side
1 Lightly secure the rotor 1 with a vise to prevent damage and
remove the bearing 2 with a puller
MA7CHIIG THE
TALLY LINES
ROTOR
BEARING Check the bearing for smooth rotation
2 If it does not rotate smoothly replace Measure the resistance across each lead of the stator coil with
an ohmmeter
2 If the measurement is not within factory replace
3 Check the continuity aoross each stator coil lead and core with
an ohmmeter
4 If infinity is not indicated replace IFactory spec ILess than 10 l
CHECKING CONTINUITY
Engines Generstors
ALTERNATOR Measure the resistance across the slip rings with an
ohmmeter
2 If the resistance is not the factory replace it
3 Check the continuity across the slip ring and core with an MEASURING
ohmmeter SLIP RINGS
4 If infinity is not indicated replace it
I Resistance I Factory spec 128 to 33 l
Slip Rino
1 Check the slip ring for score
2 If scored correct with an emery paper or on a lathe
3 Measure the 00 of slip ring with vernier calipers
4 If the measurement is less than the allowable limit replace il
227 mm
Factory spec
0894 in
Slip ring DD
221 mm
Allowable limit
0870 in
Brush Wear
1 Measure the brush length with vernier calipers
2 If the measurement is less than allowable limit replace il
3 Make sure that the brush moves smoothly
4 If the brush is defective replace il MEASURING BRUSH LENGTH
185 mm
Factory spec
0728 in
Brush length
50mm
Allowable limit
0197 Check the continuity across each diode of rectifier with an
ohmmeter
2 The rectifier is normal if the diode in the rectifier conducts in
one direction and does not conduct in the reverse Regulator
1 Check the continuity across the B terminal and the F
terminal of IC regulator with an ohmmeter
2 The IC regulator is normal if the conducts in one direction and
CHECKING CONTINUITY
does not conduct in the reverse direction
8 TERMINAL
v WESTERBEKE
Engines Generators
SERVICING
Cylinder Head
Too Clearance
1 Remove the cylinder head remove the cylinder head gasket
completely
2 Bring the piston to its top dead center fasten 15 mm dia 5 to
7 mm long fuse wires to 3 to 4 spots on the piston top with
grease so as to avoid the intake and exhaust valves and the
combustion chamber ports
3 Bring the piston to its middle position install the cylinder head
and tighten the cylinder head screw to Head
gasket must be changed to new one
4 Turn the crank shaft until the piston exceeds its top dead
center
5 Remove the cylinder head and measure squeezed fuse wires
for thickness
6 If the measurement is not within the specified value check the
oil clearance of the crankpin journal and the piston pin
072 to 090 mm
Factory 00283 to 00354 in
Top clearance
spec
981 to 1079 Nm
Cylinder head mounting
Tightening torque 100 to 110 kgfm
screw
723 to 796 ftlbs
Cylinder Head Surface Flatness E F
1 Clean the cylinder head surface
2 Place a straightedge on the cylinder heads four sides A B c o
C and D and two diagonal E and F as shown in the
figure
Measure the clearance with a feeler gauge
3 If the measurement exceeds the allowable limit correct it with
a surface grinder
IMPORTANT
Do not place the straightedge on the combustion
chamber
Be sure to check the valve recessing after correcting
Cylinder head surface 005 mm
Allowable limit
flatness 00020 in
Cylinder Head Flaw
1 Prepare an air spray red checkCode No 2 Clean the surface of the cylinder head with the detergent 2
3 Spray the cylinder head surface with the red permeative liquid
1 Leave it five to ten minutes after spraying
4 Wash away the red permeative liquid on the cylinder head Ililmll IDi smr illIlIJIl
surface with the detergent 2 AcAA IeAS Aif
5 Spray the cylinder head surface with the white developer 3
8
6 If flawed it can be identified as red marks
Engines Generators
Recessing DEPTH
1 Clean the cylinder head the valve face and seat GAUGE lU
2 Insert the valve into the valve guide
3 Measure the valve recessing with a depth gauge
4 If the measurement exceeds the allowable limit replace the
valve
If it still exceeds the allowable limit after replacing the valve
replace the cylinder head
Protrusion CYLINDER HEAD SURFACE CYLINDER HEAD SURFACE
Factory Intake o mm 0 in to
spec valve recessing
02 mm 00079 in 8
Protrusion
Valve recessing
Factory Exhaust 05 mm 00059 in to
spec valve recessing
005 mm 000t9 in A Recessing
Allowable recessing 8 Protrusion
limit 04 mm 00157 in
Valve Lapping
1 Apply compound evenly to the valve lapping surface
2 Insert the valve into the valve guide Lap the valve onto its
seat with a valve flapper or After lapping the valve wash the compound away and apply
oil then repeat valve lapping with oil
4 Apply prussian blue to the contact surface to check the seated
rate If it is Iess than 70 repeat valve lapping again
IMPORTANT
When valve lapping is performed be sure to check the
valve recessing and adjust the valve clearance after
0 0
assembling the between Valve Stem and Valve Guide
1 Remove carbon from the valve guide section
CORRECT INCORRECT INCORRECT
2 Measure the valve stem 00 with an outside Measure the valve guide 10 of the cylinder head at the most
wear part as shown with a small hole
gauge
And calculate the clearance
4 If the clearance exceeds the allowable limit replace the
valves If it still exceeds the allowable limit replace the valve
guide
Intake 6960 to 6975 mm
Factory valve 02740 to 02746 in
Valve stem 00
spec Exhaust 7960 to 7975 mm
valve 03134 to 03140 in Intake 0055 to 0085 mm
Factory valve 00022 to 00033 in
Intake 7030 to 7045 mm Clearance between spec Exhaust 0040 to 0070 mm
Factory valve 02768 to 02774 in valve stem and guide valve 00016 to 00028 in
Valve guide 10
spec Exhaust 8015 to 8030 mm 01 mm
Allowable limit
valve 03155 to 03161 in 00039 in
Engines Generators
SERVICING
Replacing Valve Guide
When removing
1 Using a valve guide replacing tool press out the used valve
guide
When installing f5 L
1 Clean a new valve guide and apply engine oil to it
2 Using a valve guide replacing tool press in a new valve guide
until it is flush with the cylinder head as shown
3 Ream precisely the ID of the valve guide to the specified
l J
dimension
IMPORTANT
Do not hit the valve guide with a hammer etc during
replacement
AI When emoving 8 When Valve and Valve Seat
NOTE
Before correcting the valve and seat check the valve
stem and the 10 of valve guide section and repair them
if necessary
After correcting the valve seat be sure to check the valve
VALVE
recessing GUIDE
1 Correcting Valve
1 Correct the valve with a valve refacer
2 Correcting Valve Seat A 8
1 Slightly correct the seat surface with a 1047 rad 60 0 intake REMOVING INSTALLING
valve or 0785 rad 45 0 exhaust valve seat cutter Code No
0790933102
2 Resurface the seat surface with a 0523 rad 30 valve seat
cutter to intake valve seat and with a 0262 rad 15 valve
seat cutter to exhaust valve seat so that the width is close to
specified valve seat width 212 mm 00835 in
3 After resurfacing the seat inspect for even valve seating
apply a thin film of compound between the valve face and
valve seat and fit them with valve lapping tool Check the valve seating with prussian blue The valve
seating
surface should show good contact ali the way around
a Identical Dimensions A Check Conlacl
bl Valve Seal Wldlh 8 Correcl Seal Wldlh
c 0523 rad 30 or C Check Conlacl
0262 rad 15 A
d 0262 rad 15 or
0523 rad 30
e 0785 ad 45 or
1047 ad 60
Engines Generators
SERVICING
Free Length and Tilt of Valve Spring
1 Measure the free length A with vernier calipers If the
measurement is less than the allowable limit replace it
2 Put the spring on a surface plate place a square on the side
VALVE SPRING
of the spring and check to see if the entire side is contact with
the square Rotate the spring and measure the maximum 8
If the measurement exceeds the allowable limit replace
3 Check the entire surface of the spring for scratches Replace
it if any
Intake 351 to 356 mm
Factory valve 13819 to 14016 in
spec Exhaust 417 to 422 mm
valve Free length A
Intake 346 mm
Allowable valve 13622 in VALVE SPRING
TESTER
limit Exhaust 412 mm
valve 16220 in
Till B Allowable limil 10 mm
039 in
Valve Spring Setting Load
1 Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine
2 Read the compression load on the gauge
3 If the measurement is less than the allowable limit replace it
63547 N 1315 mm 0016 to 0045 mm
Intake Factory spec
648 kg1315 mm Oil clearance of rocker 000063 to 000177 in
valve
Factory 142561bs 112401 in arm shaft and bearing 015 mm
spec Allowable limit
1176 N 135 mm 00059 in
Exhaust
120 kgfl35 mm
valve
Setting load 1 Selling 264 Ibs 113780 in
1597310 15984 mm
ROCKer arm shaft 00 Factory spec
length 45864 N 1315 mm 06289 10 06293 in
Intake
468 kg 1315 mm mm
valve Rocker arm 10 for shaft Factory spec
Allowable 102961bs 112401 in 06299 10 06306 in
limit 1000 N 135 mm
Exhaust
102 kgl35 mm
valve MEASURING THE SHAFTS 00
2251bs 113780 in
Oil Clearance between Rocker Arm Shaft and Bearing
1 Measure the rocker arm bearing I O with an inside
Measure the rocker arm shaft 00 with an outside
OIL CLEARANCE
micrometer and then calculate the oil clearance
3 If the clearance exceeds the allowable limit replace the rocker
arm and measure the oil clearance again If it still exceeds the
allowable limit replace also the rocker arm shaft
MEASURING THE
ROCKER ARM 10
v WESTERBEKE
Engines Generators
Rod Alignment
1 Place the push rod on V blocks
2 Measure the push rod alignment
3 If the measurement exceeds the allowable limit replace the
push rod
025mm
Push rod alignment Allowable limit MEASURING PUSH ROD ALIGNMENT
00098 in
Qj Clearance between Tappet and Tappet Guide Bore
1 Measure the tappet QD with an outside Measure the ID of the tappet guide bore with a cylinder
gauge and calculate the oil clearance
3 If the oil clearance exceeds the allowable limit or the tappet is
damaged replace the tappet
0020 to 0062 mm 0 0 00 00
Factory spec
Oil clearance between
tappet and tappet guide
bore Allowable limit
00008 to 00024 in
007mm
MEASURING TAPPET O
00 00
00028 in
0 00 0 00
23959 to 23980 mm
Tappet 00 Factory spec
09433 to 094t tin
24000 to 2402t mm
Tappat guide bore 10 Factory spec
09449 to 09457 in
Timing Gear and Gear Backlash
1 Set a dial indicator lever type with its tip on the gear tooth
2 Move the gear to measure the backlash holding its mating
gear
3 If the backlash exceeds the allowable limit check the oil
clearance of the shafts and the gear
4 If the oil clearance isnt proper replace the gear
0049 to O t 93 mm 0044 to 0177 mm
Backlash between Factory spec Factory spec
OOOt 9 to 00076 in Backlash between idle OOOt 7 to 00070 in
crank gear and idle gear gear 2 and injection
t 022 mm 022 mm
Allowable limit pump gear Allowable limit
00087 in 00087 in
0049 to O t89 mm 0047 to 0t82 mm
Factory spec Factory between idle 000t9 to 00074 in Backlash
between cam OOOt 8 to 00072 in
gear 1 and cam gear geal and balancer gear
022 rnm 1 O22mm
Allowable limit Allowable limit
00087 in 00087 in
0044 to O t 85 mm 0044 to 0183 mm
Factory spec Backlash between idle Factory between idle OOOt 7 to 00073 in
00017 to 00072 in
gear 1and idle gear 2
gear 1 and balancer
022 mm gear 2 022mm
Allowable limit Allowable limit
00087 in 00087 in
Engines Generators
SERVICING
DIAL INDICATOR
Idle Gear Side Clearance
1 Set a dial indicator with its tip on the idle gear
2 Measure the side clearance by moving the idle gear to the
front and rear
3 If the measurement exceeds the allowable limit replace the
idle gear collar
015 to 030 mm
Factory spec
00059 to 00118 in
Idle gear side clearance
09 rnm
Allowable limit
00354 in
MEASURING GEAR SIDE CLEARANCE
Camshaft Alignment
1 Support the camshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle
2 Rotate the camshaft on the V blocks and get the misalignment
half of the If the misalignment exceeds the allowable limit replace the
camshaft
001 mm
Camshaft alignment Allowable limit
000039 Side Clearance
1 Set a dial indicator with its tip on the camshaft
2 Measure the side clearance by moving the cam gear to the
front and rear
