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Westerbeke Diesel 55b Four Operator's Manual



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 SERVICE MANUAL
55B-FOUR and 55e-FOUR
 MARINE DIESEL ENGINE




           PUBLICATION NO. 049970
                2ND EDITION
             SEPTEMBER 2006




     ~    WESTERBEKE CORPORA TION. 150 JOHN HANCOCK ROAD
     I   MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780


         ----
         WEBSITE: WWW.W£ST£RB£KE.COM

     AlMM'" Metn«f National Marin~ Manufacturers Association
     -~
  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.




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

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.




A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS in the /iving/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.




                           Engines & Generators
                                                  SAFETY INSTRUCTIONS
    INTRODUCTION                                                        PREVENT BURNS - FIRE
    Read this safety 11Ul1Iual carefully. Most accidents are
!   caused by failure to follow fundamental rules and                       A WARNING: Fire can cause injury or death!
    precautiJJns. Know when dangerous conditions exist and
    toke the necessary precautiJJns to protect yourse1/, your           · Prevent flash fires. Do not smoke or permit flames or
    personnel, and your machinery.                                        sparks to occur near the carburetor, fuel line, filter, fuel
    The following safety instructions are in comp1iance with              pump, or other potential sources of spilled fuel or fuel
    the American Boat and Yacht Council (ABYC) stondards.                 vapors. Use a suitable container to catch all fuel when
                                                                          removing the fuel line, carburetor, or fuel filters.
    PREVENT ELECTRIC SHOCK                                              · Do not operate with a Coast Guard Approved flame
                                                                          arrester removed. Backfire can cause severe injury or
                                                                          death.
        A WARNING: Do nut touch AC electrical connections               · Do not operate with the air cleaner/silencer removed.
        while engine is running, or when connected to shore               Backfire can cause severe injury or death.
        power. Lethal voltage is present at these connections!          · Do not smoke or permit flames or sparks to occur near
                                                                          the fuel system. Keep the compartment and the
    ·    Do not operate this machinery without electrical                 engine/generator clean and free of debris to minimize the
         enclosures and covers in place.                                  chances of fire. Wipe up all spilled fuel and engine oil.
    ·    Shut off electrical power before accessing electrical          · Be aware - diesel fuel will burn.
         equipment
    ·    Use insulated mats whenever working on electrical              PREVENT BURNS - EXPLOSION
         equipment.
    ·    Make sure your clothing and skin are dry, not damp
         (particularly shoes) when handling electrical equipment
                                                                            A WARNING: Explosions from fuel vapOIS can cause
                                                                            injury or death!
    ·    Remove wristwatch and all jewelry when working on
         electrical equipment.                                          ·     Follow re-fueling safety instructions. Keep the vessels
    ·    Do not connect utility shore power to vessels AC                     hatches closed when fueling. Open and ventilate cabin
         circuits, except through a shiJ>-to-shore double throw               after fueling. Check below for fumes/vapor before
         transfer switch. Damage to vessels AC generator may                  running the blower. Run the blower for four minutes
         result if this procedure is not followed.                            before starting your engine.
    ·    Electrical shock results from handling a charged capaci-       ·     All fuel vapors are highly explosive. Use extreme care
         tor. Discharge capacitor by shorting terminals together.             when handling and storing fuels. Store fuel in a well-
                                                                              ventilated area away from spark-producing equipment
    PREVENT BURNS - HOT ENGINE                                                and out of the reach of children.
                                                                        ·     Do not fill the fuel tank(s) while the engine is running.
        A WARNING: Do not touch hot engine parts or                     ·     Shut off the fuel service valve at the engine when servicing
                                                                              the fuel system. Take care in catching any fuel that might
        exhaust system components. Arunning engine gets                       spill. DO NOT allow any smoking, open flames, or other
        reryhot!                                                              sources of fire near the fuel system or engine when servic-
                                                                              ing. Ensure proper ventilation exists when servicing the
    · Always check the engine coolant level at the coolant                    fuel system.
      recovery tank.
                                                                        ·     Do not alter or modify the fuel system.
                                                                        ·     Be sure all fuel supplies have a positive shutoff valve.
        A WARNING: Steam can cause injury or death!                     ·     Be certain fuel line fittings are adequately tightened and
                                                                              free of leaks.
    ·    In case of an engine overheat, allow the engine to cool        ·     Make sure a fire extinguisher is installed nearby and is
         before touching the engine or checking the coolant.                  properly maintained. Be familiar with its proper use.
                                                                              Extinguishers rated ABC by the NFPA are appropriate
                                                                              for all applications encountered in this environment.




                                                              Engines & Generators

                                                                    i
                                                SAFETY INSTRUCTIONS
ACCIDENTAl STARTING                                                      TOXIC EXHAUST GASES
    A WARNING: Accidental starting can cause injury                          A WARNING: Carbon monoxide (CO) is a deadly gas!
    Dr 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
                                                                               manifolds/water-injected 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.                               ·     Do not run the generator set or engine unless the boat is
                                                                               equipped with a functioning marine carbon monoxide
                                                                               detector that complies with ABYCA-24. Consult your
BATTERY EXPLOSION                                                              boat builder or dealer for installation of approved
                                                                               detectors.
    A WARNING: Battery explosion can cause injury                        ·     For additional information refer to ABYC T-22
    ordeath!                                                                   (educational information on Carbon Monoxide).

· Do not smoke or allow an open flame near the battery
  being serviced. Lead acid batteries emit hydrogen, a                       A WARNING: Carbon monoxide (CO) is an invisible
  highly explosive gas, which can be ignited by electrical                   odorless gas. Inhalation produces "u·like symptoms,
  arcing or by lit tobacco products. Shut off all electrical                 nausea or death!
  equipment in the vicinity to prevent electrical arcing
  during servicing.                                                      ·     Do not use copper tubing in diesel exhaust systems. Diesel
· Never connect the negative (-) battery cable to the                      fumes can rapidly destroy copper tubing in exhaust
  positive (+) connection terminal of the starter solenoid.                systems. Exhaust sulfur causes rapid deterioration of
  Do not test the battery condition by shorting the terminals              copper tubing resulting in exhaust/water leakage.
  together. Sparks could ignite battery gases or fuel vapors.            · Do not install exhaust outlet where exhaust can be drawn
  Ventilate any compartment containing batteries to prevent                through portholes, vents, or air conditioners. If the engine
  accumulation of explosive gases. To avoid sparks, do not                 exhaust discharge outlet is near the waterline, water could
  disturb the battery charger connections while the battery                enter the exhaust discharge outlet and close or restrict the
  is being charged.                                                        flow of exhaust. Avoid overloading the craft.
· Avoid contacting the terminals with tools, etc., to prevent            · Although diesel engine exhaust gases are not as toxic as
  bums or sparks that could cause an explosion. Remove                     exhaust fumes from gasoline engines, carbon monoxide
  wristwatch, rings, and any other jewelry before handling                 gas is present in diesel exhaust fumes. Some of the
  the battery.                                                             symptoms or sigus of carbon monoxide inhalation or
· Always tum the battery charger off before disconnecting                  poisoning are:
  the battery connections. Remove the negative lead first                  Vomiting        Inability to think coherently
  and reconnect it last when disconnecting the battery.
                                                                           Dizziness       Throbbing in temples
BATTERY ACID                                                               Headache        Muscular twitching
                                                                           Nausea          Weakness and sleepiness
    A WARNING: Sulfuric acid in batteries can cause                      AVOID MOVING PARTS
    severe injury Dr death!

·     When servicing the battery or checking the electrolyte                 A WARNING: Rotating parts can cause injury
      level, wear rubber gloves, a rubber apron, and eye                     or death!
      protection. Batteries contain sulfuric acid which is
      destructive. If it comes in contact with your skin, wash it        ·     Do not service the engine while it is running. If a
      off at once with water. Acid may splash on the skin or                   situation arises in which it is absolutely necessary to
      into the eyes inadvertently when removing electrolyte                    make operating adjustments, use extreme care to avoid
      caps.                                                                    touching moving parts and hot exhaust system
                                                                               components.




                                                             Engines & Generators

                                                                    ii
                                                     SAFETY INSTRUCTIONS
    ·     Do not wear loose clothing or jewelry when servicing                 ABYC, NFPA AND USCG PUBLICATIONS FOR
          equipment; tie back long hair and avoid wearing loose
          jackets, shirts, sleeves, rings, necklaces or bracelets that         INSTALLING DIESEL ENGINES
      could be caught in moving parts.                                         Read the following ABYC, NfPA and USCG publications
                                                                               for safety codes and standards. Follow their
    · Make sure all attaching hardware is properly tightened.
      Keep protective shields and guards in their respective                   recommendations when installing your engine.
      places at all times.                                                     ABYC (American Boat and Yacht Council)
    · Do not check fluid levels or the drive belts tension while               "Safety Standards for S!1IaU Craft"
      the engine is operating.                                                 Order from:
    · Stay clear of the drive shaft and the transmission coupling                 ABYC
      when the engine is runuing; hair and clothing can easily                    3069 Solomon's Island Rd.
      be caught in these rotating parts.                                          Edgewater, MD 21037
                                                                               NFPA (National Fire Protection Association)
    HAZARDOUS NOISE                                                            "Fire Protection Standard for Motor Craft"

    I~WARNING:            High noise levels can C81/S8 hearing
                                                                               Order from:
                                                                                  NfPA
                                                                                  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 Slates Coast Guard)
      removed.                                                                 "USCG 33CFR183"
    · Do not run engines for long periods with their enclosures                Order from:
      open.
                                                                                  U.S. Government Printing Office
                                                                                  Washington, D.C. 20404
        A WARNING: Do not nt lin macIJinlll1 when             ytlU are
        ,.",." fIT p/JysIt:al" Incapacifatetl by fatigue!


)   OPERATORS MANUAL
    Many of the preceding safety tips and warnings are repeated
    in your ()peratOIs Manual along with other cautions and
    notes to highlight critical information. Read your manual
    carefully, maintain your equipment, and follow all safety
    procedures.
    GASOUNE ENGINE AND GENERATOR INSTAllATIONS
    Preparations to instaII an engine should begin with a
    thorough examination of the American Boat and Yacht
    Council's (ABYC) standards. These standards are a
    combination of sources including the USCG and the NfPA.
    Sections of the ABYC standards of particular interest are:
          H-2 Ventilation
          P-l Exhaust Systems
           P-4 InboanI Engines
          E-9 DC Electrical Systems
    All installations must comply with the Federal Code of
    Regulations (FCR).




)


                                                                  Engines & Generators

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

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

SlPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failare to use a siphon-breok when
the exhaust manifold injection port is at or below the load waterline will result in
mw water dDmoge to the engine and possible flooding ofthe boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-breok.
JIOIE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic       AVAILABLE FROM
                                                                                        YOUR WESTERBEKE
engine damage. Consult the siphon-break manufacturer for proper maintenance.            OEALER

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


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




                        ,.~/WESIJ:RBEKE
                               I Engines & Generators
                                        iv
        TABLE OF CONTENTS

Parts Identification .............................................2
Introduction .........................................................3
Engine Specifications ....................................... ..4
Testing for Overhaul ............................................5
   Alternator Inspection ........................................5
Engine Troubleshooting .......................................6
Engine Disassembly........................................... 10
Engine Measurements ...................................... 11
(Prior to Disassembly)
Transmission ..................................................... 11
Injection Pump .................................................. 11
Engine Disassembly (Exploded View) .................. 12
Engine Inspection and Repair ........................... 15
Engine Assembly ...............................................25
 Sealants and Lubricants .................................. 25
 Bolts and Fasteners ......................................... 25
Engine Assembly (Exploded View) ...·...................28
Engine Assembly (External Parts) ....................... .34
Engine Assembly ...............................................38
 Engine Tuning ................................................ 38
Lubrication Diagram ..........................................39
Cooling System ..................................................40
Fuel System .......................................................43
 Governor Drawing ......................................... .46
Engine Adjustments..·........................................50
  Testing Compression ..................................... .50
  Oil Pressure .................................................... 50
  Valve Clearance .............................................. 51
  Injection TIming ............................................. 52
Warning Lights, Alarms, & Circuit Breakers ....53
Starter Motor .... ,................................................54
Dual Output Alternators ....................................58
Wiring Schematic .............................................60
Wiring Diagram ..................................................61
Tachometer .......................................................62
Alternator Testing .............................................63
Torque Data .......................................................70
Nut and Bolt Tightening Method .......................73
Tightening Torque Standard ..................... ......... 74
Metric Conversion Formulas ...............................76




           ~        WESTERBEKE
                    Engines & Generators

                            1
                                                    PARTS IDENTIFICATION

                                                                                                              INTAKE/AIR AlTER
                                             OIL                           ~UUI"'~'   PRESSURE CAP

                       THERMOSTAT
                       ASSEMBLY
                                                                                            1c~~~, ~~                 ___     EWXiATERir.U:iliNJECTED
                                                                                                                                           ElBOW


                                                                                                                     1.0. PLATE

                                                                                                       :\.......:.Jf---HI:AT EXCHANGER

         CONNECTION                                                                                                                              REAR
                                                                                                                          ANODE


   RAW WATER   D"'.D-----
                                                                                                                          COOlER



           FRONT
                                                                                              LEFT SIDE



                                                   WATER INJECTED
                                                   EXHAUST
                      PREHEAT "u,.::::=:::"":"'Y.::_::a~' 0.0.                            (3.3454 - 3.3458)
                                                                                                                                                                                                     A

                                                                                                                                                                   84.986 - 84.995
                                         ROCKER ARM SHAFT                                                            1"                                           (3.3459 - 3.3462)
                                                                                                                                                                                                     B

                                                                                                                                                                          -85.005
    Rocker Arm Correction                                                                                                                                                                            C
                                                                                                                                                                            3.3466)
    Inspect the rocker arm valve stem contact surfaces for                                                                                                              '_''''''oe mark (Stamped!"
    ridges@ and scoring®
    If the surfaces have light ridge or scoring, they may be
    honed with an oil stone.
    If the ridge or scoring is severe, the rocke'r arm must be


    --.~ (----=-]--                                             \\
                                                                                                   SCORING             ®
                     RIOGES'(li'r"---...----...



                                                                                                                                                                                                 mm (in.)
                                                                                                                                               Model        Nominal          Limit          Remarks

                                                                                                                                                              25.0           24.97      Replace if worn
                                                                                                                                                            (0.9843)        (0.9831)    beyond limit


                                                                                                        ~                WESTERBEKE
                                                                                                                         Engines & Generators

                                                                                                                                     21
                                -   ..   --------.--------------------------------~-----




                               ENGINE INSPECTION AND REPAIR
Clearance between piston pin and piston pin hole                         CONNECTING ROD AND CONNECTING
                                               mm (in.)                  ROD BEARING
                                             Standard
                                             0.002 - 0.012
                                         (0.00008 - 0.00047)

Piston ring gap
With the ring inserted into the cylinder bore, push it in
with the piston head so that it becomes a right angle to
the cylinder, and then measure the gap of the piston
ring.
If worn beyond the limit, replace the rings.



                                                                      Torsion and parallelism of connecting rod
                                                                      If worn beyond the limit-repair or replace.
                                                                                                                         mm(in.)
                                                                         Per 100 mm (3.94)        Standard             Limit
                                                                                                    0.05                 0.2
                                                                         Torsion
                                                                                                   (0.002)            (0.0079)




    ----
   1st
   compression ring

   2nd
                             Standard
                             0.2-0.35
                         (0.0079 - 0.0138)
                                                        mm(in.)
                                                      Limit



                                                       1.5
                                                    (0.0590)
                                                                         Parallelism
                                                                                                     0.05
                                                                                                   (0.002)
                                                                                                                        0.15
                                                                                                                      (0.0059)

                                                                      Clearance between small end pin hole of connecting rod
                                                                      and piston pin, inside diameter of bushing
                                                                                                                    mm (in.)
   compression                                                                                        Standard           Limit
   ring                      0.35-0.5
                         (0.0138 - 0.0197)                                                          0.008 - 0.020         0.05
                                                                        Clearance
                                                                                                  (0.0003 - 0.0008)     (0.0020)
                             0.2-0.4                    1.0
   Oil ring
                         (0.0079 - 0.0157)          (0.03937)
                                                                        Inside diameter
Clearance between piston ring groove and ring                                                        25 (0.9843)

Measure ·clearance at several places on the circumfer-
ence.
If worn beyond the limit, replace the rings or piston.




    ----
   1st
   compression ring
   2nd
   compression ring
                             Standard
                           0.085 - 0.105
                         (0.0033 - 0.0041)
                           0.050 - 0.085
                         (0.0020 - 0.0033)
                                                        mm(in.)
                                                      Limit
                                                        0.2
                                                     (0.0078)

                                                       0.15
                                                                                              MEASURING CONNECTING ROD
                                                                                              BUSHING INNER DlAMmR
                           0.030 - 0.070             (0.0059)




                                                                                          W
   Oil ring
                         (0.0011 - 0.0027)




                                                                                              PISTON PIN




                                                         Engines & Generators

                                                                22
                                      ENGINE INSPECTION AND REPAIR
     Connecting· Rod Bearing Inspection                                   CRANKSHAFT AND CRANKSHAFT BEARING
\1.         Fit the connecting rod bearing lower half into the
 )          connecting rod bearing cap.                                   Outside diameters of journal and pin
 2.         Check the connecting rod bearing lower half tension.          If worn beyond the limits-replace
            If the tension is insufficient, the bearing must be           Crank journal                                    mm (in.)
            replaced.                                                                                Standard            Limit
    . 3.    Tighten the connecting rod and the bearing cap to
                                                                                                   60.0 (2.3622)     59.86 (2.3567)
            the specified torque.