3 If the measurement exceeds the allowable limit replace the
camshaft stopper
007 to 022 mm
Factory spec
00028 to 00087 in
End play of camshaft
030 mm
Allowable limit
00118 in
Cam Height
1 Measure the height of the cam at its highest point with an CAMSHAFT ALIGNMENT
outside If the measurement is less than the allowable limit replace the
camshaft
Intake 3763 mm
Factory valve 14815 in
spec Exhaust and exhaust cam valve 15338 in
heighl Intake 3713 mm
Allowable valve 14618 in
limit Exhaust 3846 mm
valve 15141 in
WESTERBEKE MEASURING CAM HEIGHT
Engines Generators
SERVICING
Oil Clearance of Camshaft Journal
1 Measure the camshaft journal 00 with an outside
micrometer
2 Measure the cylinder block bore 10 for camshaft with an
inside micrometer
3 If the oil clearance exceeds the allowable limit replace the
camshaft
0050 to 0091 mm MEASURING THE CYLINDER BORE 10
Factory spec
Oil clearance of 000t97 to 000358 in
camshaft journal 015 mm
Allowable limit
00059 in
45934 to 45950 mm
Camshaft journal 00 Factory spec
18084 to 18091 in
46000 to 46025 mm
Camshaft bearing ID Factory spec
181 I 0 to 18120 in
Oil Clearance between Idle Gear Shaft 1 2 and Idle Gear 1 2
Bushing
1 Measure the idle gear shaft 00 with an outside Measure the idle gear bushing 10 with an inside micrometer
o
o o
and calculate the oil clearance
3 If the oil clearance exceeds the allowable limit replace the
bushing
0050 to 0091 mm
Clearance between idle Factory spec
00020 to 00036 in
gear 1 2 shaft and idle
gear 1 2 bushing 010 mm
Allowable limit
00039 in
Idle gear 1 2 bushing 45025 to 45050 mm
Factory spec
10 17726 to 17736 in
44959 to 44975 mm
Idle gear 2 shaft DD Factory spec
17700 to 17707 Idle Gear Bushing
When removing
1 Using an idle gear bushing replacing tool press out the used
bushing
When Clean a new idle gear bushing and idle gear bore and apply
engine oil to them
2 Using an idle gear bushing replacing tool press in a new
REMOVING
bushing service parts to the specified REPLACING THE IDLER GEAR
BUSHING
WESTERBEKE
Engines Generaors
SERVICING
BALANCER SHAFT
Side Clearance
1 Set a dial indicator with tip on the balancer shaft
2 Measure the side clearance by moving the balancer shaft to
the front and rear
3 If the measurement exceeds the allowable limit replace the
balancer shaft
0070 to 0220 mm
Factory spec 00028 to 00087 in
End play of balancer
shaft
Allowable limit
03 mm
00118 in
OJ L
MEASURING THE SIDE Alignment
1 Support the balancer shaft with V blocks on the surface plate
and set a dial indicator with its tip on the intermediate journal BALANCER SHAFT
ALIGNMENT
at high angle
2 Rotate the balancer shaft on the V block and get the
misalignment half of the measurement o
3 If the misalignment exceeds the allowable limit replace the
balancer shalt
INSPECTING THE l
Balancer shaft O02mm BALANCER SHAFT
Allowable 00008 in Clearance of Journal CYLINDER BLOCK
BORE
1 Measure the balancer haft journal 00 with an outside
Measure the cylinder block bore 10 A 8 for balancer shaft
with an inside If the clearance exceeds the allowable limit replace the
balancer shaft
0070 to 0159mm
Factory spec
00028 to 00063 in
Oil clearance journal O2mm
Allowable limit
00079 journal 5092 to 5094 mm
Factory spec
00 20047 to 20055 bearing 5101 to 5108 mm
Factory spec
JD 20083 10 20110 in
BALANCER SHAFT
JOURNAL
WESTERBEKE
SHAFT JOURNAL
MEASURING tHE BALANCER
Engines Generators
SERVICING
MEASURING PISTON PIN BORE
Piston and Connecting Rod
Piston Pin Bore ID
1 Measure the piston pin bore ID in both the horizontal and
vertical directions with a cylinder gauge
2 If the measurement exceeds the allowable limit replace the PISTON PIN
piston BORE
30000 to 30013 mm
Factory spec
11811 to 11816 in
Piston pin bore ID
3005 mm
Allowable limit
11831 between Piston Ring and Groove A a
1 Remove carbon from the ring grooves TOP RING FACTORY
Measure the clearance between the ring and the groove with
a feeler gauge or depth gauge
3 If the clearance exceeds allowable limit replace the ring since
compression leak and oil shortage result
4 If the clearance still exceeds the allowable limit after replacing
the ring replace the piston
0093 to 0120 mm
Compression ring 2
00037 to 00047 in
Factory spec
0020 to 0060 mm
Oil ring
00008 tq 00023 in
020 mm
Compression ring 2
00079 in
Allowable limit
015 mm
Oil ring
00059 In
Factory 8
I More than 02 mm
00079 in
MEASURING THE PISTON RING CLEARANCE
A Top Ring Key Store Type B 2nd 011 Ring
Piston Ring Gap
1 Insert the piston ring into the lower part of the liner the least
worn out part with the piston
PISTON RING GAP
2 Measure the ring gap with a feeler gauge
3 If the gap exceeds the allowable limit replace the piston ring
030 to 045 mm
Factory spec
OOt 18 to 00177 ring 1 2
125 mm
Allowable limit
00492 in
025 to 045 mm
Factory spec
00098 to 00177 in
Oil ring
125 mm
Allowable limit
00492 in
MEASURING THE RING GAP
v WESTERBEKE
Engines Generators
SERVICING
Oil Clearance between Piston Pin and Small End Bushing
1 Measure the 00 of the piston pin where it contacts the
bushing with an outside micrometer
2 Measure the 10 of the piston pin bushing at the connecting
rod small end with a cylinder gauge
Calculate the oil clearance
3 If the clearance exceeds the allowable limit replace the
bushing
If it still exceeds the allowable limit replace the piston pin
0020 to 0040 mm MEASURING THE PISTON PIN
Oil clearance between Factory spec
00008 to 00016 in
piston pin and small end
bushing O15mm
Allowable limit
00059 in
When Removing Installing
30006 to 30011 mm
Piston pin 00 Factory spec
11813to 11815 in
30031 to 30046 mm
Small end bushing 10 Factory spec
11823 to 11829 Small End Bushing
When removing
1 Press out the used bushing using a small end bushing
replacing tool REPLACING THE SMALL END BUSHING
When Clean a new small end bushing and bore and apply engine oil 026 ad 15
to them e
1 Seam
2 Insert a new bushing onto the tool and pressfit it with a press
so that the seam 1 of bushing position as shown
until it is flush with the connecting Rod Alignment
NOTE
Since the 10 of the connecting rod small end bushing is
the basis of this check check the bushing for wear
beforehand
1 Remove the piston pin in the connecting rod
2 Install the piston pin in the connecting rod
3 Install the connecting rod on the connecting rod alignment tool ALIGNING THE CONNECTING ROD
Code No Put a gauge over the piston pin and move it against the face
plate
5 If the gauge does not fit squarely against the face plate
measure the space between the pin of the gauge and the face
plate
6 If the measurement exceeds the allowable limit replace the
connecting rod O05mm
Allowable 00020 in
WESTERBEKE
Engines Generators
Crankshaft SERVICING CRANKSHAFT Side Clearance
CLEARANCE
1 Set a dial indicator with its tip on the end of the Measure the side clearance by moving the crankshaft to the
front and rear DIAL
3 If the measurement exceeds the allowable limit replace the INDICATOR
thrust bearings
4 If the same size bearing is useless because of the crankshaft
journal wear replace it with an oversize one referring to the
table and figure
015 to 031 mm
Factory spec
Crankshaft side 00059 to 00122 in
clearance 050mm
Allowable limit
00197 in CRANKSHAFT
JOURNAL
Reference DIMENSIONS
Oversize dimensions of crankshaft journal
O2mm O4mm
Oversize
0008 in 0016 in
2920 to 2925 mm 2940 to 2945 mm
Dimension A
in 11574 to 11594 in
1691 to 16915 mm 1692 to 16925 mm
Dimension B
66575 to 66594 In 66614 to 66634 in
28 to 32 mm radius 28 to 32 mm radius
Dimension C
01102 to 01260 in radius 01102 to 01260 in radius
OBS CRANKSHAFT JOURNAL
The crankshaft journal must be finefinished to higher than Alignment
1 Support the crankshaft with V block on the surface plate and
set a dial indicator with its tip on the intermediate journal at
right angle
2 Rotate the crankshaft on the V block and get the misalignment
half of the If the misalignment exceeds the allowable limit replace the
crankshaft
002mm alignment Allowable limit
000079 in
v WESTERBEKE
Engines Generators
SERVICING
Oil Clearance between Crankpin and Crankpin Bearing
PlASTIGAGE
1 Clean the crankpin and crankpin bearing
2 Put a strip of plastigage on the
center of the crankpin
3 Install the connecting rod cap and tighten the connecting rod
screws to the specified torque and remove the cap again
4 Measure the amount of the flattening with the scale and get
the oil clearance
5 If the oil clearance exceeds the allowable limit replace the
crankpin bearing
6 If the same size bearing is useless because of the crankpin
wear replace it with an undersize one referring to the table
NOTE B
Never insert the plastigage into the crankpin oil hole
Be sure not to move the crankshaft while the connecting
rod screws are tightened
a o
52977 to 52990 mm
Crankpin 00 Factory spec
20857 to 20862 in
CRANKSHAFT
0018 to 0051 mm
Oil clearance between Factory spec
00007 to 00020 in
crankpin and crankpln
bearing 020 mm
Allowable limit
00079 in
10 COLOR
Oil Clearance between Crankpin and Crankpin IMPORTANT
CRANKPIN
STD size crankpin bearing BEARING
To replace it with a specific STD service part make sure
the crankpin bearing has the same ID color as the CENTER
connecting rod WAll
THICKNESS
Connecting rod Crankpin bearing
10 Color
Largeend in dia Class Part code Center wall thick
5601 to 5602 mm 1496 to 1501 mm
Blue L
22051 to 22055 in 00589 to 00591 in
Without 5600 to 56Q1 mm 1491 to 1496 mm
color 22047 to 22051 in 00587 to 00589 in
Undersize dimensions of crankpin
O2mm 04 mm
Undersize
0008 in 0Q16 in
28 to 32 mm radius 28 to 32 mm A
01102 to 01260 in radius 01102 to 01260 in radius
10 to 15 mm radius 10 to 15 mm B
00394 to 00591 in radius 00394 to 00591 in radius
52777 to 52790 mm 52577 to 52590 mm
Dimension C
2077810 20783 In 207DO to 20705 in
The crankpin must be to higher than vvvv
WESTERBEKE
Engines Generators
SERVICING
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing
1 Clean the crankshaft journal and crankshaft bearing
2 Put a strip of press gauge on the
center of the journal
IMPORTANT
Never insert the press gauge into the oil hole of the
journal
3 Install the main bearing case and tighten the screws to the
specified torque and remove the cases again
4 Measure the amount of the flattening with the scale and get the
oil clearance
5 If the clearance exceeds the allowable limit replace the
crankshaft bearing
74977 to 74990 mm
Crankshaft journal 00 Factory spec
29518 to 29524 in A A
0018 to 0062 mm
Oil clearance between Factory spec
00007 to 00024 in
crankshaft journal and c
crankshaft bearing 020 mm B
Allowable limit
00079 in
Reference
Undersize dimensions of crankshaft journal CRANKSHAFT JOURNAL
O2mm OAmm
Undersize
0008 in 0016 in
28 to 32 mm radius 28 to 32 mm radius
Dimension A
01102 to 01260in radius 01102 to 01260 in radius
1 0 to 15 mm radius 10 to 15 mm radius
Dimension B
00394 to 00591 in radius 00394 to 00591 In radius
74777 to 74790 mm 74577 to 74590 mm
Dimension C
29440 to 29445 in 29361 to 29366 in
The crankpin must be finefinished to higher than vvvv
CRANKSHAFT Crankshaft Sleeve
CRANKCASE GUIDE
1 Remove the used crankshaft sleeve 1 using a specialuse SLEEVE 1
AUXILIARY
puller set SOCKET
2 Set the sleeve guide 4 to the Heat a new sleeve to a temperature between 150 to 200C
302 to 392 OF and fix the sleeve tothe crankshaft as shown
4 Press fit the sleeve using the auxiliary socket for pushing
NOTE
Mount the sleeve with its largely chamfered surface
facing outward
WESTERBEKE
Engines Generaors
SERVICING
Cylinder
Cylinder Wear
1 Measure the 10 of the cylinder at the six positions
with a cylinder gauge to find the maximum and minimum IOs
2 Get the difference Maximum wear between the maximum
and the minimum los
3 If the wear exceeds the allowable limit bore and hone to the
oversize dimension Refer to Correcting Cylinder
4 Visually check the cylinder wall for scratches If deep
scratches are found the cylinder should be bored Refer to
Correcting Cylinder
98000 10 98022 mm
Factory spec
Cylinder Bor tD B
9815 mm
Allowable limit
38642 in
A Top a Rightangled to Piston Pin C
B Middle b Piston Pin Direction
C Bottom Skirt
MEASURING CYLINDER Cylinder Oversize 05 mm
1 When the cylinder is worn beyond the allowable limit bore and
hone it to the specified dimension
CYLINoER 10
Cylinder tD 2 Factory spec
98500 to 98522 mm BEFORE CONNECTiON
38780 to 38788 in 1
9865mm
Maximum wear Allowable limit
3889 in
2
Horn to 12 to 20 mm uR max
CYLINDER 10
Finishing VlVl
OVERSIZE
0000047 to 0000079 in JR max
2 Replace the piston and piston rings with oversize 05
When the oversize cylinder is worn beyond the aowable
limit replace the cylinder block with a new one
Oil Pump
Rotor Lobe Clearance
1 Measure the clearance between lobes of the inner rotor and
the outer rotor with a feeler gauge
2 If the clearance exceeds the allowable limit replace the oil
pump rotor assernbly
004 to 016 mm
Clearance between Factory spec FEELER
00016 to 00063 in
inner rotor and outer GAUGE
rotor 03 mm
Allowable limit
00118 in
v WESTERBEKE
Engines Generators
between Outer Rotor and Pump Body
FEELER
1 Measure the clearance between the outer rotor and the pump GAUGE
body with a feeler gauge
2 If the clearance exceeds the allowable limit replace the oil
pump rotor assembly
0100 to 0184 mm
Clearance between Factory spec
00039 to 00072 in
outer rotor and pump
body 03 mm
Allowable limit
00118 between Rotor and Cover
1 Put a strip of plastigage onto the
rotor face with grease
2 Install the cover and tighten the screws with the specified
torque
3 Remove the cover carefully and measure the amount of the
flattening with the scale and get the clearance
4 If the clearance exceeds the allowable limit replace oil pump
rotor assembly and the cover
002510 0075 mm
Factory between 00010 to 00030 in
rotor and cover 0225 mm
Allowable limit
00089 in
PLASTIGAGE
79 to 93 torque Oil pump cover screw 080 to 095 kgfm
58 to 69 ttIbs
y WESTERBEKE
Engines Generators
ENGINE BODY
SERVICING Item Factory Specification Allowable Head Surface
Flatness 005 mm
00020 in
Top Clearance V3300E2B 072 to 090 mm
00283 to 00354 in
V3300T E2B 09210110 mm
00362 to 00433 in
Compression Pressure V3300E2B 432 MPa I 326 MPal
250 min 1 rpm 250 min rpm
44 kgfcm2 I 332 kgfcm 2 I
250 min rpm 250 min rpm
626 psi I 472 psi I
250 min rpm 250 min rpm
V3300TE2B 392 MPal 299 MPal
250 min rpm 250 min rpm
40 kgfcm21 305 kgfcm 2 I
250 min rpm 250 min 1 rpm
569 psi I 434 psi I
250 min rpm 250 min 1 Among Cylinders 10 or less
Valve Seat Width IN 212 mm
00835 in
EX 212 mm
00835 in
Valve Seat Angle IN 1047 rad
0
EX 0785 rad
0
Valve Face Angle IN 1047 rad
0
EX 0785 rad
0
Valve Recessing IN 02 to 0 mm 04 mm
0079 to 0 in 00157 in
EX 005 to 015 mm 04 mm
00019 to 00059 in 00157 in
Valve Clearance Cold 023 to 027 mm
00091 to 00106 in
Intake Valve Timing Open 024 rad 14 0
before TDC
Close 061 rad 36
after BDC
Exhaust Valve Timing Open 079 rad 45
before BDC
Close 029 rad 17 0
altel LQC
Engines Generators
SERVICING Item Factory Specification Allowable Limit
Valve Stem to Valve Guide Clearance IN 0055 to 0085 mm 01 mm
00022 to 00033 in 00039 in
Valve Stem 00 6960 to 6975 mm
IN 02740 to 02764 in
Valve Guide 10 7030 to 7045 mm
IN 02768 to 02774 in
Clearance EX 0040 to 0070 mm 01 mm
00016 to 00028 in 00039 in
Valve Stem 00 7960 to 7975 mm
EX 03134 to 03140 in
Valve Guide 10 8015 to 8030 mm
EX 03155 to 03161 in
Valve Spring Intake 351 to 356 mm 346 mm
13819 to 14016 in 13622 in
Exhaust 417 to 422 mm 412 mm
16417to 16614in 16220 in
Setting Load I Setting Length Intake 45864 N 1315 mm
63547 N I 315 mm
468 kgf I 315 mm
648 kgf 1315 mm
10296 Ibs 11 2401
14256 Ibs 112401 in
Exhaust 1176 N I 35 mm 100 N 135 mm
12 kgf 135 mm 102 kgf 135 mm
264 Ibs 113780 in 2251bs 113780 in
Tilt Valve Spring 10mm
0039 in
Rocker Arm Shaft to Rocker Arm Oil Clearance 0016 to 0045 mm 015 mm
000063 to 000177 in 00059 in
Rocker Arm Shaft 15973 to 15984 mm
00 06289 to 06293 in
Rocker Arm 10 for 16000 to 16018 mm
Shaft 06299 to 06306 in
Valve Arm Bridge and Valve Arm Bridge Clearance 0018 to 0042 mm 015 mm
Shaft 00007 to 00017 in 00059 in
Valve Arm Bridge 9050 to 9065 mm
10 03563 to 03569 in
Valve Arm Bridge
9023 to 9032 mm
Shaft
03552 to 03556 in
Push Hod Alignment 025 mm
00098 in
WESTERBEKE
Engines Generators
SERVICING Item Factory Specification Allowable Limit
Piston Ring Gap Compression Ring 030 to 045 mm 125 mm
1 00118 to 00177 in 00492 in
Compression Ring 030 to 045 mm 125 mm
2 00118 to 00177 in 00492 in
Oil Ring 025 to 045 mm 125 mm
00098 to 00177 in 00492 Rod Alignment 005 mm
00020 in
Piston Pin to Small End Bushing Clearance 0020 to 0040 mm 015 mm
00008 to 00016 in 00059 in
Piston Pin 30006 to 30011 mm
00
Small End Bushing 30031 to 30046 mm
10 11823 to 11829 in
Crankshaft Side Ciearance 015toO31 mm 050 mm
00059 to 00122 in 00197 in
Alignment 002 mm
000079 Journal 00 74977 to 74990 mm
29518 to 29524 in
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0018 to 0062 mm 020 mm
00007 to 00024 in 00079 in
Crank Pin 00 52977 to 52990 mm
20857 to 20862 in
Crank Pin to Pin Bearing Oil Clearance 0018 to 0051 mm 020 mm
00007 to 00020 in 00079 in
Cylinder Bore 10 98000 to 98022 mm 9815 mm
38582 to 38591 in 38642 in
Cylinder Bore 10 98500 to 98522 mm 9865 mm
Oversize 38780 to 38788 in 38839 in
WESTERBEKE
Engines Generators
SERVICING Item Factory Specification Allowable Limit
Timing Gear Idle Gear 1 to Crank
0049 to 0193 mm 022 mm
Gear
00019 to 00076 in 00087 in
Backlash
Idle Gear 1 to Cam
0049 to 0189 mm 022 mm
Gear
00019 to 00074 in 00087 in
Backlash
Idle Gear 1 to Idle
0044 to 0185 mm 022 mm
Gear 2
00017 to 00073 in 00087 in
Backlash
Idle Gear 2 to
Injection Pump 0044 to 0177 mm 022 mm
Gear 00017 to 00070 in 00087 in
Backlash
Cam Gear to
0047 to 0182 mm 022 mm
Balancer Gear 1
00018 to 00072 in 00087 in
Backlash
Idle Gear 1 to
0044 to 0183 mm 022 mm
Balancer Gear 2
00017 to 00072 in 00087 in
Gear Shaft 1 2 to Idle Gear 1 2 Oil Clearance 0050 to 0091 mm
00020 to 00036 in 00039 in
Idle Gear 1 2
45025 to 45050 mm
Bushing
17726 to 17736 in
Idle Gear 1 2 Shaft 44959 to 44975 mm
00 17700 to 17707 in
Idle Gear Side Clearance 015to 030 mm 09 mm
00059 to 00118 in 00354 in
Balancer Shaft Balancer Model Only Side Clearance 007 to 022 mm 03mm
00028 to 00087 in 00118 in
Balancer Shaft Balancer Model Only Alignment 002 mm
00008 in
Balancer Shaft Balancer Model Only Oil Clearance 0070 to 0159 mm 02mm
00028 to 00063 in 00079 in
Balancer Shaft
5092 to 5094 mm
Journal
20047 to 20055 in
Balancer Bearing 5101 to 5108 mm
10 20083 to 20110 in
Piston Pin Bore 10 30000 to 30013 mm 3005 mm
11811 to 11816 in 11831 Ring 2 to Ring Groove Clearance 0093 to 0120 mm 020 mm
00037 to 00047 in 00079 in
Oil Ring to Ring Groove Clearance 002 to 006 mm 015 mm
00008 to 00023 in 00059 in
WESTERBEKE
Engines Generators
SERVICING Item Factory Specification Allowable Limit
Tappet to Tappet Guide Clearance 0020 to 0062 mm 007 mm
00008 to 00024 in 00028 in
Tappet Guide Bore 24000 to 24021 mm
10 09449 to 09457 in
Tappet 23959 to 23980 mm
00 09433 to 09441 in
Camshaft Side Clearance 007 to 022 mm 03mm
00028 to 00087 in 00118 in
Alignment 001 mm
000039 in
Cam Height IN 3763 mm 3713 mm
14815 in 14618 in
EX 3896 mm 3846 mm
15338 in 15141 in
Camshaft Oil Clearance 0050 to 0091 mm 015 mm
000197 to 000358 in 00059 in
Camshaft Journal 45934 to 45950 mm
00 18084 to 18091 in
Camshaft Bearing 46000 to 46025 mm
D 18110to 18120 in
FUEL SYSTEM
Item Factory Specification Allowable Timing V3300E2B 020 to 022 rad
115 to 125
before TDC
V3300TE2B 011 toO13 rad
65 to 75 0
before TDC
Fuel Injection Nozzle Injection Pressure 1373 to 1471 MPa
140 to 150 kgfcm 2
1991 to 2134 psi
Valve Seat When the pressure is
Tightness 1275 MPa 130 kgfcm2
1849 psi the valve seat
must be fuel SYSTEM
Item Factory Specification Allowable Valve Opening 745 to 785 c
Temperature 1661 to 1733 OF
Valve Opening
Temperature 90C
Opened 194 OF
Completely
I Engines Generators
SERVICING SYSTEM
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed 49 kPa
05 kgfcm2
7 psi
At Rated Speed 196 to 392 kPa 1471 kPa
20 to 40 kgfcm2 15 kgfcm2
28 to 57 psi 213 psi
Engine Oil Pressure Switch Working Pressure 392 to 588 kPa
04 to 06 kgfcm2
56 to 84 psi
Inner Rotor to Outer Rotor Clearance 004 to 016 mm 03mm
00016 to 00063 in 00118 in
Outer Rotor to Pump Body Clearance 0100 to 0184 mm 03mm
00039 to 00072 in 00118 in
Rotor to Cover Clearance 0025 to 0075 mm 0225 mm
00010 to 00030 in 00089 in
Relief Valve Working Pressure 885 kPa
904 kgfcm2
129 SYSTEM
Item Factory Allowable 00 32 mm 314 mm
12598 in 12362 in
Mica Undercut 05mm 02mm
00197 in 00079 in
Brush Starter Length 18 mm 11 mm
07086 in 04331 Noload Voltage 14 Vat 4000 minI rpm
Rotor Coil Resistance 28 to 33 Q
Slip Ring 00 227 mm 221 mm
0894 in 0870 in
Brush Alternator Length 185 mm 50mm
0728 in 0197 in
Glow Plug Resistance Approx 10 Q
v WESTERBEKE
Engines Generators
ENGINE ADJUSTMENTS
Injection Timing
1 Make sure of matching the injection timing align mark 1 of the
injection pump unit and the plate gearcase as shown in the
2 Remove the injection pipes
3 Remove the stop solenoid
4 Turn the flywheel viewed from flywheel
side until the fuel fills up to the hole of the delivery valve
holder 2 for No1 cylinder
5 After the fuel fills up to the hole of the delivery valve holder for
No1 cylinder turn back clockwise the flywheel around 157
rad 90 0 a Injection Timing Advanced
6 Turn the flywheel to set at around 035 rad b Injection Timing Delayed
20 before TDC
VIEWING THE DELIVERY
7 Slowly turn the flywheel and stop turning VALVE HOLDER
when the fuel begins to come up to get the present injection
timing
8 Check to see the degree on flywheel
The flywheel has mark 1 TC 10 and 20 for the crank angle
before the top dead center of No1 piston
9 If the injection timing is not within the rotate the
injection pump unit to adjust the injection timing
IMPORTANT
When installing the injection pump unit to the engine
body follow the correct procedure
020 to 022 rad t t 5 to
125 before TDC
Factory
Injection timing
spec
DELIVERY
VALVE
226 to 363 Nm
Injection pipe retaining
23 to 37 kgfm
166 to 268 torque
177 to 206 Nm
Injection pump unit
18 to 21 kgfm
mounting nut
130 to t 52 ftIbs
See the Injection Pump Unit Disassembly
and Assemble section
FLYWHEEL
VIEWING THE FLYWHEEL
WESTERBEKE
Engines Generators
ENGINE Valve Clearance
IMPORTANT
Valve clearance must be checked and adjusted when
engine is cold
1 Remove the head cover
2 Align the HC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston gear case side
comes to the compression top dead center
3 Before adjusting the valve clearance of intake valve adjust the TIMING WINDOW
bridge to set the height of intake valve
4 Loosen the lock nut and return the adjusting screw
5 Slightly push the rocker arm intake side by your fingers and
ADJUSTING
screw in the adjusting screw slowly until you feel the screw SCREWS
touch the top of valve stem then tighten the lock nut
6 Loosen the lock nut of adjusting screw push rod side
and insert the thickness gauge between the rocker arm and
the bridge head Set the adjusting screw to the specified
value then tighten the lock nut
7 Adjust the clearance between the rocker arm exhaust side
and the exhaust valve to the specified value
023 to 027 mm
Valve clearance Factory spec
0009t to OOtOS in
IN EX IN EX IN EX
When No1 1s1 0 0 0 0 0 0
piston Is 0
2nd 0 0 ADJUSTING
cDmpressed
Top Dead 3rd 0 0 SCREWS
Cenler 41h
When No1 1st
piston is in 2nd 0 0 0 LOCK NUT
overlap 3rd 0 0
posilion
41h 0 0
S9 to 113 Nm
Cylinder head torque 07 to 115 kglm
screw
51 to 832 ftIbs
ENGINE COLD
023 027mm
00091 00106 in
ENGINE ADJUSTMENTS
When installing the new oil filter element wipe the filter
gaskets sealing surface on the engine block free of oil and
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter Screw the filter onto the threaded oil
filter nipple and then tighten the filter firmly by hand
APPLY CLEAN
ENGINE oL
INSTALLING
OIL PRESSURE OIL PRESSURE
To test the oil pressure remove the oil pressure sender then
install a mechanical oil pressure gauge in its place After
wanning up the engine set the engine speed at idle and read WIPE SURFACE CLEAN