                            Fm1NG THE LOWER
                            BEARIIIG




                                                    kg·m (ft. Ibs.)


            Tightening                             7.5-8.5
              torque                               (54-61)            .
                                                                          Crank pin                                        mm(in)

      Clearance between bearing and crank pin, inside di·
      ameter with bearing installed and without.
                                                                                  -                 Standard           Limit
                                                                                                   49.0 (1.9291) . 48:87 (1.9240)
                                                 mm (in.)
                                       Standard          Limit
                                      0.035 - 0.073       0.10
,          Clearance
                                    (0.0014 - 0.0029)   (0.0039)
)




                                                                          When there occurs an uneven wear to the crankShaft.
                                                                          replace it with a new one without grinding it for reuse.
                                                                          Clearance between journal and bearing inside diameter
                                                                          with bearing installed and without
                                                                                                                         mm (in)
                                                                                                       Standard           Limit
                                                                                                     0.029 - 0.072        0.11
                                                                           Clearance
                                                                                                   (0.0011 0.0028)      (0.0043)




                                                           Engines & Generators
                                                            . 23
                                ENGINE INSPECTION AND REPAIR




                                                                                                             REMOVING THE
                                                                                                             RING GEAR
                                                                   Ring Gear Installation
                                                                   1.   Heat the ring gear evenly with a gas burner to invite
                                                                        thermal expansion.
Runout of crankshaft
                                                                        Do not allow the temperature of the gas burner to
Replace if beyond limit                                                 exceed 200·C (390·F).
                                                    mm (in)        2.   Use a hammer to install the ring gear when it is suf-
            Standard                    Limit                           ficiently heated.
           0.025 (0.001)             0.05 (0.002)

Crankshaft gear
Check the crankshaft gear visually for damage and any
other defects.




                                                                   TIMING GEAR
                                                                   Uneven wear of idle gear shaft
Oil seal                                                                                                             mm (in.)
When the lip of an oil seal is found defective, replace it                     Nominal                      Limit
with a new one.                                                              45.0 (1.7717)               0.1 (0.0039)
Installation
Use the crankshaft front oil seal installer to install the
crankshaft front oil seal.




                                                                   Clearance between idle gear bushing and shaft
                                                                                                                     mm (in.)
                                                                               Standard                      Limit
                                                                    0.025 - 0.085 (0.001 - 0.0033)       0.2 (0.0079)

FLYWHEEL AND RING GEAR
Ring Gear Replacement
Ring Gear
Inspect the ring gear.
Ifthe ring gear teeth are broken orexcessively worn, the
ring gear must be replaced.
Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.

                                                      Engines & Generators

                                                              24
                                                ENGINE ASSEMBLY
GENERAL INFORMATION                                                    Bolts and Fasteners
· Be careful not to mix bolts and nuts. Metric and S.A.B.              Lightly oil head bolts and other fasteners as you assemble
  bolts are used on various engine assemblies.                         them. Bolts and other plugs that penetrate the water jacket
· During assembly, recheck clearances and insure that parts            should be sealed with PERMATEX #2 or mGH TACK.
  are being assembled in their proper order and faCing in the
  correct direction in relation to the engine block, such as,          When assembling the flywheel, coat the bolt threads with
  pistons, piston rings, bearings and bearing caps.                    LOCTITE blue.
· Apply lubricating oil to moving parts during assembly.               LITInUM based grease is waterproof, ideal for water pump
  Insure that moving parts, when assembled on the engine,              bearings and stuffing boxes.
  rotate or slide and are not subject to binding or
  excessive tension.                                                   Antiseize compounds and thread locking adhesives such as
                                                                       LOCTITE protect threaded components yet allow them to
· If there are mating marks scribed during disassembly,                come apart when necessary. LOCTITE offers levels of
  reference them correctly for assembly.                               lOCking according to the job.
· Use new gaskets, lockwashers, O-rings, packings and seals.           Heavily oil all sliding and reciprocating components, always
· Tighten the bolts and nuts on important parts of the engine          use clean engine oil.
  to specified torques using a reliable torque wrench.
· When required, use liquid sealants when required on nuts,            PISTON AND CONNECTING ROD
  bolts and gaskets. Refrain from using tape sealants.
· Most gaskets and many bolt washers are asymmetrical,                 Piston Pin Snap Ring
  make certain they are positioned properly.                           1.   Use a pair of snap ring pliers to install the piston pin
                                                                            snap ring.
Torquing Hardware                                                      2.   Check that the piston moves smoothly on the piston
Prevent mechanical damage by running fasteners down in                      pin.
three steps-II2, 213, and III torque. Exceptions are torque-to-                      SNAP RING
yield bolts and rocker arm shaft fasteners. The former are                           PLIERS
torqued as indicated. The latter-rocker shaft fasteners-should be
brought down in very small increments, working from the
                                                                                            \
center bolts out. Gaskets, especially head gaskets, might be
damaged during assembly, they should be positioned with great
care. See TORQUE SPECIFICATIONS thru out this manual.

Sealants and Lubricants
                                                                       Piston Ring
Oil based PERMATEX #2 and its mGH TACK equivalent are
excellent all purpose sealers. They are effective in just about       1.    Use a piston ring installer to install the three piston
any joint in contact with coolant, raw water, oil, or fuel. A light         ril1~s.
coating of oil or LIQUID TEFLON can be used on rubber                       Install the piston rings in the following order.
gaskets and o-rings.                                                        (1) Oil ring
LOCTITE hydraulic red sealant should be used on oil adapter                 (2) 2nd compression ring
hoses and the oil filter assembly.                                          (3) 1st compression ring
Coat both surfaces of the oil pan gasket with high temp RED                 The marked side of the two compression rings
Sll.JCONE SEALER. ..                                                        be facing up.
                                                                            The undercut side of the second compression ring
When installing gaskets that seal around water (coolant)
                                                                            will be facing down.
passages, coat both sides with WHITE SILICONE GREASE.
                                                                            As the oil ring has no any facing mark, it may face in
Do not use sealant when installing a new gasket.                            either direction.
mGH-COPPER ADHESIVE SPRAYS are useful for hold-                       2.    Lubricate the piston ring surfaces with engine oil.
ing a gasket in position during assembly.                             3.    Check that the piston rings rotate smoothly in the
Specialized gasket sealers such as HYLOMAR work well in                     piston ring grooves.
applications requiring non-hardening properties. HYLOMAR                                              "="--~) I st
is particularly effective on copper cylinder-head gaskets and
resists fuel, oil , and water.

                                                                                                ~\
                                                                                                                    2 st
NOTE: TAPE SEALANTS should be used on pipe plugs and
fitting that connect water cookmt passages.


                                                          Engines & Generators
                                                                                                        BOil
                                                               25
                                                        ENGINE ASSEMBLY
 CYUNDER HEAD ASSEMBLY                                                  Valve Stem Oil Seal


                                    Ii  Glow plug (7)
                                             ~5eal;VaIVe(1)
                                                                        1.   Lul1ricate the oil seals and valve stem sealing are
                                                                             with engine oil.




                              ,                                         2.   Use a valve stem oil seal installer to install the oil
                                                                             seal.


                                                                                    INSTAlLER ~~~


Nozzle holder   (6)~   .




                                                                        Intake and Exhaust Valves
                                                                        1.   Place the cylinder head on a flat wooden surface.
                                                                        2.   Lubricate valve stems with engine oil.
                       @

                    ~
                                                                        3.   Install the valves to the intake or exhaust guides.
                                                                             Install the valves to their original lapped valve seats.
                              Seat; Valve insert




                t.~ ~             Split collar (5)
                e> ~ Spring seat (4)
                I   ~         Valve spring (3)



            ~ dj '.
          ~/c:
            .
              . :/"')
                    ,                                                   Intake and Exhaust Valve Springs
                           .../

            'J(~~~
                                                                        Install the valve springs with their painted end (the close
                                                                        pitched end) facing down.




                                                                                                ~:::--P~/M1'FD PORTION




                                                           Engines & Generators

                                                                26
                                                 ENGINE ASSEMBLY                                             .,.    ~
                                                                                                       ~
                                                                                                             ~
 Spring Seat Split Collar                                                Piston ring (5)
                                                                                           -                 ·      ....
 1.   Use a spring compressor to push the valve spring
                                                                                                       --'          ~      "snap ring (4)
      into position.
 2.   Install the spring seat split collar.                                          Piston (1) --_-I~'J
 3.   Set the spring seat split collar by tapping lightly
      around the head of the collar with a rubber hammer.
      Spring Compressor:                                                 Piston pin (31~




                                                                                         ~
                                                                        * Rod bolt removed
                                                                                                        *
                                                                                                                                 ~.
                                                                          for clarity.




                                                                                                                             Bearing (6)
                                                                                     Capnut(B)_            ~
 Nozzle holder assembly
 Before assembling the nozzle holder assembly, check to
 see if the spray condition and the spray pressure of the                       PISTON AND CONNECTING ROD
 injection nozzle are appropriate, (Refer to "INSPECTION                       Piston
 AND SERVICE.")                        .
                                                                               Use a piston heater to heat the pistons to approximately
 Assemble to the cylinder head the gasket (heat shield),                       100°C (212°F).
 heat shield, corrugated washer and gasket (nozzle
 holder) in this order.
 Install the nozzle holder assembly, and then tighten it to
 the specified torque.
                                                   kg·m (ft. Ibs.)
       TIghtening torque             4.0 - 5.0 (29.0 - 36.0)        I
                                                                                                                                  USING A PISTON
                                                                                                                                  HEATER
~ Nozzle holder ASM                                                           Connecting Rod
                                                                              1.    Install the connecting rod to the piston with setting
  ~...... Gasket



                                                 t
                                                                                    the marks as illustrated.
      ~ Corrugated washer                                                     2.    Install the piston pin into the piston and the connect-
             ' - _ ~ Heat shield                                                    ing rod bushing.

               ~                                      Glow plug

                  ~GaSket
                                                  I
                                                                                               (Hot plug side)
                                                                                                                                  mark


                                                                                                 Front mal'K __
                                              Connector
                                                                                            Engine ~




                                                                                                   v
Glow plug and connector                                                                    front   ..
                                                                                           di,ectio
Assemble the glow plug to the cylinder head, and then
tighten it to the specified torque.
  Install the connector to the glow plug, and     ~hen    tighten
                                                                                               ~
. until snug.
 .    ...                                         kg·m (ft Ibs)                                Isuzu..m~;'~'lk:e,./o(;~~~t
                                                                                           Cylinder nl
              Parts                   TIghtening torque                                     stamped side

            Glow plug                1.5 - 2.0 (11.0 - 14.0)


                                                  ~       WESTERBEKE
                                                          EngInes & Generators
                                                               27
                                       ENGINE ASSEMBLY
Reassembly Steps                           INTERNAL PARTS
 (1) Crankshaft
 (2) Piston Assembly
 (3) Rear Seal Retainer
 (4) Camshaft                                              121
 (5) Cam Gear
  (6) Idler gear and Shaft
 (7J  011 Pump Assembly
 (8) TIming Gear Case
 (9) Flywheel Housing
(10) Flywheel
(11) Crank Pulley
(12) Oil Pipe
(13) Oil Strainer
(14)011 Pan
(15) Tappets
(16) Cylindar Head Gasket
(17) Cylinder Head Assembly
(18) Push Rods
(19) Rocker Brac;ket Assembly          *
(20) Engine Hangers




                                                                    r--'-'-'-'-'---'-'-'-'-'--,i
                                                                    .
                                                                                                   I


                                                                                               I
                                                                                               I




                                (11)




                                                                    I
                                                                    I
                                                                    L._._._._._._._._._._._._.~




                                             Engines & Generators

                                                  28
                                              ENGINE ASSEMBLY
,
        Reassembly Steps               INTERNAL PARTS

,
    )    111 Crankshaft
         121 Piston Assembly
         (31 Rear Seal Retainer
         (41 Camshaft
         151 Cam Gear
         (61 Idler gear and Shaft
         (7J Oil Pump Assembly
         (81 TIming Gear Case:
         (91 Flywheel Housing
        (101 Flywheel
        (111 Crank Pulley
        (121 011 Pipe
        (131 Oil Strainer
        (141 Oil ,Pan
        (151 Tappets
        (161 Cylinder Head Gasket
        (171 Cy6nder Head Assembly
        1181 Push Rods
        (191 Rocker Bracket Assembly
        (201 Ei>glne Hangers


)




                                                   Engines & Generators

                                                        29
                                                    ENGINE ASSEMBLY
 Installation of retainer
                                                                          3.   Apply engine oil to the shaft of the sleeve and the
 After applying engine oil to the lip of the oil seal. install                 slide of the flyweight.
 the retainer. Apply sealant.
                                                                          4.   With the lip of the sleeve placed in the cavity of t
 Tighten bolts on the retainer to the specified torque in                      flyweight. insert the shaft of the sleeve into the til-
 the order as shown in the figure left.                                        end of the camshaft.
                                             kg·m (ft. Ibs.)
                                                                          Note:
        Tightening torque                 0.8 -1.2 (6.0 - 9.0)    I       Check to see if the sleeve moves smoothly.




                 '<'l~
                 Timing pOlnt .....-:

        Sleeve




                                             Flyweight



                                                            Engines & Generators

                                                                 30
                                                                           ENGINE ASSEMBLY
             Crankshaft bearing                                                                                                               151

             Note that there is an oil hole and an oil groove in the
         I   upper bearing (on the block side), but not in the lower                                                                          2st
             bearing (on the bearing cap side).
             Fit the bearing tang firmly into the slot machined on the
             cylinder body bearing archEls.
                                                                                                                                              Ojl
                      WITH OIL HOLE
                                                                 FIT CORRECTLY

                      '~~
                                                      ·11
                                                                                                  Position the rings as shown making sure the ring gaps
                                                                                                  are away from the thrust side.

                                                                                                  Piston and Connecting Rod
                                                                                                  Lubricate the piston, the piston rings, and the connect-
                                                                                                  ing rod bearings with engine oil.
                               0 N O OIL GROOVE AND HOLE                                          Position the piston front mark towards the front of the
                                    (LOWER)                                                       engine.
             Crankshaft and bearing                                                               Use the piston ring compressor to compress the piston
             Lubricate the bearings with engine oil, install the crank-                           rings.
             shaft, install the, thrust bearings with the groove facing                           Use a hammer grip to push the piston in until it makes
             the crankshaft.                                                                      contact with the crank pin.
                      Thrust bearing                      ~                                       At the same time, rotate the crankshaft until the crankpin
                                                                                                  reaches its highest point.
                              ~                     ~- V            Crankshaft

                                 "'"'\ p\)" V~                                                    Set the bearing cap cylinder number marks and the con-

                                 P\) ~-"-,,---'"
                                                                                                  necting rod cylinder number marks.          .
                                                                                                  The marks must be faCing the injection pump side.
                                                                                                            Special tool




             Crankshaft Bearing Cap
             1.    Lubricate the bearing cap bolts with engine oil.
             2.    InstalHhe bearing caps to the crankshaft.
                   The arrow mark must be pointing to the front of the
                   engine.
             3.    Tighten the bearing cap bolts to the specified torque
                   a little at a time in the numerical order shown in the
                   illustration.
                                                             kg.m (ft. lbs.)
                  Crankshaft Bearing Cap
                                                           8.5 - 9.5 (61.0 - 69.0)                         Cylinder
                  Bolt Torque                                                                              No,

             4.    Check that the crankshaft turns smoothly by manu-
                   ally rotating it.

LUBRICATE WITH ENGINE OIL, fl-::=:;:;;:;::::::::::-':-:;:::::::;:,,;:;,;::::::::o;:; Arrow mark                                               kg·m (ft. lbs.)
                                  10         · 6                   ..,                                Tightening
                                                                                                                           4LEl              7.5-8.5
                                                                                                                                             (54-61)
                                                                                                                                                            I
                                             ·                                                          torque

                                                                                                  Note:
                                 [9::::::~~::::=~:.:::.J8 q                                       After installation, confirm that the crankshaft rotates
                                                                                   Front          smoothly.




                                                                                    Engines & Generators

                                                                                            31
                                                 ENGINE ASSEMBLY
Oil pump assembly                                                                                     Governor cover

                                         Install the oil pump
      assembly to the cylinder block.
PrO not provided                                   kg·m (ft. Ibs.)
       TIghtening torque              1.9-2.9(14.0-21.0)          I
                 Cylinder block _..I"-1'!~~




                                                                       4.    Assemble the gasket and the governor cover to the
                                                                             top of the gear case, and then tighten them ·to the
Front oil seal                                                               specified torque.
Install the front oil seal to the timing gear case.                                                                kg·m (ft. Ibs.)
Installation is made according to the "L n dimension                        Cover tightening torque         0.8 - 1.2 (6.0 - 9.0)
shown in the figure.
                                             mm (in.)

                                           L dimension
                                    60.2 - 60.8 (2.370 - 2.384)
                                                                  I     Flywheel housing
                                                                        Install the flywheel housing to the cylinder body.
                                                                                                                         kg·m (ft. Ibs.)
                                                                              Tightening torque            4.2 - 5.6 (30.0 - 40.0)     I
                   Front oil seal




TIming gear case (with governor)                                       Flywheel
                                     . Install the timing gear         Lubricate bolts with engine oil.
case to the cylinder block.
                                                                       Tighten a little at a time in the 'sequence shown in the
                                                                       illustration.
1.    Put the link plate of the governor incorporated in
      the gear case through the connecting hole of the                                                                   kg.m (ft. Ibs.)
      injection pump in advance.                                              Tightening torque           9.0 - 11.0 (65.0 - 80.0) .
2.    Apply engine oil to the bushes provided on both
      ends of the main spring lever of the governor.
3.    Apply sealant to the gear case, and then install it to
      the cylinder block or the front plate.
                                                  kg.m (ft. Ibs.)
     Case tightening torque           1.9 - 2.9 (14.0 - 21.0)     I
                                                                                                                 Apply
                                                                                                                 engine oil




                                                  ~       WESTERBEKE
                                                          Engines & Generators

                                                                  32
                                                ENGINE ASSEMBLY
Crank pulley                                                                  Tappet and head gasket
Lubricate the lip of the front, seal with qil                                 1.   Install the tappet to the cylinder block.
Instal.l the crank pulley, lock the crankshaft and tighten                    2.   When installing the head gasket, turn up the stamp
the front bolt.                                                                    mark of the parts number (last 4 digits) which is
                                                 kg·m (ft.lbs.)                    between the No.2 and No.3 cylinders of the gasket.
       Tightening torque         17.0 -19.0 (123.0 -137.0)         I


                                                                                                            Parts number (Last 4 digits)
                                                                                                               Stamp mark position
                                                                             Cylinder head assembly
                                                                             Lubricate the bolts with oil.
                                                                              Tighten the bolts in the sequence shown in the iIIustra-
                                                                            . tion to the specified torque.
                                                                                                                                      kg·m (ft Ibs)




                                                                                                                             -
Oil pipe and oil strainer                                                           Bolt size                     Tightening torque
1.   Install the oil pipe from the oil pump assembly to                            M12xl.5                  8.5-9.5
                                                                                                                                      60'-90'
     the cylinder block and .tighten the sleeve nuts.                              (8 each)                 (61 - 69)
2.   Install the oil strainer to the oil pump, and then                            M8x 1.25                              2.5-3.5
     tighten the bracket of the strainer to the No.2 bear-                         (4 each)                              (18 -25)
     ing cap.                                                                                    ..
                                                 kg.m (ft. Ibs.)                           .11

      Tightening torque              1.9-2.9 (14.0-21.0)       I
                      To 2nd bearing cap




                                                                             Push rod
                                                                             Install the push rods.

                                                                             Rocker arm bracket assembly
Oil pan                                                                     Apply liquid gasket to the the bottom of the rocker arm
                                                                            bracket assembly, being careful not to get any in the
1.   Apply sealant to the oil pan.
                                                                            groove around the oil galley as shown in the illustration.
2.   Install the oil pan to the cylinder block and tighten
                                                                            Install the rocker arm bracket assembly making sure the
     fixing bolts evenly.
                                                                            push rods align with the rocker arms and tighten to the
                                              kg·m (ft. Ibs.)
                                                                            specified torque.
      Tightening torque              0.8 - 1.2 (6.0 - 9.0)     I                                                                     kg·m (ft. Ibs.)
                                                                                   Tightening torque                    0.8 - 1.2 (6.0 - 9.0)        I
                                                                         Apply stem of sealant                               Rocker arm .......",~

                                                                                                             ROC~
                                                                                   rAvoid the application
                                                                       1l1~>- ~ of seQlant to this
                                                                             ~groc\le.
                                                                                                                         I
                                                                                     Oil gallery

                                                                       (Rocker bmcket bottom    s~r.ace)


                                                ~       WESTERBEKE
                                                        Engines & Generators

                                                              33
                                           ENGINE ASSEMBLY
 ADJUST THE VALVE CLEARANCE
 Refer to the ENGINE ADJUSTMENTS section in this
 manual.




EXTERNAL PARTS (Right-hand Side)                                        EXTERNAL PARTS (Left-hand Side)
   ,                                      .
 11) Dipstick                                                           (9) Water Pump
12) Oil Filter                                                         110) Thermostat and Water Outlet Pipe
13) Injection Pump                                                     111) Cylinder Head Cover
14) Injection Pump HouSing Cover                                       112) Exhaust Manifold
15) Fuel Pipe                                                          113) Starter
16) Leak Off Pipe                                                      114) Generafor
17) Fuel Hose                                                          115) Pulley
18) Injection Pipe                                                     116) ,Belt
                                                                                                         (11)




                                        .....,!jJ..-! (3)




                                                     14)                                                        113)




                                                                       Dipstick
Front hanger and rear hanger
                                                                       Oil filter (cartridge)
Tiglmln them to the specified torque shown below.
                                                                       1.     Insert the dipstick.
                                          kg·m (ft. Ibs.)
                                                                       2.
       Tightening torque         1.9-2.9 (14.0-21.0)         I
       Rear hanger




                     IO'_-Front
                               hanger
                                              ..-v: WESTERBEKE
                                                       Engines & Generators

                                                            34
                                                       ENGINE ASSEMBLY
    Injection pump
    Align the two (2) holes in the fuel cut lever and the gov-
    ernor and lock into place with a pin.
    This will center and hold the control link for the installa-
    tion of the injection pumps.

             Injection pump
             center position          Fuel cut lever                                             Housing cover


                         ~
                                                                                                                  Apply portion of sealant

                     .           Pin




           'Y~' ,.~'- ~. ,J.4                                                                     About2mm
                                                                                                                      About 4mm in width
                                                                                                  around the bolt hole.
                                                                                                                             from the cover edge


    Install a new shim with the same thickness as the one                    Injection pump housing cover
    that was removed. (Refer to the maintenance section on
                                                                             After applying sealant (TB1207C) to the housing cover,
    shim selection).
                                                                             install it to the cylinder block by the side of the injection
                                                                             pump.
                            _ _ _ Injection pump ASM                                                                        kg·m (ft. Ibs.)
                                                                                     Tightening torque                  0.8 - 1.2 (6.0 - 9.0)      I
                            _ .....-_Shim                                    The areas of the housing cover to which liquid gasket is
                                                                             applied are about 4 mm In width from the cover edge
                                                                             and about 2 mm around the bolts.


                                          Cylinder block                                         Solenoid ASM


    Install the injection pump making sure the rack pin is in
    the groove of the control rack before tightening the
    injection pump to the specified torque.
                                               kg.m (ft. Ibs.)
         Tightening torque                  1.9-2.9 (14.0 - 21 .0)
                                                                             . Solenoid assembly

    Remove the rack pin (6_) which is inserted into the fuel                 1.    Apply sealant (TB1207C) to the surface (bite groove)
    cut lever. and then confirm that the fuel cut lever moves                      in which the solenoid is installed.
    smoothly.                                                                Note:
                                  IInjection pump                            Avoid the application of sealant to the screw thread.
                                  I         center position




                              -~RackPin
                                                                             2.     Screw in the solenoid from the rear of the cylinder
                                                                                  . block (the rear of the No. 3 injection pump rack), and
           . Control link                                                           then tighten it to the specified torque .
                                                                                                                              kg.m (ft. Ibs.)
                                                                                     Tightening torque                1.5-2.5(11 .0-18.0)          I
                                                                                              SolenOid ASM       lnsmlled surface
                                                                                                                      Apply SUrface)
                                                                                                                  (     ofsealilnt
                                                                                                       -,--.:..-..../

)
                                                                                                             Screw thread
                                                                                                               Avoid the apPlication )
                                                                                                              ( of sealant

                                                              Engines & Generators            (not adjustable, pull to run )
                                                                     35
                                                       ENGINE ASSEMBLY
                                      Leak off pipe
                                                         ?
                                                  '''''~'''




Fuel pipe            Fuel hose
Leak off pipe
1.   Install the fuel pipe to the injection pump and then
     tighten it to the specified torque.
2.   Install the leak off pipe to the nozzle holder and then
     tighten it to the specified torque.
                                                kg.m (ft. Ibs.)
                         Tightening torque
     Fuel pipe                       2.0 - 2.5 (14.0     18.0)
     Leak off pipe                   2.5-3.5 (18.0-25.0>"                      Thermostat
                                                                               Water outlet pipe
When tightening it. hold the pipe securely by hand so
                                                                               Assemble the thermostat. install the gasket and the
that it will not rotate.
                                                                               water outlet pipe. and then tighten it to the specified
3.    Connect the fuel pipe and the leak off pipe with the                     torque.
      fuel hose and fix them with clips.
                                                                                                                             kg·m (ft. Ibs.)
In;8ct;on pipe
Install the injection pipe to the injection pump and the
                                                                                     Tightening torque           1.9-2.9 (14.0-21.0)       I
nozzle holder and tighten them up with sleeve nuts.          .
                                             kg·m (ft. Ibs.)
                                                                               Adjust the Valve Clearance
      Tightening torque                  1.5-2.5(11.0-18.0)            I        Refer to the ENGINE ADJUSTMENTS section in this
                                                                                manual .



                 .-~~                                                          Cylinder head cover
                                                                               1.   Install the gasket to the cylinder head cover.
                                                                               Notes:
                            \... _        .   Nozzle holder                    1.   Much care should be taken for the gasket not to get
             Injection   pu~~~ ~/                                                   dislocated or twisted when installing the head

                     "~                       ~
                                                                                    cover.
                                                                               2.   Avoid the application of sealant to the rubber gas-
Set the thread of the sleeve nut securely before tighten-                           ket.
ing it up_                                                                     2.   Install the cylinder head cover to the rocker arm
Water pump assembly                                                                 bracket, and tighten it to the specified torque.
                                                                                                                             kg·m (ft. Ibs.)
1.    Put sealant on the water pump where it contacts the
      block and head.                                                                Tightening torque            0.2 -0.4 (1.4- 2.9)      I
2.   Tighten to the specified torque.
                                                                                        Cylinder cover
                                                         kg.m (ft. Ibs.)
      Tightening torque                  1.9-2.9 (14.0-21.0)           I                                                   Gasket




                                                                                                                      Rocker arm
                                                                                                                      bracket
                                                        ~        WESTERBEKE
                                                                 Engines & Generators

                                                                      36
                                             ENGINE ASSEMBLY
Air inlet pipe
1.   Apply sealant (TB1207C) to the surface in which the
                                                                     Alternator
     air inlet pipe is installed.                                   1. Tighten the adjustment plate together with the water
                                                                       pump, and then install them temporarily.
2.   Install the air inlet pipe to the cylinder head cover,         2. Install the bottom of the alternator to the timing gear
     and tighten it to the specified torque.                           case, and then tighten it temporarily with bolts and
                                               kg.m (ft. Ibs.)         nuts.
      Tightening torque             0.8-1.2 (6.0-9.0)          I    3. Install the fixing bolts onto the top of the alternator
                                                                       through the adjusting plate (temporary tightening).
              Cylinder head
              cover
                                                                                               Water pump




                                              Air inlet pipe




                                                                    Drive pulley and belt
Exhaust manifold                                                    1. Install the drive pulley to the water pump and then
Assemble the gasket to the cylinder head, install the                  tighten it up (2 locations).
exhaust manifold along the stud bolts and tighten it to                                                          kg·m (ft. Ibs.)
the specified torque.
                                         kg.m (ft. Ibs.)
                                                                         Tightening torque             0.8 - 1.2 (6.0 - 9.0)     I
      Tightening torque            1.9-2.9(14.0-21.0)          I    2. Set the drive belt to each pulley.

                                   Gasket


                                          Exhaust




Starter
Install the starter to the flywheel housing, and tighten it
to the specified torque.
                                              kg·m (ft. Ibs.)
      Tightening torque            9.5-11.5(68.7-83.2)         I
For starter motor disassembly and repair, refer to the
starter motor section in this manual.
                                                                    Drive belt tension should be very tight, about 1/2"
                                                                    deflection at mid-point.
                                                                    For alternator disassembly and repair, refer to the
                                                                    MANDO ALTERNATOR SECTION in this manual.




                                                      Engines & Generators

                                                               37
                                             ENGINE ASSEMBLY
NOTE:The exhaust manifold, which was disassembled             ENGINE TUNING OPERATION
from the cylinder head, should be inspected before
reassembly.                                                   After reassembly, the engine must be tuned. This will
                                                              ensure that the engine operates at its maximum
a. Remove the exhaust elbows from the lower surface           efficiency. Fill the engine cooling system with antifreeze
   of the manifold. Clean and inspect for cracks and          mixture and the engine oil sump with lube oil
   defects. Replace as needed.                                (API spec. CF or CG-4)
b. Remove the exhaust nipples, elbows and plugs from          1. Mount the engine on a test bench and connect
   the manifold and heat exchanger.                               the fuel lines.
c. Remove water connectors from the ends of the               2. Connect the electrical wiring. Refer to the WIRING
   manifold. Be sure to note the proper location and              DIAGRAM.
   arrangement of each for proper alignment.
                                                              3. Connect the air intake line to the air cleaner.
d. Examine all parts for defects, corrosion and wear
   and replace as needed.                                     4. Connect the exhaust pipe.
f. Flush out the coolant recovery tank and clear its          5. Manually operate the fuel feed pump to feed fuel
   hose passage. Set aside to re-install on the boat.             to the engine.
                                                              6. Bleed the fuel lines of air.
HEAT EXCHANGER                                                7. Crank the engine with the starter (non-ignition
                                                                  operation) for about twenty seconds. This will
Install the heat exchanger, replace the heat exchanger            pre-lubricate the engine internal components.
zinc and aUach new hoses with new clamps to the
cooling system. Refer to the COOLING SECTION in this          B. Start the engine and allow it to run at 750 to BOO
manuall for HEAT EXCHANGER SERVICE.                               rpm for five minutes.
                                                              9. Remove the cylinder head cover while the engine
MARINE TRANSMISSION                                               is running.
1. Assemble the damper plate to the flywheel.                 10.Check that the engine oil is continuously
                                                                  circulating from the oil pump to the valve rockers
2. Reinstall the marine transmission and fill with                through the cylinder head.
   ATF Dextran III.                                               If there is no oil circulation or if the oil circulation is
                                                                  sluggish, stop the engine and make the appropriate
NUIE: Some transmissions, such as the Borg Warner Velvet          repairs or adjustments.
Drive require oil coolers. Oil coolers should be cleaned,         Reinstall the cylinder head cover.
pressure tested and repainted at engine overhaul. The
                                                              11. Increase the engine speed to 1500 rpm to do the
transmission oil cooler hoses should also be inspected.           engine warming-up operation.
Refer to the text on Heat Exchangers.                         12.Check the engine for oil, fuel, coolant, and air
                                                                  intake leakage.
                                                              13. Check for abnormal noise and odor.
                                                              14.Check for abnormal electrical charging.
                                                              15. Check the engine fastening parts for looseness.
                                                              16 When the engine coolant temperature reaches
                                                                  75°C (167°F) or more, increase the engine speed
                                                                  to 2000 rpm and allow it to run for twenty
                                                                  seconds.
                                                                  This will give the engine the essential run-in
                                                                  operating time.
                                                              17.Adjust the engine operation speed to the
                                                                  specified value.
                                                              1B.Stop the engine to complete the tuning
                                                                  procedure.
                                                              Refer to the following pages for details of
                                                              sub-assemblies. These sections also include:
                                                              Wiring Diagrams, Engine Specifications, Torque
                                                              Diagrams, Starter Motor, Alternator, Raw Water Pump,
                                                              and a detailed Troubleshooting Section.

                                                                Adjust the Valve Clearance
                                                                Refer to the ENGINE ADJUSTMENTS section in this
                                                                manual.