the oil pressure gauge BEFORE PRESSURE WILL RANGE BETWEEN 50 AND 55PSI AT 1800 RPM
LOW OIL PRESSURE
The specific safe minimum oil pressure is 5 10 psi A grad 3 Filling the Oil Sump Add new oil through the oil of oil pressure usually
indicates worn bearings cap on the top of the engine or through the side oil filL
After refilling run the generator for a few moments while
ENGINE OIL CHANGE checking the oil pressure Make sure there is no leakage
1 Draining the Oil Sump Discharge the used oil through around the new oil filter or from the oil drain system and
the sump drain hose attached to the front of the engine stop the engine Then check the quantity of oil with the
while the engine is wann Drain the used oil completely lube oil dipstick Fill to but not over the high mark on the
replace the hose in its bracket and replace the end cap dipstick should the engine require additional oil
securely
NOTE Thread size for the lube oil drain hose capped end Use a heavy duty engine oil with an API of CF
is 114 NPT CG4 CH4 or CI4 Change the engine oil after an initial 50
hours of breakin operation and every 100 hours of operation
thereafter For recommended oil use SAE 15W40
I8mlm 11161 SOCKET
oil viscosity WESTERBEKE recommends the use of
synthetic oil
WIWUIVt USING AN 8MM lJ76 SOCKET
THE OIL OR PUMP THE WARMED
UP THRU THE HOSE
2 Replocing the Oil Filter When removing the used oil
filter you may find it helpful and cleaner to punch a hole
in the upper and lower portion of the old filter to drain the
oil from it into a container before removing it This helps
to lessen spillage A small style automotive filter wrench
should be helpful in removing the old oil filter
NOTE Do not punch this hole without first loosening the
filter to make certain il can be removed OIL GALLERY
Mr WESTERBEKE
Engines Generators
FUEL SYSTEM
Fuel Injection Pressure
1 Set the injection nozzle to a nozzle tester
2 Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle
3 If the measurement is not within the factory replace the adjusting washer 1 in the nozzle holder to adjust
See the and Assembling for nozzle holder
1373 to 1471 MP
Fuel injection pressure Factory spec 140 to 150 kgffem
PRESSURE TEST
1991102134 psi
Reference
Pressure variation with 001 mm 00004 in difference of
adjusting washer thickness
Approx 235 kPa 24 kgfcm 34 psi
Nozzle Spraying Condition
1 Set the injection nozzle to a nozzle tester and check the
nozzle spraying condition
2 If the spraying condition is defective replace the nozzle piece
Valve Seat Tightness
1 Set the injection nozzle to a nozzle tester
2 Raise the fuel pressure and keep at 1275 MPa 130 kgfcm GOOD DEFECTIVE
1849 psi for 10 seconds
3 If any fuel leak is found replace the nozzle piece
No fuel leak at
1275 MP
Valve seat tightness Factory spec
130 kgffem
iB4 psi
DISASSEMBLY ADJUSTING
Nozzle Holder
1 Secure the nozzle retaining nut 7 with a vise
2 Remove the nozzle holder 1 and take out parts inside
When Assemble the nozzle in clean fuel oil
Install the push rod 4 noting its direction
After assembling the nozzle be sure to adjust the fuel injection
pressure NOZZLE
343 to 392 Nm HOLDER 1
Nozzle holder 35 to 40 kgfm
253 to 289 ftlbs
196 to 245 Nm RETAINING NUT torque Overflow pipe nut 20 to 25 kgfm
145 to 18 I ftIbs
49010686 Nm
Nozzle holder assembly 50 to 70 kgfm
362 to 506 ftIbs
yo WESTERBEKE
Engines Generators
FUEL SYSTEM
GLOW FLUGS GLOW PLUGS
To inspect the plug remove the electrical terminal connections
then unscrew each plug from the cylinder head Thoroughly
clean each plugs tip and threads with a soft brush and cleaning
solution to remove any carbon and oil deposits Visually
examine the plug tip for electrical erosion if this is evident
replace the glow plug
Touch one prod to the glow plugs wire connection and the TIP
other to the body of the glow plug as shown A good glow
plug will have a 10 15 ohm resistance This method can TIGHTENING TORQUE
10 15 MKG 7 11 FrLB
be used with the plug in or out of the engine You can also use
an ammeter to test the power drain 8 9 amps per plug FROM INJECTORS
Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 7 to 15 FUEL RETURN
seconds If the plugs dont heat up quickly check for a short
circuit When reinstalling the glow phigs use antiseize
compound on the threads FUEL INJECTION PUMP FUEL RETURN
The fuel injection pump is the most important component of
the diesel engine and therefore calls for the utmost caution
in handli ng The fuel injection pump has been thoroughly
benchtested and should not be tampered with
Speed hertz and timing are the only adjustments the
servicing dealer can perform on the injection pump See the
ENGINE ADJUSTMENT section in this manual Other types
of adjustments or repairs must be performed by a qualified
FUEL FILTER
injection service shop
NOn When servicing the jnjection pump the service shop
must be advised that the pump is being used in a generator
BLEED SCREW THE INJECTION PUMP
BLEEO SCREW SHOULD BE LEFr IN THE
OPEN POSITION mls WILL ALLOW FOR
AIR IN THE FUEL SYSTEM TO BE
ACTUATOR DELIVERED BACK THRU THE FUEL
RETURN SYSTEM DURING ENGINE
OPERATION
FUEL INJECTION FUELIN
PUMP
FUEL LI FT PUMP INLET FUEL FILTER
Periodically check the fuel connections to and out of the 1 Shut off the fuel supply to the generator Disconnect the
pump and make sure that no leakage is present and that the fuel supply line to the inlet filter and unscrew the filter
fittings are tight and secure The DC ground connecl1on at from the pump inlet Take care to catch any fuel that may
one of the pumps mounting bolts should be clean and well be present
secured by the mounting bolt to ensure proper pump
2 Thread on the replacement inlet filter and connect the fuel
When energized thru the preheat circuit the fuel lift pump supply line Use care when connecting and tightening the
will purge air from the fuel system and provide a continuous fuel supply line so as not to distort the inlet filter
flow of fuel as the engine is running
v WESTERBEKE
Engines Generators
RAW WATER PUMP 052650 PARTS LIST
PROPULSION ENGINES AND MARINE GENERATORS
CAM RETAINING SCREW
33KW EOE GENERATOR
HOSE WEAR PLATE
302574
IMPELLER SEE REAR ASSEMBLY BELOW
END COVER
049170 SCREW 4 MG x 125 x 16MM
017012 FLAT WASHER 4 M6 031783
END COVER SCREWS 6
M4x 10x8MM
034463 FRONT ASSEMBLY
NOTE The parts slwwn along with
a glycerine pack are included in
SCREW 4 M6 X 125 X 16MM WESTERBEKES PUMP KiT052650
017012 WASHER 4 031783 with the exception of the pump body
and the adapter flange
SHAFT BALL BEARING 2
ORING nUULUH
SPACER PRESSES AGAIN7
THE ORING SPACER CIRCLIP GROOVE
PINS FIT AGAINST THE LlPSEAL CIRCLIP IVLLI
THE BEARINGS 053366
AGAINST THE CIRCLIP
REAR ASSEMBLY CIRCLIP FITS INTO
GROOVE IN PUMP BODY
WESTERBEKE
Engines Generators
MARINE GENERATORS I
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Engines Generators II
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DISCONnCl TH BATTEU IN AN lEAGUe AMD IHN HVINij IH BOAT A SWITCH
WIIH A conlHUOIiS RATiNG or 15 AMPS H l VOC I n SUY IHIS TUNCTION THIS
SWIICH SHOULD HOT BE USED 10 lAKE OR aRA TH CIRCUI
1 TH PIU WIA AT HUG Z IS UNVSO AND SHOULD BE INSULATED eVTAIN PANH OHLT
4 THE GliAl WIRE AT PLIIG l IS UHUSLD UD SHOULD B IIISUIA1O AOHIAAl PANEL ONLI
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108B 63C 64A 71B
108C
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i Engines Generators
67c J
65A FOUR ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle fresh General Fresh watercooled engine block
watercooled vertical inline overhead valve with heat exchanger
mechanism Operating Temperature 1601800 f7182C
Aspiration Naturally aspirated Fresh Water Pump Centrifugal type metal impeller beltdriven
Compression Ratio 226 1 Raw Water Pump Positive displacement rubber impeller
Governor Electronic geardriven
Combustion Chamber Swirl type Raw Water Flow 170 US gpm 416Ipm
Bore Stroke at 2800 rpm
98 x 110 mm 386 x 493 inches
Piston Displacement 331 lilers 20253 cubic inches System Capacity 160 gpm 151Ipm
fresh water
Hp2800rpm 65
Air Flow Engine Cooling 150 clm 42 cmm
firing Order 1 3 4 2
NOTE The pressure differential between the outside of the engine
Inclination Continuous 14 0 compartment versus the inside of the engine compartment should not
exceed
Temporary 25 not to exceed 10 min 2 inches of water 51 mm at full open throttle measure with a manometer
Weight dry 7321bs 352 kgs
FUEL SYSTEM
TUNEUP General Open flow self bleeding self priming
Compression Pressure 626 psi 44 kgflcm at 250 rpm limit fuel pump
allowable limit 472 psi 305 kglcm fuel No2 diesel oil cetane rating of 45 or higher
Variation between Fuellnjeclion Pump Bosch type mini pump
cylinders 10 or less Fuel Injection Timing yo BlDC spill
Injection Timing 13 8TaC Injector Nozzle Bosch throttle type
Engine Speed rpm Idle 750 1000 fuel filter Spinon type
Cruise 2000 2400 Air Intake Metal screenlintake silencer box
Max 2750 2800 Air Flow Combustion 165 clm 47 cmm
Valve Clearance 023 027 mm
engine cold 000091 00106 LUBRICATION SYSTEM
Injector Pressure 1991 2134 psi 140 105 kgflcm General Pressure fed system wih external relief valve
Valve TIming Intake Opens W BTaC Oil filter Full flow paper element spinon type
Intake Closes 36 ABDC
Sump Capacity 140 US qts 132 liters
Exhaust Opens 45 BBDC includes oil lilter
Exhaust Closes 1yo ATaC
Operating Oil Pressure 28 57 psi 20 40 kgcm
engine hot
ELECTRICAL SYSTEM Oil Grade API Specification CF or CG4 Cf4 or CH4
Starting Battery 12Volt DC negative ground SAE 30 10W30 15W40
Battery Capacty 800 1000 CCA
DC Charging Allernator 60 Amp rated belt driven
EXHAUST
Starter 25Kw 12 VDC direct drive Exhaust Elbow 45
Starting Aid Glow plugs sheathed type Exhaust Hose Size 3 10 762 mm
DC Cranking Current 400 600 includes glow plugs
NOTE Engine Idle Speed must be adjusted with the engille at
nonnal operating temperature Idle speed should be adjusted
in the range specified where it operates the model transmissions will affect engine idle speeds
WESTERBEKE
Engines Generators
33KW EDE
ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle fresh General Fresh watercooled engine block
watercooled vertical inline overhead valve with heat exchanger
mechanism 46 hp at 1600 rpm maximum
Operating Temperature 160 160 F 71 62 C
Aspiration Naturally aspirated
Fresh Water Pump Centrifugal type metal impeller beltdriven
Compression Ratio 2161
Raw Water Pump Positive displacement rubber impeller
Governor Electronic geardriven
Combustion Chamber Swi type System Capacity 16 qts 151 liters
fresh water
Bore Stroke 96 x 110 mms 366 x 433 inches
Raw Water Flow Rate 110 gpm 416Ipm
Piston Displacement 331 liters 20253 cubic inches at 1600 rpm
Firing Order 1342
Inclination Continuous 200 FUEL SYSTEM
Temporary 300 not to exceed 10 min General Open flow self bleeding self priming
Weight dry 11351bs 5146 kgs fUel pump
Fuel No2 diesel cetane rating of 4S or higher
TUNEUP Fuellnjeclion Pump Bosch type minipump
Compression Pressure 626 psi 44 kgfcm at 2S0 rpm Fuel Injection TIming 7 BlDC spill
allowable limit 472 psi 305 kgfcm at 2S0 rpm
Injector Nozzle Bosch throtlle type
Variation between
cylinders 10 or less Fuel Filter Spinon type
Injection Timing 7 BlDC Air Intake Metal screenJintake silencer box
Engine Speed 1600 rpm 60 Hertz Air Flow Combustion lOS cfm 30 cmm
lS00 rpm SO Hertz
Valve Clearance 023 to 027 mm GENERATOR COOLING
engine cold 000091 to 00106 inches
Air Requirements 06 Power factor unit SOD CFM lS0 CMM
Injector Pressure 1991 to 2134 psi 140to lS0 kgfcm generator cooling
Valve Timing Intake Opens 14 BlDC NOTE Increase cooling air flow 15 for slower turning 50hz units
Intake Closes 36 ABOC
Generator Compartment 122 0 F 50 0 C maximum
Exhaust Opens 4S BBDC Ambient Temperature
Exhaust Closes 17 AlDC
AC GENERATOR
ELECTRICAL SYSTEM General 3 Phase Brushless four pole revolving field sealed
Starting Battery 12Volt DC negative ground lubricated single bearing design 12 wire
reconnectable with solid state voltage regulator