                                                    Engines'& Generators
                                                            38 .
                         LUBRICATION SYSTEM
  Valve opening pressure lkgtcm2 (14.0 PSI)




                 Oil filter                         Oil gallery




    Valve
    opening
    pressure
    4.5kg/crn'
    (64.0 PSI)




                                                1   Gov~mo,       I




                          H    '"jectiO" pump   h
                                                                          +mO:~'"1
                          L.G:Jllton ------,,,,
                          ,
                          ,
                          ,
                          ,
                          ,                     ,
                                                ,
                          i~i
                          :-~--~                :                            ,              ,
                                                                             ,
                                                                             ,              ,
                                                                                            ,
                                                                             ,              ,

                         iii
                                                                             ,
                                                                             ,              ,
                                                                                            ,
                                                                             ,
                                                                             ,              ,
                                                                                            ,
                                                                             ,
                                                                             ,              ,
                                                                                            ,
                                                                             ,
                                                                             ,
                                                                                            ,
                                                                                            ,

                                              Oil pan
       - - - - - Pressure feeding                    ----------_.--_ Non pressure feeding

        'LUBRICATING OIL CIRCULATION DIAGRAM
      Body; Oil pump
                                                          Inspection and replacement
                                                          When there is wear, damages or any other defects
                                                          found, repair or replace the rotor.
                                                          Clearance between the outer rotor or inner rotor and
                                                         ·the pump cover
                                                                                                      mm (in)
                                                                         Standard                   Limit
                                                           0.040 - 0.085 (0.0016 - 0.0033)      0.15 (0.0059)

                                                         Clearance between the periphery of the outer rotor and
                                                         the pump body
                                                                                                       mm (in)
                                                                         Standard                   Limit
                                                            0.10 - 0.185 (0.0039 - 0.0073)       0.4 (0.0157)

                                                         Clearance between the inner rotor and the outer rotor
OIL PUMP                                                                                                mm (in)
                                                                       Standard                    Limit
                                                                      0.17 (0.0067)             0.2 (0.0079)

                              ~        WESTERBEKE
                                       Engines & Generators

                                                39
                                             COOLING SYSTEM
WATER PUMP                                                                  REASSEMBLY
                              Seal unit
 DISASSEMBLY




                                                                  -Cover




                                                                  Bearing unit
                                                        Body      With a hole in the bearing unit set in line with one in the
                                                                  body, lock the bearing unit with a setscrew.
                                                                                                                kg·m (ft. Ibs.)
                               @~setscrew                             Set screw tightening torque      0.8-1.2 (6.0 -9.0)

Cover                                                                                                      Cover
1.   Loosen the set screw.
2.   Remove the cover.
Note:
The cover is applied with sealant (TB1207B). When re-
moving the cover, much care should be· taken not to
deform it by applying an excessive force to it.
                                             Impeller
                                             Seal unit
                                     Cover
                                             Bearing unit
                                                                 Impeller Seal unit
                                                                 1.     Apply BELCO bond No.4 to the surface where the
                                                                        seal unit comes into contact with the body, and then
                                                                        assemble the seal unit.
                                                                 2. Press in the impeller with a press until the clearance
 . center        4---           Setscrew                            between the pump impeller and the body gets to the
                                                                    specified value.
                                                                 Cover
                                                                 1.     Apply liquid gasket to the surface to which the cover
                                                                        is installed, and then install the cover.
                                                                 2.     Apply Screw-lock to the cover installation screws,
                                                                        and then tighten them.
                                                                 Clearance, play and tightening allowance between parts
                                                                 1.     Clearance between the pump impeller and the body
                                 Impeller                                                                         mm (in.)
                                                                        Standard           0.53 - 2.17 (0.0209 - 0.0854)    -'
                         Seal unit
                                                                 2.    Play in the water pump ball bearing.           mm (in)
                                                                              Standard                        Limit
                                                                  0.008 - 0.010 (0.0003 - 0.0004)        0.2 (0.0079)
                                                                 3.     Tightening allowance between center and
                                                                        the bearing shaft                       mm (
                                                                        Standard          0.026 - 0.061 (0.001 - 0.0024)


                                                  Engines & Generators

                                                          40
                                                       COOLING SYSTEM

                                                                                 A CAUTION: "any Df the VIIJIBS hare IIml".. uff tire
                                                                                 Impeller, /hey IIIDSf be fDrmd fD pment IIIDCkageln tire
                                                                                 cooling <1=11. They DflBn can be fDtmd In tire heat
                                                                                 mhanger.




Maintenance
The filter should be cleaned every 100 operating hours. Tap
the cartridge on a flat surface to dislodge dirt or clean off
with compressed air. If the cartridge is badly contaminated or
oily, replace it



                                                                                             HAW WATER PUMP
                                                                                             PART NO. 11361



                                                                                            RAW WATER PUMP

                                      ~NC
                                      PART NO. 11885




         TO TRANSMISSION COOLER   !:;!~~~I)S




Heat Exchanger Service
After approximately 1000 hocrs of operation, remove, clean
and pressure test the engine's heat exchanger. (A local
automotive radiator shop should be able to clean and test the
heat exchanger.)



                                                                                                 THERMOSTAT ASSEMBLY




                                                   ~      WESTERBEKE
                                                          Engines & Generators

                                                               41
                                                 RAW WATER PUMP
                                                          PN.4612D



   19 CIRCLIP (INTERN,ALL_

  2QPLATE




                                                                                                        INSPECT THE a-RING
                                                                                                        ANa IMPELLER. REPLACE
                                                                                                        IF THEY SHOW SIGNS
                                                                                                        OF WEAR.
                                                                                LIGHTLY GREASE THE
                                                                                PUMP CHAMBER, O'RING,
                                                                                AND IMPELLER WITH
                                                                                GLYCERIN.



                                                                     Inspection
                                                                     Inspect all parts and replace those showing wear or corrosion.

                                                                     Reassembly
                                                                     1. Install a new shaft seal #5 in the pump body. Apply some
PUMP OVERHAUL                                                           glycerin to the lip of the seal.
Disassembly                                                          2. Install the circlip #13 on the shaft. Support the outer
The pump when removed from the engine will have the hese                bearing #18 and push the shaft into the bearing until the
attachment nipple threaded into the inlet and outlet pons of            bearing contacts circlip.
the pump along with a drive pulley attached to the shoft of          3. Install spacer #17 against the circlip. Support the inner
the pump. Remove these attachments noting their positions               bearing #16 and push the shaft into the bearing until it
before starting the pump disassembly.                                   contacts the spacer.
                                                                     4. Apply some glycerin onto the O-ring #6 and install it on
1. Remove the four cover plate screws #12, cover plate #11              the shaft approximately 1/8" away from the inner bearing.
   and sealing O-ring #10.                                           S. Support ~e pump body on an arbor press. With a twisting
2. Remove the impeller #9 using a pair of pliers, grasping              mobon, install the shaft and bearing assembly into the
   the ~ub and pulling it out of the pump with a twisting               shaft seal #5 until the inner bearing contacts the pump
   mobon.                                                               body. Then with the push shaft and bearing, assembly into
3. Remove the screw #4 and seaIing washer #3 that hold the              the pump body so that the outer bearing just clears the
   cam in place. Remove the cam #2 and inner wear plate #8              boss for circlip #19.
   behind it                                                         6. Install circlip #19 and push the shaft and bearing
4. Remove dust plate #20 and circlip #19.                               assembly so the outer bearing #18 contacts the circlip #19.
S. Support the pump body on an arbor press and with a drift,         7. Install the dust plate #20.
   press the shaft and bearing assembly out the pulley end of        8. Install wear plate #8, cam 32 and secure it in place with
   the pump.                                                            washers and screw #4.
6. Remove the O-ring from the shaft.                                 9. Apply some glycerin to the surface of the impeller
7. Support the outer bearing #18 and push the shaft out of              housing, impeller inner surface of the cover plate #11 and
   the bearing.                                                         O-ring #10.
8. Remove the spacer #17 and circlip #13.                            to.With a twisting motion, install the impeller #9 into the
                                                                        pump. Install the O-ring. #10 and secure the cover plate
                                                                        #11 with the four screws #12.
                                                                     ll.~tall the pulley on the shaft and the hose nipples back
                                                                        mto the pump. Mount the pump on the engine. Check
                                                                        pulley alignment Attach the raw water hoses.

                                                  ~      WESTERBEKE
                                                         EngInes & Generators

                                                                42
                                                     FUEL SYSTEM
                                                        GOVERNOR
1.   The adjustments of the governor-related parts require the engine performance test.
2.   Before disassembling the governor, measure the dimensions "A" and "B" given in the structural
     drawing to ensure the same dimensions in reassembly.
3.   Do not disassemble the governor when the performance test cannot be conducted after reassembly.

     STRUCTURAL DRAWING OF GOVERNOR

                                                                        Idle speed screw


                        Start spring




                                                                                              Governor shaft



                                                                                              Set spring




         Injection   pum~ [===~]t:===~~~~~~~~~                                                Governor cover

                                   Main spring lever .......·<...:S
                                                                                              Guide lever


                                                                                              Timing gear esse

                                                                                              Tensioner lever




                                                                                           Angleich

                                            Sleeve



                                                                                            Full/oad stopper




                                                         Shifter




                                                ~         WESTERBEKE
                                                          Engines & Generators

                                                                   43
                                                           FUEL SYSTEM
    Reassembly of shifter
(1) Assemble the shifter to the guide lever, put the shaft through it, and then assemble the snap ring.
(2) After assembly, confirm that the shaft moves smoothly.
(3) Also, confirm that the shifter shakes smoothly.



    Reassembly of governor cover                                                                    Guide lever
    Assemble the related Pijrts such as the fuel cut lever and
    the idle spring to the governor cover.

(1) When assembling the shaft, apply engine oil to the
    sliding portion with the governor cover.
(2) Set both ends of the retum spring securely to the
    notched groove at the bottom of the cover and the
    bent-up arm of the lever respectively.
                                                                                                         Shifter
(3) After reassembling the govemor cover, confirm that
    the governor moves smoothly.
(4) When assembling the timing gear case to the gover-
    nor cover, tighten the · A n dimension shown in the
    illustration to 2 - 3 mm temporarily. .
The parts given in the square indicated by (") are assem-
bled after performance test.
                                                  mm (in.)




                                                                                      I~:"·
                              (When assembling temporarily)




                                                                                      :
   -A- dimension
                                  2 - 3 (0.0787 - 0.0118)

                                                  [Stop)            [Operate]
    Governor cover
                                                                                                I          '::::::


                                                                                      L      ""--L
                                                                                                                    (ll!)

                                                                                                                  Gasket

                                                                                                           Idle screw




                                                                                                                   Governor lever



           (Notched groove)                                                        Washer

                                                                                                         Idle spring
                                                                                   Washer
                                                                                                     Snap ring

                                                                                            Z
                                                                                   view of the drawing above)




                                                   ....v WESTERBEKE
                                                            Engines & Generators

                                                                 44
                                          FUEL SYSTEM
                     REASSEMBLY OF CONTROL LEVER RELATED PARTS
                                                                        Lever; Main spring


                                          Protrusion




                                                                      Bush
                                                                      Apply loctite No.SO'   )
                                                                    ( to the peniphery


(1) Put the lever (main spring) through the hole ofthe timing gear case lever.
Note:
Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case
lever respectively.                                                  .
(2) Put the return spring ofthe control lever through the shaft of the I.ever (main spring).
(3) Assemble the bushes.
    Assemble the bush of the lever (main spring) first, and then the control lever bush.
Note:
When assembling the bushes, apply Loctite (#601) to the periphery of the bushes.

(4) Hook both ends of the return spring (control lever) securely to the protrusion and the pin of the lever
    (main spring) respectively.


   Assemble the control lever.
   Assemble the O-ring to the groove of the bushes (control lever) first, and then assemble the washers
   and the control lever before tightening up the control lever with a nut.
                                                kg.m (ft. Ibs.)
   I   Control lever tightening torque    11.2 - 1.8 (9.0 -13.0)/



                                                                                  Control lever


                                               a-ring.
                                   Bush                                               Spring washer




                              ~u-~--t~
                Notes:
                1. TIghten the control lever after locking the control lever firmly.
                    (Do not tighten the control lever after locking the main spring lever.)
                2.   After assembly, confirm that the control lever moves smoothly.



                                   '~IWESTERBEKE
                                           i Ellfllnes & Generators
                                                       45
                             FUEL SYSTEM
               STRUCTURAL "DRAWING OF GOVERNOR

                                              Start spring

                                                   ~Sn.p p;n
                                                                          Control link
                                 Set spring

                          Guide tever                 I

         Floating fever
                                                     \ t
                                                      \


                                                             Link plate


Copnut   ~
            ...
            @l




                                                                                   Flyweight




                          ~       WESTERBEKE
                                  Engines & Generators

                                         46
                                                 FUEL SYSTEM
Reassembly of full-load stopper
Install the full-load stopper to the timing gear case, and then tighten it with a nut temporarily.


                                                                           Lever shaft                      Main spring lever

                                                                                              Link plate
                                                                                                                                Mainspring

                                                                                  Eye; start spring
                                 Timing gear case




                             Full load stopper                                  Guide piece
                                                                                                                                Set spring




                                                                                                           Floating lever




                                                         Reassembly of governor lever related components
                                                         Assemble each lever and spring to the timing gear case.


     Notes when assembling governor related components
 (1) When assembling components, apply engine oil to each slide (such as the end face of the lever, the
     hole in the shaft, and the periphery of the shaft).
 (2) Install the set spring securely to the groove of the pin connecting the floating lever, with much care to
     its assembling direction.
 (3) Confirm that each lever moves by its dead weight before installing the start spring.
(4) After assembly, confirm that each lever moves smoothly.
    And also confirm that each spring operates properly.




                                           ~        WESTERBEKE
                                                    Engines & Generators
                                                        47
                                                     FUEL SYSTEM
                                                                       FUEL UFT PUMP
                                                                       Periodically check the fuel connections to and out of the
                                                                       pump and make sure that no leakage is present and that the
                                                                       fittings are tight and secure. The DC ground connection at
                                                                       one of the pumps mounting bolts should be clean and well
                                                                       secured by the mounting bolt to ensure proper pump
                                                                       operations.
                                                                       When enetgized thru the preheat circuit, the fuel lift pump
                                                                       will purge air from the fuel system and provide a continuous
                                                                       flow of fuel as the engine is running.
                                                                       A small fuel filter has been added to the incoming fuel
                                                                       line to ensure that filtered fuel enters the fuel lift pump.



        THE IJ.RING GASKET
        ONlY NESJS ro BE
        FIEP/ACED IF IT SHOWS
        SlSNSOFWEAR



                                                                        FROM
                                                                        PREHEAT


Changing the Fuel Filter Element
 Refer to the illIIstratWn above.
L Shut off the fuel supply.
2. 'Ibm the fuel filter bowl countercIockwise to remove.
3. Pull the filter eIemeut SlIaight down and off.
4. InsJ!ecl both O-rings and replace if worn.
5. Wipe the O-rings with clean fuel and snap the new filter            NOZZLE ASSEMBLY
    up into place over the small O-ring.
                                                                       Inspection and replacement
6. Clean off the filter bowl and threads. (The bowl can be
    pro-filled with fiicJ). Screw the bowl inta place when the         Place the removed nozzle in the clean light oil, disas-
    O-ring contacts the bousing. TIghten the bowl fumly by             semble it into the nozzle body and the needle valve and
                                                                       clean them thoroughly. Then check to see if the valve
    hand                                                               moves smoothly in the body.
7. TIle key-on preheat sequence will allow the lift pump to            When it does not move smoothly, repair or replace the
   .fill the fuel filter.                                              nozzle.
8. Run the engmes and inspect for leaks.
                                                                       Injection pipe
                                                                                                                   Leak off pipe
FUB.INJECTION PUMP
The fuel injeCtion pump is a very important component of
the di.escJ engine, requiring the utmost care in handling.
The fuel injection pump bas been thoroughly bench-tested                                                                           DISASSEMBLY
and the owner-operator is cautioned not to attempt to service
it If it requires servicing, remove it and take it to an                                                                   Packing

authorized fuel injection pump service facility. Do not
attempt to disassemble and repair it



                                                                                                           \~o
                                                                      Injection pump
                                                                                        \     \
                                                                                            L.-            /
                                                                                                               /       ~   Ev
                                                                                                                            A -
                                                                                                                              l -
                                                                                                                                      He.tsh/eld


                                                                                                  Gasket               ·   fdP'
                                                 "'t)IY"   WESTERBEKE
                                                           EngInes ~ Generators

                                                                 48
                                                    FUEL SYSTEM
INJECTION TESTING
1. Using the nozzle tester, check the spray pattern and injec-
                                                                                                                               Shim
   tion starting pressure of nozzle and, if it exceeds the
   limit, adjust or replace the nozzle. When using nozzle
   tester, take thefol\owing precautions:                                                                                      Nozzle spring
a. If the diesel fuel of the nozzle tester is discolored,                                                                      Spring seat
   replace it At the same time, clean or replace the filter.
                                                                                                                               Spacer
b. Set the nozzle tester in a clean place where there is no
   dust or dirt                                                           Body
Co Mount the nozzle and nozzle holder on the nozzle
                                                                                                                               NozzleASM
   tester.
d. Use the fuel at the approximate temperature
   of 68' F (20' C)
                                                                                                                       RETAINING NUT
e. Operate the hand lever of nozzle tester several times to
   bleed the air in the nozzle line, then move the hand
   lever at intervals of one stroke per second while read-
   ing the injection starting pressure.
                                                                                                 Nozzle holder ASM
                            INJEtnON PRESSURE                        GLOW PLUGS
                            1920 PSI                                 The glow plugs are wired through the preheat solenoid.
                                                                     When PREHEAT is pressed at the control panel this
                                                                     solenoid should "click" on and the glow plug should
                           NOZZlE                                    begin to get hot.
                           TESTER                                    Inspection
                                                                     To inspect the          plug, remove the electrical terminal con-
                                                                     nections, then          unscrew or unclamp each plug from the
                                                                     cylinder head.          Thoroughly clean each plug's tip and
                                                                     threads with a          soft brush and cleaning solution to
                                                                     remove ali the          carbon and oil deposits. While cleaning,
                                                                     examine the tip for wear and burn erosion; if it has
                                                                     eroded too much, replace the plug.
                                                                     Testing
                                                                     An accurate way to test glow plugs is with an ohmmeter.
 A CAUTION: The spray injected from the nDZZle is                    Touch one prod to the glow plug's wire connection, and
                                                                     the other to the body of the glow plug, as shown. A
 of such velocity that It may penetrate deeply Into the              good glow plug will have a 0.4 - 0.6 ohm resistance.
 skin of ffngers and hands, destroying tissue. If It                 This method can be used with the plug in or out of the
 enters the bloodstream, it may cause blood poisoning.               engine. You can also use an ammeter to test the -power
                                                                     drain (5 - 6 amps per plug).
        good    No good   No good No good

        10                  !=.JI
                            r
                                       '01.
                                       I
        I


     !
    About 4°
                            f..I\
                            (,
                             ./11\
                            ., I
                                       T
Check to see if the spray condition and the injection pressure
are normal. Adjust them to the specified value respectively         GLOW PLUG llGHTENING TORQUE
when they do not meet the standard value. Use shims to                         1.0· 1.51of.l(G (7 -11 FT-LB)
adjust the injection pressure.
                                                                                                                     USIIIGA
                                                                                                                     TESTUGHT




                                                                                                                                               +
                                                        Engines & Generators
                                                               49
                                                 ENGINE ADJUSTMENTS
    TESTING ENGINE COMPRESSION                                               Low Compression
    Make certain the oil level (dipstick) is at the correct level            When low compression is found, determine the cause by
    and the air intake filter is clean. The battery and starter motor        applying a small amount of oil in the cylinder thru the glow
    must also be in good condition.                                          plug hole. Allow the oil to settle.
    1. Warm the engine to normal operating temperature.                      Install the pressure gauge and repeat the above test If the
    2. Disconnect the wire to the fuel shutdown solenoid.                    compression reading rises dramatically, the fault is with the
                                                                             rings. If the compression valve does not rise, the problem is
    3. Remove all the glow plugs from the engine and install
       the compression gauge/adapter combination to the                      with the valves.
       cylinder On which the compression is to be measured.                  A slight rise in compression would indicate a problem with
                                                                             both the rings and the valves.