Battery Capacity 6001000 CCA
Single Phase Reconnectable to Double Della
DC Charging A1temator 60 Amp rated beltdriven
Voltage 3 Phase Reference connection chart and AC voltages
Starter 2SKw 12VDC direct drive multiple
Starting Aid Glow plugs sheathed type Voltage Single Phase 120 or 1201240 volts 60 Hz
115230 volts SO Hz
DC Cranking Current 260 320 Amps
Voltage Regulation or 2 no load to full rated amperage outlet
LUBRICATION SYSTEM Frequency Regulation or 3 hz 5 no load to full rated amperage
General Pressure fed system with external relief valve outlet
Oil Alter Full flow paper element spinon type
Sump Capacity 14 US qts 132 liters
includes oil filter
Operating Oil Pressure 26 S7 psi 20 40 kIJcm
engine hot
Oil Grade API Specification CF CG4 or CF4
SAE 10W30 lSW40
Engines Generators
330260KW EDE
AC GENERATOR Single Phase I AG GENERATOR 3 Phase
Single Phase Brushless six pole revoMng field Three Phase Brushless spole revolving field Sealed
Sealed lubncated slnglebeanng design 12 lubncated singlebeanng design 12 Lead
Lead reconnectable Double Delta for 1201240 Solid state voltage regulator
volts 60hz Senes Star for 230 volts 50hz
With solid state voltage regulator Vonage 3 phase Low Voltage WYE 240 Volts
60 Hertz High Voltage WYE 480 Volts
Vottage 120 or 1201240 vans 60 hertz DELTA 277 Valls
230 Volts 50 Hertz
Voltage 3 Phase High Voltage WYE 400 Volts
Voltage Regulalion 2 no load to full load 50 Hertz DELTA 230 Regulation 3 Hertz
5 no load to full load Amperage 3 phase Low Voltage WYE 993 Amps
60 Hertz High Voltage WYE 496 Amps
Rating Vans AC DELTA 860 Amps
60 Hz 1800 rpm 120 volts 275 amps
1201240 volts 27511375 amps Amperage 3 phase High Voltage WYE 469 Amps
50 Hertz DELTA 816 Amps
50 Hz 1500 rpm 230 volts 113 amps
Generator Cooling 225 250 cfm 566 637 cmm
Air COOling 500 cfm 141 cmm 60 Hz at 1800 rpm NOlE Increase airsupply 15 far 50 Hertz
Air requirements aperaffan 1500 rpm
Single 3 phase NOlE Increase air supply 15 for 50 Hertz
aperaUan 1500 rpm Generator Compartment 122F 50C maximum
Ambient Compartment 122F 50C maximum NOlE Forred venUlaUan should be Temperature
to maintain generator NOlE Forred ventilation should be provided
temperatures belaw 104F 40C
to maintain generator comparlment
temperatures below 104F 40C
WESTERBEKE
Engines Generators
25521DKW EDE
AC GENERATOR Single Phase AC GENERATOR 3 Phase
Single Phase Brushless six pole revoMng field Three Phase Brushless sixpole revolving field Sealed
Sealed lubricaled design 12 lubricated design 12 Lead
Lead reconnectable Double Della for 1201240 Solid state vollage regulalor
valls 60hz Series Slar for 230 volts 50hz
With solid slate vollage regulator Vollage 3 phase Low Voltage WYE 240 Valls
60 Hertz High Voliage WYE 4BO Valls
Voltage 120 or 1201240 volts 60 hertz DELTA 277 Valls
230 Valls 50 Hertz
Voltage 3 Phase High Vollage WYE 400 Volts
vonage Regulalion 2 no load to full load 50 Hertz DELTA 230 Regulation 3
Hertz 5 no load to full load Amperage 3 phase Low Vollage WYE 76 Amps
60 Hertz High Vollage WYE 3B Amps
Rating Volts AC DELTA 665 Amps
0 Hz 1800 rpm 120 volts 2125 amps
1UIIW 1201240 valls 21251063 amps Amperage 3 phase High Vollage WYE 379 Amps
50 Hertz DELTA 659 Amps
50 Hz 1500 IJIIIO 230 valls 913 amps
UIIW Generator Cooling 225 250 elm 566 637 emm
Air Cooling 400 elm 113 emm 60 Hz at 1BOO rpm NOTE Increase air supply 15 tor 50 Hetlz
rur requlremenls opemOon 1500 rpm
Single 3 phase NOTE Increase air supply 15 tor50 Hetlz
opemNon 1500 rpm Generator Compartment 122F 50C maximum
Ambient Compartment 122F 50C maximum NOTE Forced venOlation should be Temperature
to maintain generator NOTE Foed venOlaOon should be provided
tempellltures below 104F 40C
to maintain genemtor compartment
lempemtures below 104F 40C
285235KW EDE
AC GENERATOR Single Phase AC GENERATOR 3 Phase
Single Phase Brushless six pole revolving field Three Phase Brushless Sixpole revolving field Sealed
Sealed lubncated design 12 lubricated design 12 Lead
Lead reconnectable Double Delta for 1201240 Solid state vollage regulator
volts 60hz Series Star for 230 valls 50hz
With solid state vonage regulator Voltage 3 phase Low Voltage WYE 240 Valls
60 Hertz High Voltage WYE 4BO Valls
Voltage 120 or 1201240 volts 60 hertz DELTA 277 Valls
230 Valls 50 Hertz
Vollage 3 Phase High Vollage WYE 400 VoIIs
Voltage Regulation 2 no load to tuilioad 50 Hertz DELTA 230 Regulation
3 Hertz 5 no load to fuilioad Amperage 3 phase Low Vonage WYE B58 Amps
60 Hertz High Voltage WYE 429 Amps
RatIng Volts AC DELTA 743 Amps
0 Hz 1800 rpm 120volls 2375 amps
1201240 valls 237511 BB amps Amperage 3 phase High Voltage WYE 424 Amps
50 Hertz DELTA 73B Amps
50 Hz 1500 rpm 230 volts 1022 amps
Generator COOling 225 250 elm 566 637 emm
Air Cooling 400 elm 113 emm 60 Hz at 1BOO rpm NOTE Increase air supply 15 for 50 Hetlz
Air requirements opellltion 1500 rpm
Single 3 phase NOTE Increase air supply 15 for 50 Hetlz
opellltion 1500 rpm Generalor Compartment 122F 50C maximum
Ambient Compartment 122F 50C maximum NOTE Forced venNfaNon should be Temperature
to maintain generator NOTE Forced ventilation shoufd be provided
tempellltures below 104F 40C
to maintain generator compartment
tempellltures below 104F 40C
toY WESTERBEKE
Engines Generators
200KW EDER
AC GENERATOR Single Phase AC GENERATOR 3 Phase
Single Phase Brushless sixpole revolving field Three Phase Brushless sixpole revolving field Sealed
Seal lubricated single bearing design 200 Kw 60 Hertz lubricated design 12 Lead
12 lead Double Della for 160 Kw 50 Hertz Solid state voltage regulator
1201240 volts 60hz Series Slar for 230
volts 50hz with solid slate regulator Vollage 3 phase Low Vollage WYE 240 Volts
60 Hertz High Vollage WYE 480 Volts
Vollage 120 or 1201240 volts 60 hertz DELTA 277 Volts
230 Volts 50 Hertz
Vollage 3 Phase High Voltage WYE 400 Volts
Vollage Regulation 2 no load to full load 50 Hertz DELTA 230 Regulation
3 Henz 5 no load to full load Amperage 3 phase Low Vollage WYE 60 Amps
60 Hertz High Vollage WYE 30 Amps
Rating Volts AC DELTA 59 Amps
60 Hz 18011 rpm 120 volts 1666 amps
2O0KW 1201240 volts 1666833 amps Amperage 3 phase High Vollage WYE 289 Amps
50 Hertz DELTA 502 Amps
50 Hz 1500 rpm 230 volts 695 amps
160KW Generator Compartment 122F 50C maximum
Ambient Cooling 400 cfm 113 cmm NOTE Forced ventilation should be provided
Air requirements fa maintain generator 3 phase NOTE
Increase air supply 15 for 50 Hertz temperatures below 104F 40C
operation 1500 Compartment 122F 50C NOTE Forced ventilation should be provided
to maintain generator compattment
temperatures below 104F 40C
260KW EDER
AC GENERATOR Single Phase AC GENERATOR 3 Phase
Single Phase Brushless sixpole revolving field Three Phase Brushless sixpole revolving field Sealed
Seal lubricated single bearing design 260 Kw 60 Hertz lubricated design 12 Lead
12 lead Double Della for 208 Kw 50 Hertz Solid slate vollage regulator
1201240 volts 60hz Series Slar for 230
volts 50hz with solid slate regulator Vollage 3 phase Low Vollage WYE 240 Volts
60 Hertz High Vollage WYE 480 Volts
Voltage 120 or 1201240 volts 60 hertz DELTA 277 Volts
230 Volts 50 Hertz
Vollage 3 Phase High Voltage WYE 400 Volts
Vollage Regulation 2 no load to tuilioad 50 Hertz DELTA 230 Regulation
3 Hertz 5 no load to full load Amperage 3 phase Low Vollage WYE 782 Amps
60 Hertz High Vollage WYE 391 Amps
Rating Volts AC DELTA 678 Amps
60 Hz 18011 rpm 120 volts 2t66 amps
260 KW 1201240 volts 21661083 amps Amperage 3 phase High Voltage WYE 375 Amps
50 Hertz DELTA 653 Amps
50 Hz 1500 rpm 230 volts 904 amps
2O8KW Generator Compartment 122F 50C maximum
Ambient Cooling 400cfm 113 cmm NOTE Forced ventilation should be provided
Air requirements to maintain generator 3 phase NOTE
Increase air supply 15 for 50 Hertz temperatures below 104F 40C
operation 1500 Compartment 12n 50C NOTE Forced ventilation should be provided
to maintain generator compartment
temperatures below 104F 40C
REVISED AUGUST 209
Engines Generators
TORQUE NOTE
For marked screws bolts and nuts on the table apply engine oil to their threads and seats before
tightening
The letter M in Size x Pitch means that the screw bolt or nut dimension stands for metric The size is
the nominal outside diameter in mm of the threads The pitch is the nominal distance in mm between
two threads
Item Size x Pitch Nm kgfm head cover screw 69 to 113 07 to
115 51 to head screw M12x 125 981 to 1079 100 to 110 723 to rod screw M10 x 125
785 to 834 80 to 85 579 to screw M12 x 125 981 to 1078 100 to 110 723 to screw
M16x15 2550 to 2746 260 to 280 1881 to 2025
Main bearing case screw M14x15 1373to 1471 140 to 150 1013 to 1085
Rocker arm br dcket screw M10x125 490 to 559 50 to 57 362 to 412
Nozzle holdor assembly M20 x 15 490 to 686 50 to 70 362 to 506
Nozzle holder 343 to 392 35 to 40 253 to pipe retaining nut M12 x 15 226
to 363 23 to 37 166 to 268
Overflow pipe assembly retaining nut M12x15 196 to 245 20 to 25 145 to 181
Oil switch taper screw R 18 147 to 196 15 to 20 108 to 145
Oil cooler joint screw 392 to 441 40 to 45 289 to 325
Oil pump cover screw 79 to 93 080 to 095 58 to 69
Glow plugs M10 x 125 196 to 245 20 to 25 145 to terminal B mounting nut M8 x 125 98
to 118 10 to 12 72 to 87
Injection pump gear mounting nut M14x15 736 to 834 75 to 85 542 to pump unit mounting nut M8 x 125 177
to 206 18 to 21 case cover M8 x 125 235 to 275 24 to 28 174 to 203
Relief valve retaining screw 686 to 784 70 to 80 506 to 579
Idle gear mounting screw M8 x 125 235 to 275 24 to 28 174 to 203
Plate mounting screw M8 x 125 235 to 275 24 to 28 174 to 203
Camshaft set screw M8 x 125 235 to 275 24 to 28 174 to 203
Flywheel housing mounting screw M12 x 125 775 to 902 79 to 92 571 to 2 mounting screw M10 x 125 490 to
559 50 to 57 362 to pump mounting screw M8 x 125 235 to 275 24 to 28 174 to pump mounting nut
M8 x 125 177 to 206 18t021 130 to 152
Boost Actuator 392 to 451 40 to 46 289 to 333
Governor weight mounting nut M12 x 125 628 to 726 64 to 74 463 to 535
Fuel camshaft stopper mounting screw 79 to 93 080 to 095 58 to 69
WESTERBEKE
Engines Generators
TORQUE Item Size x Pitch Nm kgfm ftlbs
Governor housing mounting screw M6 x 10 98 to 113 10t0115 723 to 832
Antirotation nut M5 x 08 28 to 40 029 to 041 21 to 30
Balancer shaft set screw M8 x 125 235 to 275 24 to 28 174 to 203
Bearing case cover mounting screw M8 x 125 235 to 275 24 to 28 174 to 203
Alternator pulley nut 583 to 789 595 to 805 430 to 582
When the tightening torques are not specified tighten the screws bolts and nuts according to the table below
Standard Screw and Bolt Special Screw and Bolt
Unit Nm kgfm Itlbs Nm kgfm Itlbs
M6 79 to 93 080 to 095 58 to 69 98 to t t3 tOO to 115 723 to 832
M8 t77 to 206 t8 to 2t 130 to 152 235 to 275 24 to 28 174 to 203
M10 392 to 451 40 to 46 289 to 333 48110559 49 to 57 354 to 412
M12 628 to 726 64 to 74 463 to 535 775 to 902 79 to 92 571 to 665
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads Prior to sure to check out the numbers as shown below
Punched number Screw and bolt material grade
None or 4 Standard screw and bolt 8841 S20C
7 Spcial screw and bolt S43C S48C Engines Generators
SPECIAL TOOLS
Diesel Engine Compression Tester
Code No 0790930208 Assembly 0790931251 G
0790930934 A to F
0790931211 E and F
0790931231 H
0790931271 I
0790931281 J
3 4 5 6 7 8 9
Application Use to measure diesel engine compression and
diagnostics of need for major overhaul
ttt 1
Gauge
L Joint
Adaptor F
Adaptor G
3 Adaptor A 9 Adaptor H
4 Adaptor B 10 Adaptor t
5 Adaptor C 11 Adaptor J
6 Adaptor E
Oil Pressure Tester
Code No 0791632032
Application Use to measure lubricating oil pressure
Ii
1 Gauge 5 Adaptor 2
I J 4 5 6 2 Cable 6 Adaptor 3
A tJ 3 Threaded Joint 7 Adaptor 4
4 Adaptor 1 8 Adaptor 5
1 2 3 7 8
Plastigaae
Code No 0790930241
Application Use to check the oil clearance between
crankshaft and bearing etc
Measlring Green 0025 to 0076 mm 0001 to 0003 in
range Red 0051 to 0152 mm 0002 to 0006 in
Blue 0102 to 0229 mm 0004 to 0009 in
Connecting Rod Alignment Tool
Code No 0790931661
Application Use to check the connecting rod alignment
Applicable Connecting rod big end 10
range 30 to 75 mm 118 to 295 in dia
Connecting rod length
65 to 300 mm 256 to 1181 in
Red Check
Code No 0790931371
Application Use to check cracks on cylinder head cylinder
block etc
v WESTERBEKE
Engines Generators
SPECIAL TOOLS
The following special tools are not provided so make them referring to the figure
Engine Stand
Application Use to support engine
c D
E F A 480 mm 1890 in
50 rnm 197 in
If IIIIP
10BS mm 4272 in
263 mm 1035 in
I 1B F
125 mm 0492 in
2375 mm 9350 in
A J 1425 mm 5610 in
H 95 rnm 374 in
I 414 mm dia oS5 in dia
J 40 rnm 157 in
K 210 mm 827 in
L 190 mm 748 in
M 100 mm 394 in
N 6 mm 024 in
0 6 mm 024 In
p 25 mm dia 098 in dia
C10 Chamfer 10 mm 0394 in
Flywheel Stopper for SAE Flywheel and Housing
Application Use to loosen and tighten the flywheel screw
A 140 mm 55 in
A B I C o I
C 493 mm 194 in
l1 0 493 mm 194 in
B 238 mm 094 in
F 238 mm 094 in
G 11 mm dia 043 in dia
H I J H 565 mm 222 in
I 565 mm 222 in
J 8 mm 031 in
Tool for Aligning the Crankcase 1 and 2
Application Use for aligning the crankcase 1 and 2
A 115 mm 45276 In
B 56 mm 22047 in
C 17 mm 06693 in
0 20 mm 07874 in
E 14 mm dia 05512 in dla
F 11 mm dia 04331 In dia
G 14 mm dia 05512 in dia
H 175 mm 06890 in
I 175 mm 06890 in
J 35 mm 13780 in
K 19 mm 07480 in
WESTERBEKE
Engines Generators
SPECIAL TOOLS
Gear Case Oil Seal Replacing Tool
A Application Use to press fit the oil seal
B A 1488 mm 58582 in
f B 50 mm 19685 in
E C 188 mm 07401 in
L D 137 to 139 mm 05394 to 05472 in
E 11 mm O433 in
IF G H I J K F 18 mm dia 07087 in dia
G 38 rnm dia 14961 in dia
h L
H 45 rnm dia 17716 in dia
I 579 to 581 mm dis 22795 to 22874 in dia
M J 795 mm dia 31299 in dia
K 87 mm dia 3452 in dia
L 12 mm 04724 In
M 40 mm 15748 In
N 120 mm 47244 in
Small End Bushing Replacing Tool
Application Use to press out and to press fit the small end
bushing
C Press oul
A 157mm61811 in
0 FI B 145 mm 0571 in
C 120 mm 47244 in
c1 71
a b
C1 C2 D
300 mm dis 11811 in dia
3295 mm dia 12972 in dia
F 20 mm dla 07874 in dia
a 63 Jim 250 In
b 63 tim 250 pin
C1 Chamfer 10 mm 0039 in
C2 Chamfer 20 mm 0079 in
Press Iii
A 157mm61811 in
B 145 mm 0571 in
C 120 mm 47244 in
D 300 mm dia 11811 in dia
E 42000 mm dla 16535 in dia
F 20 mm dia 07874 in dia
a 63 pm 250 pin
b 63 pm 250 lin
C1 Chamfer 10 mm 0039 in
C2 Chamfer 20 mm 0079 in
Engines Generators
SPECIAL TOOLS
Injection Pumo Gear Puller
Application Use for remove the injection pump gear governor shaft
A 10 rnm dia 039 in dia
B M16 x Pitch 15
C 19 mm 075 in
0 05 mm radius 002 in 5 R G
089 rad 50
10 mm O39 in
20 mm 079 in
H 5 mm 020 In
I 95 mm 374 in
J 125 rnm 493 in
K 5 mm 020 in
L M16 x Pitch 15
M 30 mm 118in
N 95 mm 03740 in
0 11 mm 04331 in
p 95 mm 03740 in
Q 155 mm 06102 in
R 45 mm radius 01 B in radius
S 20 mm 079 in
T 20 mm 079 in
U 80 mm 31496 In
W 12 rnm 047 in
C2 Chamfer 20 mm 0079 in
Idle Gear Bushing Replacing Tool
Application Use to press out and to press fit the bushing
1 For idle gear bushing
L C
A 196 mm 77165 in
B 37Smm 1476 In
0 FI C 150 mm 59055 in
0 4495 mm dia17697 in dia
ci b Cl C2 E 48100 to 48075 mm dia 18937 to 18927 in dia
F 20 mm dia 07874 in dia
a 63 lim 250 liin
b 63 Jim 250 Jiin
Cl Chamfer 10 mm 0039 in
C2 Chamfer 20 mm 0079 in
Engines Generators
SPECIAL TOOLS
Valve Guide Replacing Tool
Application Use to press out and press fit the valve guide
o Intake valve guide
E F
A 20 mm dia 079 in dia
B 117 to 119 mm dia 0460 to 0468 india
C 65 to 66 mm dia 0256 to 0259 india
f2 Cl C1
0 225 mm 886 in
A B C E 70 mm 276 in
F 45 mm 177 in
G 25 mm O9B in
H I 67 to 70 mm dia 0263 to 0275 india
J 20 mm dia 0787 india
K 125 to 128 mm dia 0492 to 0504 india
L B9 to 91 mm 0350 to 0358 in
Cl Chamfer 1 0 mm 0039 in
C2 Chamfer 20 mm O079 in
CO3 Chamfer 03 mm 0012 in
Exhaust valve guide
A 20 mm dla 079 in dia
B 1296 to 1298 mm dia 0510 to 0511 india
C 750 to 770 mm dia 0295 to 0303 india
0 225 mm 866 in
E 80 mm 315 in
F 40 mm 157 in
G 145 to 155 mm 057 to 061 in
H 5 mm 0197 in
I 80 to 81 mm dia 031 to 032 india
J 175 to 185 mm dia 0689 to 0728 indla
K 131 to 132 mm dia 0516 to 0520 india
L 99 to 101 mm 0390 to 0398 in
Cl Chamfer 10 mm 0039 in
C2 Chamfer 20 mm 0079 in
CO3 Chamfer 03 mm 0012 in
Balancer Bushing Replacing Tool 1 Assembly
Application Use to press fit the bushing
No name of ParI Qly Remarks
1 Shaft 1
2 Piece 1 1
3 Piece 2 1
4 Boll 2 M6 x Pl0
WESTERBEKE
EngInes Generators
SPECIAL TOOLS
Jig for Governor Connecting Rod
Application Use for connecting the governor connecting rod to
the rack pin of the fuel injection pump assembly
A A1 mm O0394 in radius V 3 rnm 01181 In
B Chamfer 02 mm 00079 in W 10 mm 03937 in
C Chamfer 2 mm OOlB in X a mm 03150 in
D 35 rnm dia13780 in dia
E Chamfer 1 mm 00394 in
F Chamfer 01 rom 00039 in
G R1 mm 00394 in radius
1 Malenai 845CD 2 Permanent Magnet a rnm H Chamfer 02 rom 00079 in
03150 in dia i RS mm 03150 In radius
Thickness 3 mm 01181 in
J Rl mm 00394 in radius
K Rl rom 00394 in radius
L Chamfer 02 rom 00079 in
M Chamfer 02 mm 00079 in
N 29 0 6 mm O2362 inj
p 107 mm O4213 in
a 35 mm 13780 in
R 993 mm 39035 in
8 4565 to 4575 mm 17972 to 18012 in
T 145 mm 57087 in
u 1615 to 1635 mm dia 06359 to 06439 in dia
Auxlhary Socket for Fixing Crankshaft Sleeve
A CO2 C3
Application Use to fix the crankshaft sleeve
A Rmax t25 S
B 945 to 950 mm 37205 to 37402 in
BCD C 40 mm 15748 in
D 30mm 11811 in
E 12 mm 04724 in
F 79 to 81 mm O3110 to 03189 in
E L G 20 mm O078 in
G H 130mm51181 in
i 99410 996 mm 3913410 39213 in
J 9505 to 9520 mm 37421 10 37480 in
FO K 3 mm dia 01181 indla
L 15 mm 05905 in
H I J r M 10 mm 03937 in
N 90 mm 35433 in
0 115 mm 45275 in
p 16910 171 mm 0665410 06732 in
Cl Chamfer 10 mm 0039 in
N C3 Chamfer 30 mm 01181 in
LM 9 C5 Chamfer 50 mm 01969 in
CO2 Chamfer 02 mm 00079 in
1603 Chamfer 03 mm 00118 in
Engines Generators
SPECIAL TOOLS
Balancer Bushing Replacing Tools 3 4 5
la Application Use to press fit the bushing
4 No Name of Part Oy
1 Bracket 1
2 Flange Nul 1
3 Washer 1
4 Shaft 1
5 Piece 1
2 1
1 K7
AA 6
Crevis
Washer
8 8 Cotter Pin 1
9 Joint 1 1
10 Piece 2 1
3 9 4
11 Joint 2 1
12 Piece 3 1
a Tool 3 e Tool5
2 b Tool4 A Section
Balancer Bushing Replacing Tool Components parts
1 Bracket
A 12 mm 047 in
3 11 4
8 50 mm 197 in
C Chamfer 1 mm 004 in
0 60 mm 315 in
E 104 mm 409 in
F 22 mm 087 in
G 13 mm dia 051 in dia
F A B
2 Shaft
A 44 mm dia 173 in dia
B 12 mm 047 in
o E C Chamfer 1 mm 004 In
c 0 3 mm 012 in
E 3 rnm 012 in
A F 30 mm 118in
G 38 mm 138 in
H 35 rnm 136 in
I M12 x P125
J 53 mm 209 inl
K 4 mm 016 in
L 75 mm 295 in
M 57 mm 224 in
70 mm 276 in
0 195 rnm O77 in
p 12 mm 047 in
0 08 mm O03 in
A 6 mm 024 in
WESTERBEKE
Engines Generators
SPECIAL TOOLS
3 Piece 1
A 26 mm 102 in
B 18 mm 071 in
C 165 to 170 mm 06496 to 06693 in
0 15 mm 006 in
E 540 to 542 mm dia 21260 to 21339 in dia
F 5055 to 5075 mm dia 19902 to 19980 in dia
G 16 mm 063 in
H Chamfer 1 mm 004 in
I 85 mm dia 033 in dia
J 04 mm DOIS in
K 3 mm 012 in
L 19 mm 075 in
M Chamfer 05 mm 002 in
N 36 mm 142 in
0 45 mm dia 177 in dia
p 078 rad 45
Q 115 mm 045 in
4 Joint 1
M12 x Pl2S
Chamfer 1 mm 004 In
85 mm 335 in
70 mm 276 in
cfD I 1 C 30 mm dia 118 in dla L 178 mm 701 in
A rB 0 13 mm dia 051 in dia
G I
E Chamfer 3 mm 012 in
H K F 3mmO12in
J 45 mm 177 in
H 75 mm 295 in
I 57 mm 224 in
5 Piece2
A A 26 mm 102 in
B 18 mm 0l1 in
C 165 to 170 mm 06496 to 06693 in
l L rJ
15 mm 006 in
535 to 537 mm diet 21063 to 21142 in dla
E F nl
1 Q
F 5005 to 5025 mm dia 19705 to 19783 in dia
G 16 mm 063 in
Chamfer 1 mm 004 in
85 mm dia 033 in dia
J 04 mm 00157 in
K L 19 mm 075 in 0 45 mm dia 177 in dia
M Chamfer 05 mm 002 in P 078 rad 45
N 36 mm 142 in Q 115 mm 045 in
v WESTERBEKE
Engines Generators
SPECIAL TOOLS
6 Joint 2
A M12 x P125
8 Chamfer 1 mm 004 in
ctDI
30 mm dia 118 in dia
13 mm dia 051 in dia
Chamfer 3 mm 012 in
H K F 3 mm 012 in
J G 45 mm 177 in
H 75 mm 295 in
I 57 mm 224 in
J 85 mm 335 in
K 70 mm 276 in
L 394 mm 1551 in
7 Piece 3
A 26 mm 102 in
8 18 mm O7t in
C 165 to 170 mm 0649610 06693 in
D 15 mm 006 in
E 530 to 532 mm dia 20866 to 20945 in dia
F 4955 to 4975 mm dia 19508 to 19587 in dia
G 16 mm 063 in
H Chamfer 1 mm 004 in
I 85 mm dia 033 in dia
J 04 mm 00157 in
K 3 mm 012 in
L 19 mm 075 in
M Chamfer 05 mm 002 in
N 36 mm 142 in
0 45 mm dia 177 in dia
p 078 ad 45
Q 115 mm 045 in
Engines Generaors
SPECIAL TOOLS
Balancer Bushing Replacing Tool 1 Componenls Parts
A 1 Shaft
E B F A 498 mm 1961 in
D F B 3188103192 mm 125726 to 125669 in
G tt K
1028101032 mm 4047210 40630 in
60 mm 236 in
J M
N t
I E
8 mm 031 in
5 mm 020 in
x y G 30 mm dla ttS in dia
H 65 mm dia 256 in dia
I 6 mm 024 in
J Chamfer 1 mm 004 in
K 53 mm dia 209 in dia
L 547 to 549 mm dia 21535 1021614 in dia
M 026 rad 15
N Chamfer 05 mm 002 in
0 41 mm dla 161 in die
p 32 mm dla 126 In dia
Q 33961 to 340 mm die 1330 to 13386 in dia
A 18 mm dia 071 in dla
S 1996710 200 mm dla 07861 to 07874 In die
U 3 mm 012 in
V 1491 to 1494 mm 58701 to 58819 in
W 3651 to 3654 mm 143740 to 143858 in
X 123 mm 484 In
y 375 mm 1476 in
Z M6 x Pl0 depth 7 mm 028 in
a Chamfer 2 mm 008 in
2 Piece 1
A Chamfer 01 mm 0004 in
B 1 mm 004 in
B C Chamfer 1 mm 004 in
D E C G 0 53810539 mm dia 2118110 21220 in dia
E 20021020041 mm dia 0788210 07890 in dia
F 48 mm dia 189 in dia
C G 49934 to 4994 mm dia in dia
J H 8 mm 031 in
I 2 mm 008 in
J 35 mm 138 in
K 5 mm 020 in
L 026 rad 15
Engines Generators
SPECIAL TOOLS
3 Piece 2
A Chamfer 01 rnm O004 in
8 1 mm 004 in
B C Chamfer 1 mm 004 in
C F
o E G D 54310544 mm dia 2137810 21417 in dia
AL E 34025 to 3405 mm dia 13396 to 13406 in dia
r J K
F 485 mm dia 19094 in dia
G 50421 to 5044 mm dia 19851 to 19858 in dia
J H 8 mm 031 in
I 2 mm OOB in
J 35 mm 138 in
K 5 mm O20 in
L 026 rad 15 0
Balancer Bushing Replacing Tool 2
A Application Use to press fit the bushing
A 35 mm 138 in
8 33 mm 130 In
C Chamfer 05 mm 002 in
E F G H
D 1 mm O04 in
E Chamfer 1 mm 004 In
L F 40 mm dia 157 in dia
M G 50921 to 5094 mm dia 20048 to 20055 in dia
H 548 to 549 mm dia 21575 to 21614 in dia
I 30 mm dia 118 in dia
J 49 mm dia 193 In dia
K 6 mm 024 in
L 125 mm 492 in
M 160 mm 630 in
N 3 mm 012 in
0 5 mm 020 in
p 026 rad 15
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 indi
more than is required to keep it running after it is started cated by the motors require much more current to start them than
others Splitphase AC motors require more current to start
o When the generator is run at 1800 RPM the AC voltage
output frequency is 60 Hertz
under similar than other types They are com
Therefore to change the generators the
monly used on easystarting loads such as or where loads are applied after the motor is generators drive engines speed must be changed
using the
dips witch on the ECU The AC output configuration of the
started such as small power tools Because they require 5 to
7 times as much current to start as to run their use should be generator changed and the connections on the whenever possible if the
electric motor is to be dri sensing PC board changed
ven by a small generator Capacitor and Generator require from 2 to 4 times as much current to start as
to run The current required to start any motor varies with the
o Maintaining reasonable cleanliness is important
Connections of terminal boards and rectifiers may become
load connected to it An electric motor connected to an air corroded and insulation surfaces may start conducting for example will
require more current than a
salts dust engine exhaus carbon etc are allowed to
motor to which no load is connected build up Clogged ventilation openings may cause exces
In general the cunent required to start 115bIt motors connected sive heating and reduced life of windings
to medium starting loads will be approximately as follows o For unusually severe conditions thin petro
MOTOR SIZE AMPS FOR AMPS FOR leumbase coatings should be sprayed or brushed over all
HPJ RUNNING
AMPERES
TARTIN
AMPERES surfaces to reduce rusting and corrosion Typical materials
16 32 64 to 224 suggested are Daubert Chemical Co NonRust AC4o