                                                                             DlL PRESSURE
                                                                             Low Oil Pressure
                                                                             The specified safe minimum oil pressure is 5 - 10 psi. A
                                                                             gradual loss of oil pressure usually indicates worn bearings.
                                                                             For additional information on low oil pressure readings, see
    Note:
                                                                             the ENGINE TROUBLESHOOTING chart.
    Compression pressure may be measured starting at any
    cylinder and in no particular cylinder order. However, it
    is very important that the compression pressure be                       Testing Oil Pressure
    measured in each cylinder.                                               To test oil pressure, remove the oil pressure sender then
    Therefore, start at the No. 1 cylinder and work back. In                 install a mechanical oil pressure 'gauge in its place. After
    this way, you will be sure to measure the compression                    warming up the engine, set the engine speed at idle and read
    pressure in each cylinder.                                               the oil pressure gauge.

    4. Oose the raw water seacock (thru-hull).                                           558 FOUR OIL PRESSURE
    5. Crank the engine and allow the gauge to reach a                                   43 TO 65 PSI (290 TO 590 KPa) NORMAL
       maximum reading, then record that reading.
    6. Repeal: this process for each cylinder.
    NOTE: Ifthe readings are below the limit, the engine needs
        an overlraul.

                55B FOUR COMPRESSION PRESSURE
                441 PSI (3.04 MPa) NORMAL AT CRANKING
                SPEED OF 250 RPM.                                                                                          OIL PRESSURE
                44.1 PSI BETWEEN CYLINDERS                                                                                 SWITCH


                                                                                                                 ~
·
    7. Re-install the glow plugs (use anti-seize compound on                          MECHANICAL
       the threads) and reset the fuel shut-off to the run position.                  OIL PRESSURE
                                                                                      GAUGE
    S. Open the raw water seacock (tbru-hull).

      Compression ga.Jge' ....... \




                                                               Engines & Generators

                                                                        50
                                           ENGINE ADJUSTMENTS
 VALVE CLEARANCE ADJUSTMENT                                             3. In accordance with the conditions of cylinder No.1, mea-
                                                                           sure and adjust if required the clearance of the valves
  The valve clearance must be adjusted every 500 operating                 marked with eiiher @ or · in the table below.
  hours or whenever the valve rocker is abnormally noisy.
  Valve adJustment should only be done when engine is cold.
  Cold engine valve clearance is O.OI5in (O.4Omm).                               Cylinder No.                   1           2           3           4
                                                                              Valve arrangement             I       E   I       E   I       E   I       E
                                                                        When No.1 cylinder is at TOe
                                                                        in the compression stroke
                                                                        When Np. 4 cylinder is at TOe
                                                                                                           ··· ·            @ @                 @ @
                                                                        in the compression stroke
                                                                                             I: Inlet   E: Exhaust

                                                                        4. On completion of the valve clearance alignment make a
                                                                           mark alignment as in 1 by giving a turn to the crankshaft
                                                                           in the normal direction. Then measure and adjust the
                                           VALVE CLEARANCE                 clearance of the other valves.


 NOTE: The cylinder head bolts have been tightened with the
                                                                            A CAUTION: The rocker ann is made of die-cast
 "Angular 1ightening Method". There/ore, it is not necessary                aluminum. Therefore, be careful not to tighten the
 to retighten the cylinder head bolts before adjusting the valve            adjusting screw to excess.
 elearanees.
 ADJUSTMENT PROCEDURE                                                   Adjusbnent of Injection Timing
                   f                                                    The injection timing may not be re-adjusted. Take care not to
                                                                        forget to insert a shim in the mounting surface when
                                         CRANK PULLEY                   reassembling the injection pump after disassembly.


TDCMAR~K~                Q;         "
                         ",Co. V
           "".-~
           ::::7
                   ======
 1. Thm the crankshaft clockwise so that the marlc groove 0';'
    the crank pulley is aligned with the TDC mark (cast out)
    on the timing gear case cover.
 2. Remove the cylinder head cover and check to see if cylin- :
    der No.1 is at TDC in the compression stroke or at IDC
    in the exhaust stroke. When the intake and exhaust valves
    are closed, the cylinder is at TDC in the compression
    stroke, and when only the exhaust valve is open, it is at
    TDC in the exhaust stroke.


CYUNOER NO.1
COMPRESSION




                                                   '~/WESTERBEKE
                                                          i Engines & Generators
                                                                   51
                                         ENGINE ADJUSTMENTS
.INJECTION TIMING
                                                                        Injection timing   I                              BTDC 16·
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made.              Note:
                                                                  The injection timing varies according to the specifica·
1.   Remove the injection pipe of the No.1 cylinder.              tions of the machine.
2.   Remove the delivery valve holder of the injection
     pump of the No. 1 cylinder, and then pull out the            6.     Adjust the injection timing with a shim between the
     delivery spring.                                                    injection pump and the cylinder block.
3.   With the spring left removed, install the delivery                  Shim is available in the following 9 types, and "iden·
     valve holder.                                                       tification mark" is stamped (or imprinted) on the top
                                                                         face.
               oelivery valve
                         holder       Injection pump              Identification mark of shim and its thickness                  (mm)
                                                                       Mark Thickness          Mark   Thickness     Mark    Thickness
                                                                        2        0.2            5        0.5          8         0.8
                                                                        3        0.3            6        0.6         10         1.0
                                                                        4        0.4            7        0.7         12         1.2
                                  \

                         ,,/                                      Note:
                                                                  For each of the injection pumps of three cylinders, the
                                                                  shim adjustment is made at the same time.
4.   Slowly tum the crankshaft pulley clockwise, at the
     same time, continue to feed the fuel.                        When a shim is missing while overhauling the engine
                                                                  and the shim thickness is unknown, assemble the
     When the fuel stop flowing out from the No.1 deliv·          engine with provisional shim inserted. After assembling
     ery valve holder, stop turning the crankshaft.               the engine, check the injection timing and adjust the
     This crank angle position is the starting point of           shim until the normal injection timing is obtained.
     injection.                                                   Reference:
5.   In the condition at Step (4) above, confirm what             To add the 0.1 mm shim thickness corresponds to the 1
     degree the "groove mark" of the crank pulley is at,          degree of crankshaft angle advance.
     when seen by the "timing mark", provided in the
     timing gear case.
     When the value is out of the range of the normal                                                    Injection pump
     injection timhg, adjust it accordingly.
                                                                                                               Cylinder block




                                                       Engines & Generators

                                                             52
                           WARNING LIGHTS, ALARMS &CIR~UlT BREAKER
       ALTERNATOR WARNINGS                                                 LOW OIL PRESSURE ALARM SWITCH
       The Captain Control Panel indicates alternator low dischaIge        A low oil pressure alarm switch is located on the engine
   I   with a red warning light.                                           block. This switch's sensor monitors the engine's oil
       The Admiral Control Panel uses a voltmeter to monitor the           pressure. Should the engine's oil pressure fall to 5 - 10 psi
       perfonnance of the alternator.                                      (0.4 - 0.7 kgfcm'), this switch will activate a pulsating
                                                                           alarm.
       COOlANT TEMPERATURE SWITCH
       A coolant temperature switch is located on the thermostat
       housing. This switch will activate a continuous alarm if
       the coolant's operating temperature reaches approximately
       2100 P (99°C).


                                                                                                                              OIL PRESSURE AlARM
                                                                                                                              SWITCH
                                                                                                                            .,.~




TOALAR'M BUZZE5.~                                                          ENGINE CIRCUIT BREAKER
                                                                           The DC harness on the engine is protected by an engine
                                                                           mounted manual reset circuit breaker (20 arnps DC).
                                                                           Excessive current draw or electrical overload anywhere in
                                                                           the instrument panel wiring or engine wiring will cause the
                                                                           breaker to trip. In this event most engines will shut down
                                                                           because the opened breaker disconnects the fuel supply. If
                                                                           this should occur, check and repair the source of the problem.
                                                                           After repairing the fault, reset the breaker and restart the
                                                                           engine.


                                                                                                                             BREAKER




                                                                              TWO
                                                                              WIRES




                                                       ~       WESTERBEKE
                                                               Engines & Generators

                                                                      53
                                                    STARTER MOTOR
DESCRIPTION                                                          No-Load Test
The sttuter can be roughly divided into the following sections:      1. Connect the ammeter, voltmeter, and battery to the starter
· A motor section which generates a drive power.                        as illustrated.
· An ovemmning clutch section whicb transmits an arma-               2. When the switch is closed, the pinion must protrude and
  lUre tmque, preventing motor overrun after starting.                  the starter must run smoothly (at 3000 rpm or more). If
· A switch section (solenoid) whicb is operated wben actu-              the current or starter speed is out of specification, disas-
  ating the overrunning clutch through a lever and whicb                semble the starter and repair it
    supplies load current to the motor.

The starter is a new type, small, light-weight and is called a
high-speed internal-reduction starter. The pinion shaft is sep-
3I8Ie ftom the motor shaft; the pinion slides only on the pin-
ion sIIoI4 A reduction gear is installed between the motor
shaft and a pinion shaft. The pinion sliding part is not
exposed outside the starter so that the pinion may slide
smoothly without becoming fouled with dust and grease. The
motor shaft is supported at both ends on ball bearings. The
lever mech8!!ism, switch and overrunning clutch inner circuit
                                                                    r - - - - - - - - - - - I SAnERY 1 - - - - - ,
are identical to conventional ones.

AD.IISIMENT AND REPAIR                                                  A    CAUTION: Use thick wires as mut:h as possible and
                                                                        tighten e'l8ry tetminal SllCursly. This is a solBl/oid shift-
If any almormaIity is found by the following tests, the starter         type starter whlt:h makes a rotating sound loudsr than
should be disassembled and repaired.                                    that of a dITBCt-dri'18 type stalter. When dllfflcting
                                                                        starter rotation at the pinion tip, be careful not to come
Piaion Gap Inspection                                                   In contact wfth the pinion gsar when/t protrudes.
1. 'Connect a battery (12V) between the starter terminaI S
    and the starter body, and the pinion drive should rotate out
    and stop.                                                        SOLENOID
                                                                     Perform the following tests. If any test result is not
                                                                     satisfactory, replace the solenoid assembly.
 A c:AIJID: IlI1rtI1t apply               w/tage tor over 10
I                                                                    1. lnspect the solenoid for continuity between terminals
                              battery.


                                                                         (+) and (-) and between terminals S and the body and
· - - t:III1lImIoIIsI                                                    M and the body. There should be no continuity found
2. tightly push the pinion bsck and measure the return                   between terminals S and M. Continuity will be found
    stroke (called pinion gap).                                          between terminals S and the body and terminaI M and
                                                                         the body.
3. If the pinion gap is not within the standmd range, (0.5 to
   2.0 mm), adjust it by increasing or decreasing the number
   of shims on the solenoid The gap is decreased as the
   number of shims increases.




 GENTLYPUSH
 BACK                                                                               MUlTIMETER

                                                                     NOTE: Disconnect the wire from terminal M.
                                                                     2. Connect a battery to the solenoid's terminal S for (+)
                                                                        and M for (-). Have a switch in the + lead and close it
                                                                        The pinion drive should extend fully out
    1.5:2.D ....
                                                                        A CAUTION: Do not apply battery current for mote
                                                                        than 10 seconds when testing the solenOid.
                      PlalOaGAP


                                                   ,,,,,,,1WESTERBEICE
                                                          i Engines & Generators
                                                                   54
                                                            STARTER MOTOR
                                                                              4. Return test:. With a battery connected to the solenoid ter-
                                                                                 minal M (-) and to the starter body, manually pull out the
                                                      ~ COIINECTDR OFF           pinion fully. The pinion must return to its original position
') . AT11IACTION lEST                                                            when released from holding by hand.




        3. Holding test. With a b8ttery connected to the solenoid ter-
           minal S (+) and to the starter body, manually pull out the
           pinion fully. The pinion must remain at that position even
           jlYben released from holding with your hand.




                                                                                                     RETURN TEST
                                                      ~CI)NNECTOR OFF




        STARIER DISASSEMBLY                                                   7. Pull out the reduction gear lever and lever spring from the
                                                                                 front bracket
        L Discon....,. the wire from the solenoid terminal M (-).
                                                                              8. On the pinion side, pry the snap ring out, and pull out the
      . 2. Loosen the two screws fastening the solenoid. Remove                  pinionandpinionsrurll
           the solenoid assembly.
                                                                              9. At each end of the armature. remove the ball bearing with
        3. Remove the two long through bolts and two screws
 )         fas1r:ning the brush holder. Remove the rear bracket
                                                                                 a bearing puller. It is impossible to replace the ball bearing
                                                                                 press-fitted in the front bracket Ii that bearing has worn
        4. WlIh the brushes pulled away from the armature,                       off, replace the front bracket assembly.
           remove the yoke and brush holder assembly. Then pull
           the armature out                                                                             TERMINALM
        5. Remove the cover, pry the snap ring out, and remove the
           washer.
        6. Unscrew the bolts and remove the center bracket At the
           same time, the washers f~ the pinion shaft end play
           adjustmeDt will come off.


                                  WEAR & CfflP"ING.

                 STARTBI
                 . II011IR


                        SNAPRIUn_-~~""'-Y


               LEVER SPRING
                                                                                                          NOTE: Jnspect, c/eOJl and replace
                                                                                                          if necessary brush, COTTU1UJ!er,
                                                                                                          solenoid, Ql77U2ture, elc. See the
                                                                                                          Jollawing pages.

  )
      PINION
                                                                  Engine,s & Generators

                                                                         55
                                                     STARTER MOTOR
STARlER INSPECTION                                                                                          /CRIICUS CLOTH

Solenoid
Inspect the solenoid for continuity between terminals S and
M and between tenninals S and body. No continuity should
be found between S and M. Continuity should be found
between S and the body and M and the body.




                                                                      Brush and Brush Holder Inspection
                                                                       1. Check the brushes. If worn out beyond the service limit,
                                                                           replace the brushes.
                                                                      Brush Height
                                                                      StlJlUiard 17 nun (0.669 in)
                                                                      limit 6 nun (0.236 in)


                                                                                 BRUSHES
Inspecting Tbe Annature
L Check.the aonature with a growler tester. If it's short
  c:ircuited, repIace the 8IlllllIDre. Also check: for insulation      2. Check the brush spring tension. A weak or defective
  between the C(>IIl1IIlloicator and its shaft. If poorly                 spring will cause excessive brush wear; replace the springs
  insulated, repIace the armaIlIre.                                       if suspect


                                            ARMATURE                                 BRUSH HOLOER
                                              CHECK                                  ASSEMBLY




                                                                       3. Check for insulation between the positive brush holder
2. Measure the commutator O.D. and the depth of undercut                  and holder base. If poorly insulated, replace the holder
   Repair or repIace4t if the service limit is exceeded Also              assembly. Also check the brush holders for proper staking.
   check: the comm1i1ator outside surlace for dirtiness and
   rouglmess. If rough, polish the commutator with fine
   aocus cloth.




                                 CoIlUlUllDr O.D. StJuulJzrd
                                      StiuuIIlrd: 38.7 nun (1.523 in)
                              D~ .l·.....ce limit: -1.0 nun (-0.039 in)




                                                    1~/WES)SFlBEKE
                                                            , Engines & Generators

                                                                    56
                                                     STARTER MOTOR
  Field Coil Inspection                                                2. Greasing. Whenever the starter has been overhauled,
                                                                          apply grease to the following parts:
  1. Check for insulation between one end (brush) of the
     coil and yoke.                                                       a. Armature shaft gear and reduction gear.
  2. Check for continuity between both ends (brushes)                    b. All bearings.
     of the coil                                                         c. Bearing shaft washers and snap rings.
  3. Check the poles and coil for tightness.                              d. Bearing sleeves.
                                                                          e. Pinion.
                                                                         f. Sliding portion of lever.


                                                                        A CAUTION: Never Slllear the starter fitting ~rface,
                                                                        terminals, bnIshes, I1r c/JlRlllutatl1r with grease.

                                                                       3. After reassembly, check by conducting a no-load test
                                                                          again.


                                                                                                    GEAR

. FIELD COIL TEST



  STARTER ADJUSTMm AND REASSEMBLY
                                                                           WASHER




                                                                         SNAP RING
                                                                                                                                 ..
    A CAUTION: IJeforB installing, thl1lDUghly clean the                      --~I~-O.5          mm MAX
    stalter flange and mollJltfng SIIrfat:es, reml1w alillil,
    old paint, aad IU$I. Starter perflJrmanCB largely
    depends I1n the quality 111 the wiring. Use wire 111 suffi-                           PINION SHAFT END PLAY
    cient size aIJd grade between the battery and starter
    and fully tig/ttBn to the rellll/nal.

  Reassemble the starter assembly in the reverse order of
  disassembly, making sure of the following:
  1. Pinion shaft end play adjustment. Set the end play (thrust
      gap) to between 0.5 to 2 mm by inserting an adjusting
      washer between the center bracket and the reduction gear.
     .a. Fit the pinion shaft, reduction gear washer and snap
         ting to the center bracket
      b. Measure end play by moving the pinion shaft in the
         axiaI direction. If the end play exceeds 0.5 mm,
         increase the number of adjusting washers inserted.




                                                   ,.~/WESTmBEKE
                                                           I Engines & Generators
                                                                  57
                                           DUAL OUTPUT ALTERNATORS
                                                                                                                               SPACER TO MOUNTING
                                                                                                                               BRACKET

DESCRIPTION
Dual outpw and high output alternators are available as
optional equipment on most WESTERBEKE engines. These
alternators can be installed during factory assembly or as                  CABLE
                                                                         TO BATTERY (POSITIVEI
add-on equipment at anytime.
Dual alternators can be configured to charge two banks of
balteries at the same time or, using a battery selector switch,
cbarge each set of batteries separately.                    TO
                                                                                                                                       PULLEY
 IISTAl1ATlON
If an optional dual alternator has already been factory installed, .
simply follow the WESTERBEKE wiring diagram and the
engine installation instructions.
If the new dual alternator is being added to an existing ''in-
the-boat" engine, carefully follow the alternator installation
instructions below:
L Disconnect the alternators negative cable from the
     battery.
2. Remove the alternator and disconnect or tape off the
     output [positive] cable. Do not reuse.
3. Install the new alternator.
4. Attach a new heavy gauge output cable[s] from the
     alternator's output terminal [s]. Using the cable sizes
     indicated.
                                                                                                                 DUAL OUTPUT ALTERNATOR
                                                                                                                 [CHARGING ONE BAnERY]

    (ALWAYS USE FINE STRAND CABlEl

S. Make certain that the batteries negative post ground
                                                                        BATTERY 1 ___--:::;-~
   cable to the engine block is the same heavy gauge as
   the positive cable.
6. Mount the regulator to a flat surface in a cool dry
   location.
   a. Connect the black wire to the ground terminal on the
      alternator.                                                  TO


  A CAUTION: DIl nllt CIInnect any pllwer stJUTeB with-
  Ilut first fJ1/Junding the regulatllr.


    b. Plug the 2-pin connector into the alternator, make
        certain it is firmly seated.
    c. The red "battery sense" wire should be connected to
        the batteries positive [+] post [or the positive cable].
    d.. The brown wire "keyed ignition" is the key circuit
        which actuates the regulator, this wire must connect                                     """.!fila".. ~ONNECTS TO PINK AND
        to a switched [+] 12 volt source. Refer to the                                                         .         LEADS. THE PINK
                                                                                                             Z.-"",WIJ~E CONNECTS TO THE
       WESTERBEKE WIRING DIAGRAM for the proper                                                                            BUZZER. THE BLUE
      connection.                                                                                                  WIRE CONNECTS TO THE
                                                                                                                  OIL PRESSURE SWITCH.
Dual Pulleys
A variety of accessory pulleys for high powered and dual                                                   DUAL OUTPUT ALTERNATOR
chaIging alternators are available from your                                                               [CHARGING TWO BAnERIES]
dealer.


                                                            Engines & Generators

                                                                   58
                                              DUAL OUTPUT ALTERNATORS
TROUBLESHOOTING                                                          Alternator Testing
NOTE: Before troubleshooting, mrzke certain that the drive               The regulator is functioning properly and the batteries
belts are tight and the batteries are in good condition.                 are in good condition.
Regulator Testing                                                        1. Test the voltage at the alternator plug with the engine
                                                                             off·key on. The voltage at the alternator terminal F and
The red "battery sensing" wire A connects to the battery, it                 the voltage in the plug [blue wire F] from the regulator
must always read battery voltage. If battery voltage is not                  should read the same.
presen~ trace the wire for a bad connection.
                                                                         2. Hold a screw driver close [112"] to the alternator pulley.
The orange wire S should read 0 volts with the key off, 12                   If voltage is present you should feel the magnetic field. If
volts [approximately] with the key on. If the readings are                  .no~ the problem may be the brushes [worn] or the rotor
incorrec~ trace the wire for a bad connection.                               [open circuit].
The blue wire F supplies current to the alternator fields, its           3. Start the engine, at fast idle the output terminals should
voltage will vary depending on the battery charge or actual                 indicate 14.2 volts [no load]. A reading of 12.6 would
load/rpm. The readings can vary from 4 to 12 volts with the                  indic~te the alternator is not performing properly.
key on, 0 volts with the key off.
                                                                             Apply a load such as an electric bilge pump, the voltage
KEY ON · NO VOLTAGE    REGULATOR IS DEFECTIVE                               should maintain at least 13.8 volts. 13 volts or less
KEY OFF· BATTERY VOLTAGE   REGULATOR IS DEFECTIVE                           indicates the alternator is faulty.
REGULATOR TEST POINTS AND PROPER VOLTAGE
Tennlnal/Color   IgnJUon 011   IgnRion On      Engine Running            NOTES:
 I Brown         0 volts       2 ·12 valls     14.2 volls                o    When the engine is first started, it takes a few moments
 A Red           12.6 volls    12 vulls        14.2 valls                     for the altel71lllOr to "ldck in" and take the load. There
 S Orange        ovalls        ovalls          6·8 Valls                     is a noticeable change in the sound of the engine and the
 F Blue          Ovolls        10 ·11 valls    4 ·12volls                    RPM gauge will excite.
 Alt.OUlpUi      12.6 valls    12 valls        14.2 volls
                                                                         o    A slight whine is normlll when running with a full load
                                                                             on the aitel71lllOr.
                                                                         o   When the alternator is producing high amperage, it will
                                                                             become very hot.
                                                                         o   When replacing the altel71lllOr drive belts, always
                                                                             purchase and replace dual belts in matched pairs.




                                                   t'fllV'IWESTERBEKE
                                                            I Engines & Generators
                                                                   59
                                                                                                 WIRING SCHEMATIC
  +                          STAIIT
                                                                                                       ~
       II vot
                         r-,
                          m.                               S1ARTCA

                         J
                         1
                                ' I
                                                       ~@--------- -----,
                         ~-"                                                                                          1
                                       PItHtAl
                                   r-,SOl.                       ~~~~
                                                                                                                      1
                                                                                                                      1
                         ~~:
                                                                 J   G'L'OW';L!G'S
                                                                                                                      1
                                                                                                                      1
                                 ~-~                                                                                  1
                                                             ALttRNA10R
                                                                                                                      1     J. TH[ '[IIK WIR[ AT ~LUG 2 IS InIUUD AIID SHOULD BE INSUUl(D, C~"A[N 'ANtl ONLY ·
                                                              .~~                                                     1

                     ( ...
                                                                                                                            4. THE GRAY .IRE AT 'lUG 2 IS UMusro UD SHOULD lit INSULAl(D, AOKIUL 'ANEL OIIU.
                                                                                                                      1
Y .·. n.                     C.B ·                                                                                    1
                                                                                                                      1

                                                                                 LIH PUMP
                                                                                                           r---J.-----,I
                                                                                                              TO ALT. I
                                                                                                           , .,,- TeRM.

                                                                                       P                        J ~gf~ I
        Ii      ;;
                 =~
                                                                         S~~EA
                                                                              rU[L
                                                                              S~'e-II,!!O.!.._

                                                                                     /"":0..
                                                                                               InUl

                                                                                                           U
                                                                                                           I
                                                                                                           I
                                                                                                           1
                                                                                                                fl~ ,I'
                                                                                                               ~L!. \::::::U- ~1:
                                                                                                           I lQBP 1 30B~ ONl'/
                                                                                                                                   _I




       IJ
                                                                                                                                     I

                "                                                         ""';::;:
                                                                         ,[IIDU
                                                                                                           -----------
                                                                                                           I        '.MIIV6i         I                                                              .'4 LT. BLU

                                                                                                                                                                                                         fl4 PINK
                                                                         difcH X",..I"




                                                                 1                               1    =

                                                                                                                                                                .,0 R[O
                                                                                                                                                                                              .1.4   BRN



  .n                                                                     lAC_ora
                                                                                                      ADMIRAL                                                   @pRESTOI ITE 72 AMP                           AI T

  ,   .
      .n
       ft.                                                                   · ."                     PANEL

                                                                                                                                                                ,,4   8RN

                                                                         VOLTMUtA

  SUIT
      ...                                                                 +          ."                                                                         ~14   GRA

                                                                                     ..1.
                                                                                     ...
                                                                                 GAUGE




                                                                                                                                                           1114 PINK



                                                                                                                                                         414 LT. 8L



                                                                                                                                                    @ I t I YfjRSAl PROPUI S I                           Wr
                               "
                                               i                       ':~M~R
                                                                                                                                                     PR STO ITF 51 AMP. A


   ...
 ~'"                               ~   " "                               I                            CAPTAIN
                ,        AtT.

                         ~
                                       "
                                                     ..                               ". ~
                                                                                      ""
                                                                                      lESf
                                                                                                      PANEL
                                                                                                                                                                               51 AMP.         AI TERNATOR
                                                                                                                                                                              ST"NOARO AllERtiA10R ON TilE

 ... i
 "~k
                :
                ~
                         ::f,~                     04 02
                                                                               "
                                                                                                                                                                              638 01. 63C Il'.. i IB IT. 826 IT,
                                                                                                                                                                              1086 D. & 10SC ~.

                'i       =
                         ~ r,~;            "
                         "61'
                                                             n
                                                                     "
lJ.=:J
 '1[101[101
  SIlIrCti
                     ",-UN
                               ,
                     ·


                                           WIRING SCHEMATIC #39144
                                                                                                                                     ,~   AtD

                                                                                                                          ',sruuW:: lWIT~';.'W,)   19




                                                                                                                                                   OPT IONAI                AI IERNATORS®
                                                                                                                                                        'J~A,    1&0.1., I!OA. ltsT[1I ALHRNAlORi
                                                                                                                               AVAI'An'{qM 1H!     no rv ue ty              liB II UB ty ,nRD        I    '9MjXIQNI~




                                                                                               ~          WESTERBEKE
                                                                                                       'Englnes & Generators

                                                                                                               60
                                                     WIRING DIAGRAM                             &I.'Wf.?A




                                                                                                    r~I'
                                                              Q   II flQSURC
                                                                   mID                              I~
                                         -1+ ·~.iI."!H!l''- +
                                                                                                    1    "N , ME

             ~   - - - - YIl-----,_
                                                             -+ - - - - - - -                         IU
                                                                                                           MODELS)



            16'
$[[   HOH   2:~
            I$j
             1
             1
             1


        ·\~v~
                                                                                                     ! !   rT PUlAI'



            aA!.ll!!
NOTE: An on-off swiI&h
should be installed in this
circuft to disconnect the
slllrterflOm the battel}' in
an emergency and when
leaving the.boat Twelve
volt engine sIllrte,.
typically dtaw 200 to 300                                                               ADM I RAL
amps when etanking. A                                                                   PANEL
switch with a continuous
tating of 175 amps at 12
vac will normally serve
this function, but a swiJch                                                                         WIRING DIAGRAM #39144
must never be used to                                                          1
                                                                               I·
"make' the sIllrter circuit




                                                                                    "
                                                                                                                        CAPTAIN
                                                                                                                        PANEL
                               ----------------------------~




                                              r~~f~~~==R-:
                                                  o                                                                               1
                                                                                                                                  1
                                                                                                                                  1
                                                                                                                                  1
                                                                                                                                  1
                                                                                                                                  1
                                                                                                                                  1




                                                 ~       WESTERBEKE
                                                         Engines & Generators

                                                                  61
                                                     TACHOMETER
TACHOMETEB,IIIOUR METER                                               NOTE: Cumn! model tachometers use a coarse adjustmen!
                                                                      dial 10 set the tachometer 10 the crankshaft pulley rpms. The
 The tachometerlhour meter used in propulsion engine instru-
                                                                      calibrating screw is then used for fine tuning.
ment panels contains two separate electrical circuits with a
 common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the (+) terminal
on the back of the instrument
'The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
.tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8
volts DC.
The following are procedures to follow when troubleshooting
                                                                                                                           TERMiNAl
a fault in eithei- of the two circuits in a tachometerlhour
meter.
Hour meter Inoperative
Oteck for the proper DC voltage between (+) and (-)
terminals.                                                            TACHOMETER CHECK (New Installation)
L Voltage present - meter is defective - repair or replace.           NOTE: In a new installntion having new insrrumen! panels.
                                                                      the tachometer may not always be comctly calibrated 10 the
2. VolIllge not present - trace (+) and (-) electrical con-           engine's rpm This calibration should be checked in all new
    nections for fault (Jump 12 volts DC to meter (+)                 instal1ntions.
    terminaJ to verify the operation.)
                                                                      1. Warm up the engine to normal operating temperature.
Tachometer Inoperative                                                    Remove any specks on the crankshaft pulley with a clean
Check for the proper AC voltage between tachometer input                  cloth and place a piece of suitable reflecting tape on the
terminal and (-) terminal with the engine running.                        pulley to facilitate use of a photoelectric type tachometer.
L Voltage present - attempt adjusting meter through calibra-          2. Start and idle the engine.
    tion access hole. No results, repair or replace meter.            3. Aim the light of the tachometer onto the refiecting tape to
2. AC voltage not present - check for proper alternator DC                confirm the engine speed. Check the instrument panel
   output voltage.                                                        tachometer reading. Adjust the tachometer in the panel by
                                                                          using the instrument coarse adjustment to calibrate the
3. Check for AC voltage at tach terminal on alternator to                 instrument reading to the closest R.P.M. that the photo tach
   ground                                                                 is showing. Then use the fine calibration adjustment to
4. Check electrical connections from tachometer input ter·                bring the instrument to the exact reading as the photo tach.
   minaI to alternator connection.
Tachometer Sticking
1. Check for proper AC voltage between "tach inp."
   terminaJ and (-) terminal.
2. Check for good ground connection between meter (-)
   terminaJ and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt
Tachom~lnaccurate
a. With a hand-held tach on the front of the crankshaft
   pulley retaining nut or with a strobe-type tach, read the
   front crankshaft pulley !pm at idle.
b. Adjust the "tachometer with a SmaIl PbilIips type screw-
   driver through the calibration access hole in the rear of
   the tachometer. Zero the tach and bring it to the !pm
   indicated by the strobe or hand tach. (Verify the !pm at
   idle and at high speed and adjust the tach as needed).




                                                 ~       WESTERBEKE
                                                         Engines & Genellltors

                                                                 62
                                 WESTERBEKE 51A MANDO ALTERNATOR
                                                DISASSEMBLY AND TESTING

                                                                         A WARNING: A failed alternator can become very
                                                                         hot. Do not touch until the alternator has cooled down.

                                                    REAR HOUSING

                                                                         A WARNING Before starting the engine, make
                                                                         certain that everyone is clear of moving parts! Keep
                                                                         away from sheaves and belts during test procedures.

      FAN
                                                                         A WARNING Multimeters and DC Circuits
                                                                         DC and AC Circuits are otter mixed together in marine
                                                                         applications. Always disconnect shore power cords,
                                                                         isolate DC and AC converters and shut down generators
            HOUSING
                                                                         before performing DC testing. No AC tests should be
                                           . ASSEMBLY COVER
                                                                         made without proper knowledge of AC circuits.