114 46 92 to 322 and Ashland Tectyle 506 or equivalent
113 52 104 to 728 o The drive discs on single bearing generators should be
112 72 144 to 292 checked periodically if possible for tightness of screws
314 102 204 to 408 and for any evidence of incipient cracking failure Discs
1 13 26 to 52 should not be allowed to become rusty because rust may
accelerate cracking The bolts which fasten the drive disc
NOTE In Ihe above lable Ihe maximum Amps for Starting is to the generator shaft must be hardened steel SAE grade
more for some small molors Ihan for larger ones The reason 8 identified by 6 radial marks one at each of the 6 cor
for Ihis js Ihallhe hardesl slaning types Splilphase are nol ners of the head
made jn larger sizes
o The rear armature bearing is lubricated and sealed no
Because the heavy surge of current needed for starting maintenance is required However if the bearing is required for only an
instant the generator will not noisy or have it replaced
be damaged if it can bring the motor up to speed in a few o Examine bearing at periodic intervals No side If difficulty is experienced
in starting motors turn of shaft should be detected when force is applied if side
off all other electrical loads and if possible reduce the load motion is detectable bearings are wearing or wear on
on the electric motor shaft of bearing socket outside bearing has occurred
Repair must be made quickly or major components wiJI
Required Operating Speed rub and cause major damage to the generaor first with no load applied
then at half the Carbon Monoxide Detector
generators capacity and finally loaded to its full capacity as
WESTERBEKE recommends mounting a on the generators data plate The output voltage
monoxide detector in the vesssels Jiving quarters Carbon
should be checked periodically to ensure proper operation of
Monoxide even in small amounts is deadly
the generating plant and the appliances it supplies If an AC
voltmeter or ampmeter is not installed to monitor voltage and The presence of carbon monoxide indicates an exhaust leak
load check it with a portable meter and amp probe from the engine or generator or from the exhaust elbow
exhaust hose or that fumes from a nearby vessel are
entering your boat
If carbon monoxide is present ventilate the area with clean
air and correct the problem Engnes Generators
TWELVE LEAD BOARD CONNECTIONS
AND NOMINAL VOLTAGES L
SERIES WYE L PARALLEL WYE 12
1
SERIES
STAR 3
PARALLEL
STAR N
SERIES
DELTA 10
L L
9 L L 91 8N7 L
1011 23 67 1012 24 68 1011
0 0 0 12 o
o o
5 9 13 57 112 98
911
0 0
Ll l2 L3 N Ll L2
L3 N Ll L2 L3
50 Hz LL 400 volts 50 Hz LL 200 volts 50 Hz LL 230 volts
50 Hz LN 230 volts 50 Hz LN liS volts 50 Hz tN 115 volts
60 Hz LL480 volts 60 Hz LL 240 volts 60 Hz LL 277 volts
60 Hz LN 277 volts 60 Hz LN 138 volts 60 Hz LN 138 volts
Refer to Note 1
L L
PARALLEL THREE PHASE 2
DELTA ZIGZAG
11 N
lOt 4 6 5
L 6 5 L L N 3 L L
1012 24 68 1012 24 68 810 212
0 0 0 3711
o 0
1 3 5 7 9 11 1 3
Ll L2 L3 N 11 l2 II L2
L3 N
50 Hz LL 115 volts 50 Hz LL 230 volts 50 Hz LL 346 volts
60 Hz LL 138 volts 50 HzLN ll5 volts 50 Hz LN 200 volts
60 Hz LL 277 volts 60 Hz LL4IS volts
DOUBLE 60 Hz LN 138 volts 60 Hz LN 240
volts
DELTA Refer to Note 1 Refer to Note 2
7 10
DOUBLE
L 4 1 L DELTA
2WlRE
7 10
811 23 69 Note 1 Single phase ampemge load
o 0 TIe phase current must 110 exceed the L 4
N
o nomillal vallie
1 10 5 12 7 4 811 23
69
Nole 2 1711ee phase zigzag cOlnection
The rated power must be nwZlipied by
0866
C 0
1 10 5 12 7 4
50 Hz 1L 230 volts
50 Hz 1N 115 volls
60 Hz L1 240 volts N
II
60 Hz LN 120volts 50 Hz LN 230 volts
60 Hz LN 240 vollS
Engines Generators
ELECTRONIC REGULATION SR72G AVR
AMP FUSE
ADJUSTABLE THRESHOLD
OVERLOAD PROTECTION
ADJUSTABLE THRESHOLD
OF UNDERSPEED
PROTECTION INTERVENTION
DO FOR 60Hz
rnl REMOVE FOR 50Hz
o EXCITER voltage regulator AVR ensures optimum AC generator In both of these cases tlle SR72 supply can vary
from 80 TIlis advanced design AVR is equipped with 270 VAC But it should be noted that terminals 2 and 3
circuitry protection to guard against operating conditions tllat should be bridged for supply with voltage between 80 and
could be detrimental to the AC generator The following 160 VAC while the same terminals should be left open if details the voltage
regulators adjustments and voltage is between 160 and 270 These procedures should be performed by a Sensing Sensing
should be connected to terminals 4 and S
qualified technician and can vary from 80 to 350 VAC The sensing is single
phase only and therefore is normally connected to one
TERMINAL CONNECTIONS alternator phase
1 Excitation field DC negative Operation at 60 Hz When operating at 60 Hz terminals SA
2 Exciter field jumper to 3 if the regulator AC supply and 6 should be connected to each other in order to keep tlle
between S and 3A is less than 160 VAC low frequency protection correctly Exciter field DC Supply voltage to regulator Ae
4 Sensing voltage
A WARNING Be aware that high voltages may be
present Take all necessary precautionms to safe guard
5 Supply voltage to regulator Ae against electrical hazards
6 Jumper to SA for 60 Hz Not used
5B Npt used
FUNCTIONS OF THE REGULATOR Volt Witll this it is possible to adjust the
5C Sensing voltage voltage generated by the alternator in a very simple way If
POSSIBLE CONNECTIONS the screw is tumed clockwise the voltage increases if tlle
screw is turned it Field The exciter field negative should be
connected to terminal 1 of the electronic regulator normally Stab This potentiometer optinlizes altemator blue or black while the positive
nonnally red or If turned clockwise the stability decreases and the should be connected to terminal 3
time decreases but the voltage tends to be less stable If
turned the response time increases and the
Supply There are two voltage tends to be more stable
1 The supply coincides with the sensing In tllis case the In order to adjust tlIis potentiometer cOlTectly we advise
SR712 supply should be connected to tenninals 3 and S using the following metllod
in case of threephase generators terminal S is normally
connected Witll the star point Ternnnals 3 and 4 should 1 The generator must be working starting frolll zero load
be connected to each otller in such a way that the supply and the potentiometer must be at maximum stability
is also sensing This connection in necessary when the turned fully generator does 1I0t have auxiliary winding for supplying
2 Slightly tum clockwise until tlle light generated by tlle
the regulator filament lamp oscillates at this point tUIll tlle
2 The supply and sensing separate Tins is the case of a potentiometer slowly until tlle light
generator equipped with auxiliary winding for regulator stabilizes
supply Supply is always connected to terminals 3 and 5
of the regulator
Engines Generators
ELECTRONIC REGULATION SR72G AVR TRlIHAl aLOCK CONCTIONS
SMOWH AR COHrlGURO
fOR lOH tOHoa VAt
Hertz With this which is normally
then sealed by the manufacturer it is possible TO AC SENSE
to adjust the low frequency protection intervention To CONNECTIONS

recalibrate this protection you must take the generator to a
nonnal zero load condition tum the potentiometer
0 0
clockwise until the limit position is reached then decrease
the nominal speed by 10 Then turn the potentiometer REFER TO THE COMPLETE
and measure the voltage value until it has WIRING DIAGRAM 52951
decreased by 5 volts
When the speed decreases by more than 10 of the nominal
value the voltage also decreases blocking
IN THIS MANUAL
n IT
generator overheating Even if we advise calibrating this
5
protection at 10 of the nominal value it is obviously
possible to calibrate the threshold at other values
15 4
Amp With this it is possible to adjust the CJ
plm i
intervention level of the overload protection This protection
system has an intervention delay which permits a temporary
overload necessary when starting motors or similar
I I I Itl
To modify this protection you must overload the generator I 0
I
by 15 of the normal load turn the potentiometer to
minimum and wait about twenty seconds
During this period of time the voltage value decreases In this
condition and while turning the potentiometer clockwise fix
t r l
EXCITER
the generator voltage value at 10 less than the nominal one
At this point while the initial overload is being removed the
voltage increases to the nominal value 1f II SlU
G I
Fuse The electronic regulator is equipped with a fuse which
protects the alternator from overheating in cases of regulator
malfunction The fuse 250V5A quick acting F type can be
I I
replaoed easily TO PANEL
FUSE
ROTOR
INTERNAL WIRING DIAGRAM
12 WIRE RECDNNECTABLE 1
r i
I r 9
I I r I 8
EXCITER
I ROTOR
COMPONENT
I
r i VALUES IN OHMS
AT 86F
I ill iJ J r
I iI I DIODE T r
STATOR
each wlndlng 0041
I I I I I I
I L I L I
AUXIlIARY 09
L r 1 EXCITER STATORll3
EXCITER ROTOR O 72
IL IlIlllllWUIJ F
each pair
ROTOR 27
1111 p I III
hO W NOTE EXCITER DC VOLTAGE I AUXILIARY VOLTAGE
o IncJ NO LOAO 70 VUC 215 VAC
FULllOAU 140 VUC 222 VAC
D VOLTAGE RmULATOR
YEllOW
Engines Generators
GENERATOR SERVICING
TESTING THE MAGNETIC PICK UP COIL MAGNETIC PICKUP MPU INSTALLATION
Test the speed sensor connector for voltage and resistance The MPU is installed in the threaded opening on the side
values of the flywheel bellhousing This positions the MPU over
If the values are correct remove and inspect the magnetic the teeth of the flywheel ring gear
pick up With the wires disconnected unscrew the Viewing through this opening manually rotate the engine
magnetic pick up from the generator housing and visually crankshaft so as to position the flat of one of tlle ring
inspect the contact end If any damage is detected replace gears teeth directly under the opening Thread the MPU
the unit into the opening until it gently contacts the flat of this
tooth Thread is 38 x 24 Back the MPU out of the
NOTE the installation instructions opening one tum and then lock it in this position with
provided with the new magnetic pick up coil
the jam nut This will position the end of the MPU
approximately 0030 inches away from the flats of the
SPEED SENSOR TEST VALUES
ring gear teeth
Voltage whIle cranking
15 25 VAC To enure the MPU is positioned correctly slowly rotate
the crankshaft by 360 by hand to assure there is no
physical contact between the MPU and the ring gear teeth
If contact is felt between the MPU and the flywheel teeth
Resistance al rest 950 1000 ohm
the MPU may be damaged Remove the MPU and inspect
it Replace if necessary and repeat the above
installation NOTE When replacing the Magnetic PickUp MPU it
MUST be replaced without cutting and splicing into the
existing wiring cable Doing so will cause a erratic AC
signal to the controller
003010
WESTERBEKE
Engines Generators
GENERATOR NOTE AC GENERATOR MUST
BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ
FAULT PROBABLE CAUSE
NO AC VOLTAGE OUTPUT AT NO LOAD 1 Short or open in the 4 Open in exciter
main stator winding stator winding
2 Shorted suppressor 5 Open in rotating
on exciter rotor field winding
3 Four or more shorted or 6 Shorted condenser
open diodes on exciter rotor on exciter VOLTAGE PRODUCED AT 1 Blown 6 AMP fuse 3 Shorted or open main
NO LOAD 15 20 VOLTS AC auxiliary circuit feed to AVA stator auxiliary winding
2 Faulty voltage AC VOLTAGE OUTPUT AT 1 Reset voltage 4 Faulty voltage regulator
NO LOAD 60 100 VAC
2 Open or shorted diodes in 5 Short in rotating field winding
exciter rotor 1 to 3 diodes
3 Open or short in one of the three 6 Short in the exciter stator
exciter rotor 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
EDE GENERATOR TESTING THE VOLTAGE
THE POSITIVE TEST LEAD
TO THE BATTERY f TERMINAL
ON THE STARTER THE NEGATIVE TEST LEAD
TO THE CASE TO GROUND
VOLTAGE
TO EXCITE THE GENERATOR
1 Lift the DC yellow wire and the DC blue wire off 4 Connect the black test lead to the metal case ground
the regulator Attach the test leads to these wires as of the generator This will now put a 12VDC circuit