       EXCITER
       TERMINAL
                                                       TERMINALP


I   COVER


    SENSING
    TERMINAL

            GROUND                                                     REFER TO THE
            TERMINALE                                                  WIRING DIAGRAMS FOR THE ABOVE
                                                                       WIRING HARNESS CONNECTIONS

                                                                       TESTING THE EXCITATION CIRCUIT
     TESTING THE OUTPUT CIRCUIT                                       1. Connect the positive (+)voltmeter lead to the excitation
     1. Connect the positive voltmeter lead to the output                terminal R on the alternator and the negative (-) lead to
        terminal B and connect the negative lead to the ground           the ground terminal E on the alternator.
        terminal E on the alternator.                                 2. Tum the ignition switch to the on position and note the
     2. Wiggle the engine wiring harness while observing the             voltmeter reading. The reading should be 1.3 to 2.5
        voltmeter, The meter should indicate the approximate             volts (see illustration).
        battery voltage, and should not vary. If no reading is        3. If the reading is between .75 and 1.1 volts, the
        obtained, or if the reading varies, check the alternator         rotor field circuit probably is shorted or grounded.
        output circuit for loose or dirty connections or                 Disassemble the alternator and test the rotor as
        damaged wiring.                                                  described under CLEAN AND TEST ALTERNATOR
                                                                         COMPONENTS in this section.
    NOTE: Prior to any alternator testing, inspect the entire
    alternator system wiring for defects. Check all connections       4. If the reading is between 6.0 and 7.0 volts, the rotor
    for tightness and cleanliness, panicu/arly battery cable              field circuit probably is open. Remove the regulator
    clamps and battery terminals. Inspect the alternator drive            and inspect it for worn brushes or dirty slip rings.
    belt for excessive wear and replace if necessary. Also adjust         Replace the brushes if they are less than l/4in. (6 mm)
    for proper belt tension.                                            . long. If the brushes and slip rings are in good condi-
                                                                          tion, disassemble the alternator and test the rotor, as
                                                                          outlined under CLEAN AND TEST ALTERNATOR
                                                                          COMPONENTS in this section.

                                                              Engines & Generators

                                                                    63
                                     MANDO ALTERNATOR SERVICE
                                                                        e. Remove the regulator cover.
TESTING THE EXCITER LEAD
                                                                        f. Temporarily re-install Jumper (A) and all associated
                                                                           nuts. Leave Jumper (B) installed.
                                                                        g. Remove the plastic plug from the side of the
                                                                           regulator.
                                                                        b. Connect a jumper between the top brush lead
                                                                           and the ground.




                                                                         JUMPER A


5. H no reading is obtained, an open exists in the
   aliernator-excitation lead or in the excitation circuit of          COVER
   the regulator. Disconnect the lead from exc terminal R.
   Connect the positive voltmeter lead to the excitation              SENSING                                           ......--OUTPUT
   lead and the negative voltmeter lead to ground terminal            TERMINAL                                                  TERMINAL
   E. If the voltmeter now indicates an approximate. battery
   voltage, the voltage regulator is defective and must be
                                                                                  GROUND
   replaced. If no voltage is indicated, check the excitation
   circuit for loose or dirty connections or damaged wiring.                                                                B
                                                                                                   \
                                                                                                       \
TEST VOLTAGE REGULATOR                                                                                     I
Perfonn this test to determine if the voltage regulator is                               CONNECT    ..
operating correctly, using a 0 - 20 volt DC voltmeter.                                   JUMPER WIRE \
                                                                                                               \
NOTE: The battery must be folly charged to obtain a proper                                                     \
voltage reading in this test. If necessary, charge the battery
with a battery chargeror allow the engine to run a sufficient
length of time to fully charge the battery before taking a                   REGUlATOR
reading.
1. Connect the positive (+) voltmeter lead to the positive
   battery terminal and the negative (-) voltmeter lead to
   the negative terminal.
2. Start the engine and run it at fast idle until the engine
   reaches its normal operating temperature. Adjust the                        PLASTIC PLUG
                                                                                                                      LEAD
   engine speed to 1500 - 2000 rpm and observe the                                                                 FROM BRUSH
   voltmeter for the highest reading. The reading should
   be between 13.7 and 14.7 volts.
3. If the reading is high, check for a loose or dirty                   i.    Repeat steps 1 and 2.
   alternator ground lead connection. If the connection is              NOTE: Do not let the voltage exceed 16 volts.
   good, the voltage regulator is faulty and must be
                                                                        j. If a voltmeter reading of 14.5 volts or above is
   replaced. Be sure to disconnect the battery cables before
                                                                           now obtained, the voltage regulator is faulty and
   attempting to remove the alternator.
                                                                           must be replaced. If the voltmeter reading is below
4. If the reading is low:                                                  14.5 volts, inspect the brushes and slip rings for
   a. Stop the engine and remove the alternator wiring                     wear, dirt or damage. If the brushes and slip rings
       connections.                                                        are good, the alternator is fault internally.
   b. Remove the Phillips cover screw from the regulator                   Disassemble the alternator and test the components,
      cover (see illustration).                                            as outlined in this section.              .
   c. Remove the nut from the output terminal and the
      nut from the sensing tenninal, and remove Jumper
       (A).
   d. Remove another nut from the sensing terminal, and
      the nut from the excitation terminal.



                                                        Engines & Generators

                                                                 64
                                             MANDO ALTERNATOR SERVICE
       REMOVE ALTERNATOR                                                        10. Place an oversized V-belt around the pulley and fasten
                                                                                    the pulley in a vise.
       1. Disconnect the negative (-) battery ground cable.
                                                                                11. Use a 7/8 in. box wrench to loosen and remove the
   I   2. Disconnect the wiring leads.                                              pulley nut.
       3. Loosen the screws. Holding the alternator, rotate it                  12. Remove the pulley nut, lockwasher, pulley, fan, and
          toward the engine and lift the belt off the pulley.                       spacer.
       4. Remove the screws and washers and remove the alternator.




                                                                 TERMINAL




          SCREWS 'fff:~ll§A:;;-~

                                                                                          PUUEY AND FAN COMPONENTS


          ~~~~IftRE~~~~~~,,=
CAPACITOR COVER
ASSEMBLY                                                                          A   CAUTION: DO NOT insert screwdriver blades
                                  ~~
                                                                                  more than 1/16 in. (1.6 mmJ. Damage to the stator
                                                                TERMINAL          winding could result from deeper penetration.


                                                                                NOTE: Score the stator. and the front and rear housings so
                                                                                the unit may be reassembled correctly.
                                                                                13. Remove the four through-bolts and carefully pry the
       DISASSEMBLE ALTERNATOR                                                       front housing away from the rear housing using two
                                                                                    screwdrivers.
       1. Remove the tenninal nuts to remove the jumper (see
          illustration).
                                                                                                    'Y';;:::::::::::-/ 11.._-- nl:lln HOUSING
       2. Remove the remaining tenninal nuts.
       3. Remove the capacitor.
       4. Remove the Phillips screw from the regulator cover.                                                          k--FRONT
                                                                            SCREW DRIVER                                     HOUSING
       5. Remove the brush/regulator-assembly cover.
       6. Remove the nut from the terminal.
       7. Remove the jumper.                                                           HOUSING AND STATOR REMOVAl
       8. Remove the !enninal insulators.
       9. Remove the two Phillips screws and remove the                         14. Carefully push the rotor assembly out of the front
          brush/regulator assembly.                                                 housing and rear housing.



                                                     V-BELT




                                                                                NOTE: If the bearing is removed from the housing. a new
                                                                                bearing must be installed.
                                                                                15. After removing the three bearing locking screws, care
        PUllEY\                                                                     fully press the front bearing out of the housing. Press
        REMOVAl                                                                     against the inner race of the bearing.


                                                                  Engines & Generators

                                                                           65
                                       MANDO ALTERNATOR SERVICE
                                                                    2. Inspect and test the diode-trio assembly:
                                                                        3.   Using a commercial diode tester, a 12-volt DC test
                                                                             lamp or an ohmmeter, check the resistance between
                                               BEARING LOCKING               each of the three diode terminals and the indicator
                                               SCREWS                        light stud.

                                                                                                                 light stud
                                            FRONT BEARING

                                                                    DIODE TERMINAL

            BEARING
            DRIVER

                                                                                          DIODE TRIO ASSEMBLY

                                                                    b. Reverse the tester leads and repeat the resistance
                                                HOUSING                checks.
                                                                    c. A very low resistance should be indicated in one
  16. Remove the rectifier assembly by removing the Phillips            direction and a very high resistance should be indi-
      screw and lifting out the assembly.                               cated in the other direction if the diodes are nonnal.
                                                                    d. If any diode appears to be defective, replace the
                                                                       complete assembly. Do not attempt to replace an
                                                                       individual diode.
                                                                    3. Test the diode-rectifier bridge as follows:
RECTJRER ASSiMBLY                                                      3. Using a commercial diode tester, check for
                                                                          continuity from each of three terminals to the
                                                                          ouput terminal.




                                                                                                                   OUTPUT



                      RECTIFIER REMOVAL                                                                            RECTIFIER
                                                                               TERMINAL                            DIDOES

  CLEAN AND TEST ALTERNATOR COMPONENTS                                 b. Reverse ·the tester leads and repeat Step 3.
  1. Inspect and test the brush/regulator assembly. The                c. Continuity should exist in only one direction and
     brush set may be reused if the brushes are 1/4 in.
                                                                             all diodes should check alike.
   . (6 mm) or longer. The brushes must not be oil soaked,             d. Perfonn the same continuity checks between the
    . cracked or gt"9Oved.                                                three terminals and strap ground terminal. This
     Test for continuity between I and 2, and 3 and 4 using               should show continuity in only one direction
     3 test lamp or an ohmmeter. These checks will indicate                 through the diodes and all diodes should check
     a good brush/regulator assembly; replace the complete                  alike.
     assembly, if necessary.                                           e. If any diode appears to be defective, replace the
                                                                          rectifier assembly.




              TESTING BRUSH ASSEMBLY



                                                      Engines & Generators

                                                               66
                                     MANDO ALTERNATOR SERVICE
4, Clean and inspect the front and rear housings:  0




   a. Inspect the rear housing for cracks or breaks in the
        casting, stripped threads or a damaged bearing bore.
        Replace the housing if any of these conditions exist.
   b. Inspect the front housing for cracks, stripped or'
        damaged threads in the adjusting ear, or an out-of-
        round bore in the mounting foot. If possible,
        correct slightly damaged threads using a tap.           b. Check the resistance from each lead (I, 2, and 3) to
        Replace the housing, if necessary.                              the laminations (4). There should be no continuity
   e. If the housings are to be reused, clean them in                   if the insulation is good.
        solvent and dry with compressed air.                       e. Inspect the stator windings for signs of discoloration.
S. Clean and inspect the rotor shaft bearings:                          A discolored winding should be replaced.
   NOTE: Do not use a solvent on the rear rotor bearing            d. If a winding shows a high resistance or an open
   since it is serviced as a unil wilh Ihe rOIOr.                       circuit between any two of the three winding
                                                                        terminals or indicates poor insulation between the
   a .. The bearings should be wiped clean with a lint-free             windings and the laminations, the stator must be
      , cloth containing a moderate amount of commercial                replaced.
        solvent. Do not inunerse a bearing in solvent, or
        use pressurized solvent or air.                         8. Check the rotor assembly as follows:
   b. Check the bearings for obvious damage, looseness             NOTE: If slip rings need 10 be replaced, you must
        or rough rotation. Replace a bearing if any doubt          replace the entire rotor.
        exists as to its condition.                                a. Visually inspect for physical defects such as dam-
        NOTE: If the rear rolor bearing needs replacement,              aged shaft threads, worn or damaged bearing areas,
        rep/oce the entire rolor.                                       burned or pitted slip rings or scuffed pole fingers.
6. Inspect the belt pulley for rough or badly worn belt            b. Measure the winding resistance across the slip rings
   grooves or keyway, and for cracks or breaks. Remove                  (A). Place the ohmmeter leads on the edges of the
   minor burrs aild correct minor surface damage; replace               slip rings, not on the brush contact surfaces. The
   a badly worn or damaged pulley.                        0
                                                                        correct winding resistance at 70 - 80° F (21 -
                                                                       27° C) is 4.1 to 4.7 ohms.
                                                                   c. Minor burning or pitting of the slip ring surfaces
     FRONT                                                             can be removed using a croCus cloth. Thoroughly
                                                                       wipe the slip rings clean afrer polishing, removing
                                                   FRONT               all grit and dust.                               .
                                                   BEARING
                                                                   d.Check for a grounded slip ring or rotor winding by
                                                                       measuting the resistance from each slip ring to the
                                                                       rotor body or pole finger (B). An open circuit should
                                                        HOUSING        be indicated in both cases for a good rotor.
                                                                   e. If the windings are defective or physical damage
                                                                     o




                                                                       cannot be corrected, replace the rotor assembly.
                                                                9. Use a comm!,rcial capacitor checker to test the
                                                                   capacitor for capacity, shorts, leakage, and series
                                                                   resistance.




                                    BEARING


7. Test the stator windings as follows:
   a. Using an ohmmeter or test lamp, check for
      continuity between all three leads (I, 2, and 3).
      A lo~ ohm reading or lit test lamp should be
      observed.
                                                                                   INTERNAL CIRCUIT WIRING



                                                       Engines & Generators

                                                                67
                                          MANDO ALTERNATOR SERVICE
                                                                     2. Place the rotor (pulley end up) on the bed of an arbor
                                                                        press, on two steel blocks.
                                                                     3. Press the front housing and bearing assembly down
                                                                        onto the rotor shaft. Press against the bearing's inner
                                                                        race only, using a sleeve driver. Take care to insure that
                                                  ANGERS                the rotor leads clear the steel blocks.


                                                                          SLEEVE DRIVER
                                                                                                                FRONT HOUSING AND
                                                                                                                BEARING ASSEMBLY




TESTING THE ROTOR                                                        ROTOR




                                                                     INSTAlliNG THE FRONT HOUSING ON THE ROTOR ASSEMBLY
 ASSEMBLE ALTERNATOR                                                 4. Install the rectifier assembly into the rear housing.
 1. Carefully press the front bearing inta the front housing,        5. Insert the Phillips screw and tighten it.
    pushing agajnst the bearing's outer raoe using a hearing
    driver. Lock the bearing in place with screws.
    TORQUE: 25 - 351lrin (2.8 - 4.0 Nm)


                                                                        RECTIAER
                                                                        ASSEMBLY


                                                  BEARING

                                                    HOUSING




                                                                     6. Assemble the front and rear housings as follows:
                                                                        a. Put the siator winding in the front housing with the
                  FRONT BEARING ASSEMBLY                                   stator leads away from the front housing and the
                                                                           notches in the stator laminations aligned with the
                                                                           four through-bolt holes in the housing.
                                                                        b. Align the scribe marks you made in the stator, and
                                                                           front and rear housings during disassembly.
                                               BEARING LOCKING          c. Slip the rear housing into place over the rotor shaft.
                                               SCREWS                       Align the mounting holes and put the stator leads
                                                                           through the holes at the top of the rear housing.
                                                                        d. Install the four bolts and tighten them.
                                                                            TORQUE: 35· 651b·ft (4.0· 7.3 Nm)
                                                                            NOTE: If the front housing is new, the through-bolt
                                             FRONT BEARING                  will not be tapped.



                ASSEMBUNG THE BEARINGS

                                                       Engines & Generators

                                                                68
                                          MANDO ALTERNATOR SERVICE
7. Install the spacer and the fan. Then push the pulley,            INSTALL ALTERNATOR
   lockwasher and nut onto the shaft. Tum the nut a few
                                                                    1. Install the alternator, screws and washers.
   turns.
8. Place an oversized V-belt around the pulley and fasten           2. Connect the wiring leads.
   the pulley in a vise.                                            3. Put the belt on the alternator, crankshaft and coolant
                                                                       pump pUlleys.
                                                                    4. Adjust the alternator belt's tension (see DRIVE BELT
                                                                       ADJUSTMENT under ENGINE ADJUSTMENTS).
                                                  'OVERSIZEO
                                                                           MANDO ALTERNATOR SPECIFICATIONS
                                                                     Battery Vollage       12 von
                                                                     Maximum Speed         13500 RPM
                                                                     Cutin Speed           Max. 2000 RPM (at exc.)
                                                                                           Max. 1500 RPM (at l2)
                                                                     Reg. Set Vollage      14.7Votts
                                                                     Ambient Temp.         -2O'C ·10O'C
                                                                     Ground                Negalive


        INSTALLING THE PULLEY AND THE FAN NUT
9. Use a torque wrench to the tighten the nut.
    TORQUE: 35·50 Ilrtt (47 - 68 Nm)
10. Carefully install the brush/regulator assembly on the
    rear housing with the two mounting screws.
11. install the small terminal insulators.
12. Install the large terminal insulator.
13. Install the jumper.
14. Install the nut on the terminal.
15. Install the brush/regulator assembly cover.
16. Install the Phillips screw for the brush/regulator
    assembly cover.
    TORQUE: 25 - 351b·tt (2.8 - 5.1 Nm)
17. Install the capacitor.
18. Install the tenninal nuts.
19. Install the jumper.
20. Install the last terminal nut.