shown black to the blue wire red to the yellow wire through the exciter stalor of the generator
2 Connect the red test lead to the battery voltage 5 AC output voltage should be aboUl 30 higher lhan normal
12VDC at the battery cable connection on the adjacent This indicates that the exciter stator main rotor and stator
starter motor solenoid windings are OK
3 Open the generators AC breaker start the generator and 6 Monitor the auxiliary circuit voltage inlo tile regulator
observe the AC output voltage between the line and correct vollage should be 220 230 VAC indicating this
neutral residual l520VAC circuit is ok
v WESTERBEKE
Engines Generators
EXCITER ROTOR VOLTAGE EXCITER ROTOR TESTING THE EXCITER ROTOR WINDINGS
AND ROTATING FIELD These windings are tested in pairs A to B B to C and C to A
as shown on the the exciter field so the is visible at the 12 OClock THE ROTATING FIELD the ohm meter probes on the two large red wires
and These are the connecting wires for the rotating wires do not need to be lifted off their when testing there is an ohm valve discrepancy or a
continuity to ground the rotor shaft
If this occurs lift these two large field wires off the diode
plates isolate them and repeat the above test
NOTE When removing these wires be careful notto drop the
screws or washers into the rotor
EXCITER ROTOR WINDINGS
Disconnect these three wires from the diode bridge plates
taking care not to drop any screws or washers
With the wires clear from the bridge plates test each pair
with an ohm meter A to B B to C and C to A
No continuity should be found between the rotor and any of
these three winding pairs
TESTING THE DIODES
Diodes can be checked with an ohmmeter Disconnect the
VIEW OF ROTOR wire of the particular diode and test its resistance in both
FROM THE directions A perfectly functioning diode will show a very
BEARING END high resistance in one direction and a very low resistance in
the opposite direction A faulty diode will show either a very
12 aCLOCK POSITION low resistance or an infinite resistance in both directions
Should the whole bridge be replaced remember to tighten
the screws with a suitable wrench and strictly comply with
the polarities and internal wiring diagrams in manual
fDIDDE
WESTERBEKE
Engines Generators
INTERNAL WIRING SCHEMATIC
EXCITER FIELD
TRANSIENT
r i
I I
I EXCITER ROTOR I
I WINDINGS
I I
I I
I 6 I
I IDt
I j DIODE I
1 I
GREEN
EXCITER ISOLATION
DIODE PLATES
Engines Generators
CHANGING HERTZ AND VOLTAGE
3 There are three line connections When an L3 is not
A CAUTION As a precaution against an present on the AC tenninal block insulate and tie off
the L3 connection from the Voltage Sensing Board
URlntlmttonat
on the control panel 4 Inside the control box locate the ECU and position the
dip switch in the correct position for the
desired
1 Refer to the previous page that illustrates the various AC
voltage output for both the 60 Hertz and 5 Verify all connections are correct and tum off any AC
50 Hertz applications Select the configuration for the panel breakers
HertzIVoltage required 6 Start the generator and monitor Ule AC output voltage at
2 Reconfigure the 12 AC connections on the tenninal the generators tenninal board Line to line line to neutral
board carefully following the illustration Reference Adjust the voltage regulator board as needed to obtain the
below the voltage sensing diagram and its connections correct voltage Check the generator with
to the AC tenninal block There are three line your hertz meter
connections when needed and a neutral These 7 Turn on the AC panel breakers and load unit and monitor
connections MUST correspond to and be connected to the operation
the line L connections on the AC tenninal board and DIP SWITCH
the neutral connection as well to its connection Failure to properly connect these voltage
sense connections can result in an AC output voltage WHEN CHANGING mE fault shut down either from low or high AC voltage
or FREQUENCY 50160 HZ SWITCH 11
incorrect AC voltage displayed on the LCD display ON mE CONmOL PANEL ECU
BOARD MUST BE SWITCHED ECU When reconfiguring the AC output ensure that the ON FOR 50 HZ AND OFF FOR
60 HZ
AVR Neutral and line connections are properly connected to
the AC terminal block
AC OUTPUT VOLTAGE SENSING BOARD o
116WHTEJ
lID 0
lID
60 HZ JUMPER TIl 110
f IB 4 10
o iO
IREMOVE rOR
50 HZI 0 0 1111 0
8 I
III II
II II
2 o
oouBLE DELTA
13W1RE SPLIT SINGlE PHASE
OOUBLE 08TA
12WIRE SINGLE PHASE
o 120240V60 H1
IIO220VSO HI 240V60 Hz
220V50 HI
255330 EDE IPHASE 3PHASE NOTE Tie off the L3 sensing
connection when not in use
y WESTERBEKE
Engines Generators
MECC ALTE GENERATOR
inspect the rotor carrier bearing Replace this Remove all dirt oil grease and dust build up from the
bearing at 10000 hours of normal operation or sooner if external surface of the generator Buildup reduces heat
wear is evident dissipation and causes the AC generator end to operate at a
Inspect and clean the control box interior look for loose higher temperature This results in a loss of efficiency and
broken or burned wires and terminals Use low air pressure reduces service life
25 psi max to remove dirt and dust from BEARING SUPPOR
BRACKfT
PARTS it become necessary to disassemble the statorrotor 4 Support the rotor assembly with a sling and using a
assembly from the engine use the following as a guide 17mm box wrench unbolt the rotor assembly from the
1 Properly supporlllift the rear of the engine to allow the flywheel
generator to be unbolted from the rear support isolators
2 Mark then disconnect the that exit the
generator from their connections in the control box Be
sure to properly mark the connection points the generator
leds connect to Make an illustration if needed whether
the generator is to be reinstalled or a replacement is to
be installed This is to ensure proper reconnection of
Unbolt the control box and lift it off the
generator
3 Remove the rear vent cover Support the generator with a
sling or fabricated lifting eye Using a 17mm socket
wrench remove the four bolts that attach the generator
stator housing assembly to the flywheel housing
carefully work the stator assembly off the rear bearing
and off and over the rotor assembly
DISC
EnQlnes Generators
MECC ALTE GENERATOR
ASSEMBLY OF THE GENERATOR TO THE ENGINE
1 Position the rotor assembly onto the flywheel aligning the 4 Rotate the generator by hand two full revolutions to
holes in the drive discs with the holes in the flywheel ensure the generator rotates freely Reinstall the rear
Install the M8 x 125 x 25mm bolts blue loctite on ventcover
threads and torque to 21 Nm 16 ftlb Install a threaded S Secure the generator to its rear isolators Route the
rod MI2 x 175 x 90mm long into the threaded end of generator wiring into the control box and mount the
the rotor shaft control box to the generator Reconnect all wire
connections test run
M8 X 125 X 25MM DRIVE
2 With the aid of a sling or fabricated lifting eye support
the stator housing assembly and carefully guide it over
the rotor assembly until the rear bearing contacts the
bearing boss in the rear support
3 Place a large washer of at least 80mm in diameter with a
center hole of 15mm onto the threaded rod followed by a
12mm x 175 nut Center the rear bearing in the bearing
boss of the support plate Tighten the nut until the bear
ing seats fully into the boss Secure the stator housing
assembly to the bell housing using the four MIO x 35mm
screws Torque to 35 Nm 25 ftlb remove the nut
washer and threaded rod
Engines Generators
DECIMAL TO METRIC EQUIVALENT of Fractions of
Decimal in Metric mm Decimal in Metric mm
an inch an inch
164 0015625 039688 3364 0515625 1309687
132 003125 079375 1732 053125 1349375
364 0046875 119062 3564 0546875 1389062
116 00625 158750 916 05625 1428750
564 0078125 198437 3764 0578125 1468437
332 009375 238125 1932 059375 1508125
764 0109375 277812 3964 0609375 1547812
18 0125 3175 58 0625 1587500
964 0140625 357187 4164 0640625 1627187
532 015625 396875 2132 065625 1666875
1164 0171875 436562 4364 0671875 1706562
3116 01875 476250 1116 06875 1746250
1364 0203125 515937 4564 0703125 1785937
732 021875 555625 2332 071875 1825625
1564 0234375 595312 4764 0734375 1865312
14 0250 635000 34 0750 1905000
1764 0265625 674687 4964 0765625 1944687
932 028125 714375 2532 078125 1984375
1964 0296875 754062 5164 0796875 2024062
5116 03125 793750 1316 08125 2063750
2164 0328125 833437 5364 0828125 2103437
1132 034375 873125 2732 084375 2143125
2364 0359375 912812 55164 0859375 2182812
38 0375 952500 78 0875 2222500
2564 0390625 992187 5764 0890625 2262187
1332 040625 1031875 2932 090625 2301875
2764 0421875 1071562 5964 0921875 2341562
716 04375 1111250 1516 09375 2381250
2964 0453125 1150937 6164 0953125 2420937
1532 046875 1190625 3132 096875 2460625
3184 0484375 1230312 6364 0984375 2500312
12 0500 1270000 1 100 2540000
WESTERBEKE
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet It x 305 Meters m 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
Imperiat Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Ftuid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pI 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 Dunces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascats kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water HO x 07355 Inches of Mercury x 13783 HO
tnches of Water HO x 03613 psi x 27684 HO
Inches of Water HO x 248 Kllopascals kPa x 4026 HO
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUa CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per liter KmL
Kilometers Per liter Krnll x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per liter Krnll
Kilometers Per liter Kml x 2352 US
Degree Fahrenheit OF DC X 18 32
Degree Celsius DC OF 32 x 56
UQUID WEIGHTS
Diesel Oil 1 US gallon 713 Ibs
Fresh Water 1 US gallon 833 tbs
Gasoline 1 US gallon 61 Ibs
Salt Water 1 US gallon 856 tbs
WESTERBEKE
Engines Generators
INDEX
AC Output 72 Fuel Camshaft 23
Alternator Service 35 Gear Case Cover 27
Assembly Procedures 12 Gear Case Plate Pressure 2 Governor Fork Lever 2 I
Cylinder Block 8 Governor Housing Assembly 18
Cylinder Head 8 Governor Weight Procedures I I Idle Gears 28
Dynamic Balancer 9 Idle GearCamshaft 27
Electronic Regulation 85 Injection Nozzle 20
Engine 3 Injection Pump 24
Exciting the Generator 89 Injection Pump Unit 19
Exciter Rotor 90 Installing InjectiGn Pump 25
General Description 8 Oil PanOil Strainer 29
Generator General Information 83 Rod 29
Generator Parts Breakdown 93 Pistons 30
Senerator Testing Voltage 89 Plate Gear Case 28
Governor I 0 Rocker ArmPush Rod 15
Head Cover 8 Stop Lever 22
Internal Wfring Schematic 91 Thermostat 20
Magnetic PickUp Coil 87 Valve 16
Metric Conversion Chart Water PumpOil Cooler 26
Metric Equi valent Chart 96 Engine Breakdown Generator 92 Fuel Injection rings Fuel Lift
Pump 65
Service 55 Glow Plugs 65
Special Tools 72 Injection Timing 65AFour 68 Injectors 33 EDE 69 Inlet Fuel Filter 285
EDER 69a Oil Filter Servicing 55 Oil Pressure 63
Starter Motor Service 34 Raw Water Pump 66
Terminal Board Connections 84 Valve Clearance 62
Testing for OverhauL 2 Engine Voltage 89 Balancer Shaft Alignment 47
Torque 70 Balancer Shaft Side Clearance Marine 11 13 Cam Height 3 Camshaft Alignment
Chart Generator 88 Camshaft lournal 46
Tuning Operations I 3 Connecting Rod Alignment 49
Water Pump 66 Crankshaft 50
Wiring Diagrams 67 Crankshaft Sleeve 52
Wiring Schematic Internal 91 Cylinder Cylinder
Head 40
Bearing Case Cover 3 I Idler Gear Bushing 46
Boost Arms 21 Oil Clearance 51
Connecting Rod Cap 29 Oil Clearance Crankshaft 52
Crankcases 1 2 32 011 Pump 53
Crankshaft 33 Piston and Connecting Rod 48
Cylinder Head Gasket 16 Piston Ring Gap 48
Cylinder Head Tappet 15 Timing GearCamshaft 44
Cylinder HeadlYalves 14 Top Clearance 40
Fan Drive Industrial 26 Valve GuideNalve Seat 42
Aywheel and Crankshaft 31 Valve Lapping 41
Aywheel Housing 32 Valve Spring 43
y WESTERBEKE
Engines Generators
v WESTERBEKE
Engines

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