                                                         Engines & Generators

                                                               69
                                                  TORQUE DATA
                                                       Kg-m (Ib-H)




                                                                          CYUNDER BLOCK AND OTHER COMPONENTS


                                                                                                 2.5 -3.5
                                                                                               (1B.O -25.3)




                                                                            i   1.5-2.5
                                                                            ~10.8 -18.01
                                                                                           I




                              I 1.9-2.9
                              (13.7 - 21.01
                                              I

CYUNDER HEAD ANo.CYUNDER HEAD COVER                                                                               POSitiOning)
                                                                                                              (      pIn.




                                                                                                                  0.8-12
                                                     7.0- 9.0                                                     15.8-8.4)
                                                   (50.6 - 65.0)



                                                                                                              .~




                                          ~        WESTERBEKE
                                                   Engines & Generators

                                                          70
                                                        TORQUE DATA
                                                             Kg-m (Ib-H)

     CYLINDER BLOCK AND OTHER COMPONENTS




     Don't remove ~hiS   bolt)
    ( from connecting rod.
                                                                                                           COOLING FAN AND WATER PUMP




        1
        t


                                                                                        To cylinder head




  17.0 -19.0
                      IApplV engine oi'l.I
1123.0 - 137.4}




   (.): Apply Locktite No.262 to set up side of stud.
      (Important)




                                                                           t.:..:::::...=",   [(1::~:~OII




                                                         Engines & Generators

                                                              71
                                                                           TORQUE DATA
                                                                                     Kg-m (Ib-II)
(With PTO provided)




                                                                      .    (5.8-8.7) .
                                                                                       ~I
                                                                            0.8---=-=-12
                                                                          r--=-I             - - - -




                                                                           GASKET LOCATION
                                                            LOCATIONS WHERE GASKETS ARE USED
                                                                                                Gasket; joint bolt




                                      Corrugated washer
                                                                 .,.
                                                                 ~.

                                                             ·· ~.
                                                                            ----"

                                                                            18
                                      =ield~i!!I
                                             Gasket;
                                             water outlet pipe            \
                                                                                                                                        ''''

                      Q-ring;
                      control lever




                                         Oil seal;
                                         crankshaft front
                                                                                                       I   plug      Gasket;
                                                                     O-ring;
                                                                     Oil pump                                        exhaust silencer




                                                                                   Engines & Generators

                                                                                           72
                       ANGULAR NUT AND BOLT TIGHTENING METHOD
1. Carefully waSh the nuts and bolts to remove all oil and           6. Draw another line (F-G) on the face of each of the parts
   grease.                                                              to be clamped. TItis line will be in the direction of the
2. Apply a coat of molybdenum disulfide grease to the                   specified angle (Q) across the center (E) of the nut or
   threads and setting faces of the nuts and bolts.                     bolt
3. Tighten the nuts and bolts to the specified torque (snug          7. Use a socket wrench to tighten each nut or bolt to the
   torque) with a torque. wrench.                                       point where the line (A-B) is aligned with the line (F-G).
          CENTER LINE                                                   Example' Specified Angle and Tightening Rotation
      ~-+--                                              LINE              A         30·          1112 ofa tum


                                    ~--~C            l          D
                                                                           B
                                                                           C
                                                                           D
                                                                                     60·
                                                                                     90·
                                                                                     180·
                                                                                                  1/6 ofa tum
                                                                                                  1/4 ofa tum
                                                                                                  112 ofa tum
                                                                           E         360·         One full tum




                                                                                                                    ~
4. Draw a line (A-B) across the center of each bolt.
5. Draw another line (C-D) on the face of each of the parts
   to be clamped. TItis line should be an extension of the                                                                      E
   line (A-B).




                 COINCIDING LINE.
                                      G



                                                                             Apply a coat of molybdenum disulfide grease to the
                                                                             threads and setting faces of the nuts and bolts.



                                          TOOLS AND TESTING GEAR



                                                                                 IS><
      COMPRESSION GAUGE ADAPTER                                                                       FRONT DlL SEAL SmlNG TOOL
                                                       REAR OIL SEAL SmlNG TOOL
                                                       WITH DRIVE HANDLE                              WITH DRIVE HANDLE



           ptl   15                               CONTACT THE WESTERBEKE CORPORATION FOR
 U       VALVE GUIDE SEAL SmlNG TOOL
                                                  INFORMATION ON THESE AND OTHER SPECIAL TOOLS




                                                         Engines & Generators

                                                                73
       STANDARD BOLTS I TIGHTENING TORQUE SPECIFICATIONS
NOTE: The torque values given in the following table should be appli~d where a particular torque is not specified.


                                                                                                                    kg . m




  ~~                                         ~ ~ ~ ~
               cation
  Bolt
  diameter X
  pitch (mm)
                                              07.+0,2
      M 6 X 1.0             0.6 ±0.2
                                               · -0.3
                                                                 08 +0.2
                                                                  · -0.3
                                                                                   09 +0.2
                                                                                    · -0.3            --
                                              16 +0.4            18 +0.5                 +0.5
      M 8X1.25              1.3 ±0.5                                               2.1                2.4 ±0.7
                                               · -0.6             · -0.6                 -0.7

      M10 X 1.25            2.8 ±0.7          33 +0.8            38 +0.9           4.3 ±0.9           5.1 ±1.3
                                               · -0.9             · -1.0

     "M10 X 1.5             2.7 ±0.7          3.2 ±0.8           3.7 ±0.9          4.2 ±1.0           4.9 ±1.2

      M12 X 1.25            62 +1.3           67 +1.4            77 +1.6           88 +1.8            97 +1.9
                             . -1.2            · -1.3             · -1.5            · -1.7             . -2.0

     *M12 X 1.75            5.8 ±1.2          6.3 ±1.2           7.2 ±1.4          8.2 ±1.6           9.1 ±1.8

                                                                                         =;:~
                                   +2                 +2
      M14 X 1.5             9.7              10.4              11.9 =;:!          13.6              14.5 ±2.9
                                  -1.9              -2.1

     *M14 X 2.0             9.1 ±1.8          9.8 ±1.9         11.2 ±2.2          12.8 ±2.5         13.6 ±2.7

      M16 X 1.5            13.3 +2.7         15.1 ±3.1         17.3 ±3.5          19.7 ±4.0         20.4 ±4.1

     *M16 X 2.0            12.7 ±2.5         14.4 ±2.9         16.5 ±3.3          18.8 ±3.8         19.5 ±3.9

                                                    +4.4
      M18 X ~.5            19.2 ±3.8         21.7              24.9 ±5.0          28.4 ±5.7         29.3 ±5.9
                                                    -4.3

                                                                                                           =~:~
     *M18 X 2.5                                     +4.4
                           19.2 ±3.8         21.8              25.0 ±5.0         28.5 ±5.7          29.4
                                                    -4.3
                                                    +6.1                              +7.9
      M20 X 1.5            26.3 ±5.3         30.0              34.4 ±6.9         39.2 -7.8          40.4 ±8.1
                                                     -6
                                                                                         +7.2
     *M20 X 2.5           24.3 ±4.9          27.8   =~:;       31.8 ±6.4         36.3
                                                                                         -7.3
                                                                                                    37.4 ±7.S

      M22 X 1.5           32.0=1~:~          40.4 ±8.1         46.3   =~:;   i   528+10.5           54.1 ±10.8
                                                                             1     · -10.6

     *M22 X 2.5           27.8 ±5.6          37.6 ±7.5         43.1 ±8.6
                                                                             i   49.1 ±9.8          50.3 ±10.1

      M24 X 2.0           45.8 ±9.2          47.9=1~::         54 9 +17.6        626+ 20.1          70.6 ±14.1
                                                                 · -11.0           · -12.6

     *M24 X 3.0           43.1 ±8.6          45.1 ±9.0         51.7 ±10.3    I   589+ 11 .8         66.4 ::!:13.3
                                                                             I     · -11.7


. NOTE: Bolts marked with an asterisk are used for female threaded parts made of soft materials such as castings.




                                         ~      WESTERBEKE
                                                Engines & Generators

                                                       74
                       .TIGHTENING TORQUE SPECIFICATIONS
    NOTE: The torque values given in the following table should be applied where a particular torque is not specified.

    FLANGED HEAD BOLT                                                                                         kg·m (lb ft!N·m)




     ~ ®f'                                                        ~                                   @!'
             marking
     Nominal

     =.XDitch)

         M6 x1
                                   0.5-0.9                              0.6-1.2                          ---
                              (3.61-a50/4.6 -8.5)                (4.33-8.67/5.88-11.76)
                                   1.1-2.0                                1.4-2.9                         1.9-3.4
         Me x 1.25
                           (7.95-14.46/10.78-19.61)              (4.33 -8.67/5.88-11.76)         (13.74-24.59118.63-33.34)
                                     2.3-3.9                            3.6-6.4                           4.3-7.2
         M10x1.25
                           (17.35 - 28.20/23.53 - 38.24)       (26.03-44.12/35.30-59.82)         (31.10-52.07/42.16-70.60)
                                    2.3-3.8                             3.5-5.8                           4.1-6.8
        ""10 x 1.5
                           (16.63-27.48/22.55-37.26)           (25.31-41.95/34.32 -56.87)        (29.65-49.18/40.20-66.88)
                                    5.6-8.4                             7.9-11.9                          8.7-13.0
         M12 x 1.25
                          (40.50 -60.75/54.91-82.37)          (57.14 -86.07/77.47 -116.69)       (62.92-94.02l85.31-127.4P.)
                                   3.5-9.5                              7.3-10.9                         8.1-12.2
        "'12 x 1.75
                          (37.61-56.41/50.99 -76.49)          (52.80 -78.83/71.58-106.89)       (58.58-88.24/79.43 -119.64)
                                   8.5-12.7                           11.7-17.6                           12.6-18.9
         M14 x 1.5
                          (61.48-91.85183.35-124.54)         (84.62-127.301114.73-172.59)      (91.13 -136.701123.56-185.34)
                                   7.6-11.5                           11.1-16.6                         11.8-17.7
        .14x2
                          (57.14-85.34/77.47-115.71 )        (80.28-120.06/108.85-162.79)      (85.34-128.02/115.71-173.57)
                                    11.8-17.7                          17.1-26.5                         18.0-27.1
         M16x1.5
                         (85.34 -128.02/115.71 -173.57)      (125.85-189.50/170.63 -256.93)    (130.19-196.01/176.52 -265.76)
                                  11.2-16.7                            16.6-24.9                          17.2-25.7
       "'16x2
                         (81.00-120.791109.83-163.77)        (120.06-180.101162.79-244.18) .   (124.40 -186.611168.67 -253.01)
    A bolt with an asterisk 1*) is used for female screws of soft material such as cast iron.




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                                              ~        WESTERBEKE
                                                       Engines & Generators

                                                           J.5
STANDARD AND METRIC CONVERSION DATA
LENGTH·DISTANCE
   Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
   Feet (It) x .305 = Meters (m) x 3.281 = Feet
   Miles x 1.609 = Kilometers (km) x .0621 = Miles
DISTANCE EQUIVALENTS
   1 Degree of Latitude = 60 Nm = 111.120 km
   1 Minute of Latitude = 1 Nm = 1.852 km
VOLUME
   Cubic Inches (in') x 16.387 = Cubic Centimeters x .061 =in'
   Imperial Pints (IMP pt) x .568 = lfters (l) x 1.76 = IMP pt
   Imperial Quarts (IMP qt) x 1.137 = lfters (L) x.88 = IMP qt
   Imperial Gallons (IMP gal) x 4.546 = Uters (l) x .22 = IMP gal
   Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
   Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
   Fluid Ounces x 29.573 = Millilfters x .034 = Ounces
   US Pints (US pt) x .473 = lfters(l) x 2.113 = Pints
   US Quarts (US qt) x .946 = lfters (l) x 1.057 = Quarts
   US Gallons (US gal) x 3.785 = Liters (l) x .264 = Gallons
MASS·WEIGHT
   Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
   Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds
PRESSURE
   Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
   Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
   Inches of Water (H.o) x .07355 = Inches of Mercury x 13.783 = H20
   Inches of Water (fi,0) x .03613 = psi x 27.684 = H20
   Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20

TORQUE
   Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 =in-Ib
   Pounds-Force Feet (It-Ib) x 1.356 = Newton Meters (Nm) x .738 = It-Ib
VELOCITY
   Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER
   Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUa CONSUMPTION
  Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/l)
  Kilometers Per lfter (KmIL) x 2.352 = IMP MPG
  Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/l)
  Kilometers Per lfter (KmIL) x 2.352 = US MPG
TEMPERATURE
  Degree Fahrenheft (oF) = (OC X 1.8) + 32
  Degree Celsius (OC) = (OF - 32) x .56

UQUID WEIGHTS
  Diesel Oil = 1 US gallon = 7.13 Ibs
  Fresh Water = 1 US gallon = 8.33 Ibs
  Gasoline = 1 US gallon = 6.1 Ibs
  Salt Water = 1 US gallon = 8.56 Ibs


                        ~       WESTERBEKE
                                ,Engines & Ge.nerators

                                      76
             ENGLISH TO METRIC CONVERSION CHART
      Multiply Temperature              By                To aet eauivalent number of:
      Dearee Fahrenheit (0",       (OF-32\ : 1.8                 Dearee Celsius °C\
      Multiply Acceleration             By                To get eouivalent number of:
        FooVSecond'(ftlsec')         0.3048                      Meter/second'(mfs')
       Inch/second'CinJsec'1         0.0254                     Meter/second' Imfs')
         Multiely Toraue               By                 To eel eauivalent number of:
         Pound-inch(lb·in.)          0.11298                    Newton-meters (N·m)
         Pound-foot IIb·1t)          1.3558                     Newton-meters IN·m)
          Multiply Power               By                 To eet eaulvalent number of:
         Horsepower (hpl              0.746                         KilowaHs IkWI
MultiDlv Pressure or stress            By                 To   g~t ~quivalent    number of:
 Inches of water fin. H ,0)          0.2491                       Kilopascals IkPal
 Pounds/S...ll!Jare in. liMn.')       6.895                       Kilopascals (kPll)
 Mulliel- Enerav or Work               By                 To aet equivalent number of:
     British Thermal Unit IBtu)       1055                            Joules IJ)
         Fool:J!.ound (ft·lbl        1.3558                           JoulesJJ\.
                                  3,600,000. or
       kilowatt-hour (kW·hr)                                    Joules (J = one W/s)
                                    3.6 x 10'
          Mull.iJ!ly Ught              By                 To aet eQuivalent number of:
         Foot candle (fc)            1.0764                    Lumensimeter'lImfm'l
MuitiDIv Fuel Performance              By                To get_eguivalent number of:
        Miles/aal Imile/oaJ)         0.4251                     Kilometersllner (kmlLl
      Gallons/mile (eaVmilel         2.3527                     LHerlkilometer (Ukml
        Multiely Vetocltv              By                To oet eauivalent number of:
                                                     .
       Mlles/hour (mllelhrl          1.6093                    Kilometerslhouf (kmlhr)


         Mul!!I!!Y. LenAlh             By                To aet eaulvalent number of:
             Inch lin.1               25.4                        Millimeters Imm)
              Fool Iftl             0.3048                          Meters 1m)
             Yard Iydl              0.9144                          Meters Iml
            Mile (mile)              1.609                        Kilometers Ikml
          Mul!!I!!Y Area               By                To aet eauivalent number of:
             Inch'lin.')             6452                        MilJimeters'lmm')
             Inch'lin.'l              6.45'                      Centimetersl fcm 2\
             Foot'ift'l            . 0.0929                         Meters'im'l
            Yard'Cyd'l              0.8361                          Meters'tm'l
        Multiply Volume               fa                 To oet eouivalent number of:
            Inch'lin.')              16387                       MiJlimelers'lmm')
            Inch'lin.')             16.387                       Cenlimelers'(cm')
            Inch'lin.')             0.0164                           LHers III
            Quart lat)              0.9464                           LHers (Ll
          'Gallon   iaah             3.785                           LHers (Ll
            Yard'lvd')             . 0.7646                         Melers'lm'l
         Mulliply Mass                By                 To aet eauivalent number of:
 .
           Pound Ob)                0.4536                        Kjoorams (ko\
            Ton /ton)               907.18                        Kiloarams Ikol
            Ton lion)                0.907                           Tonne ttl
         Multiply Force               B.Y                To aet equivalent number of:
          Kiloaram Ike)             9.807                          Newtons INl
           Ounce (oz\               0.2780                         Newtons INl
           Pound lib)               4.448                          Newtons INl




                                    Engines & Generators

                                             77
                                               INDEX
A1airms ...................................53            Engine Compression ...................... .50
Alternator Dual Output ....................58            Engine Disassembly ........................ 10
Alternator Thsting and Repair ...............63          Camshaft ................................ .13
Circuit Breaker .......................... .53           Crankshaft End Play ....................... .11
Compression Engine .......................50             Idler Gear End Play ........................ 11
Cooling System ............................40            Injection Pump . ........................... .11
Dual Output Alternator ................... .58           Internal Parts Drawing ...................... 12
Engine Adjustments ........................50            Measurements ............................. 11
Engine Assembly ..........................25             Piston and Connecting Rod . .................. 14
Air Intake Filter ........................... .41        Piston Ring .............................. .14
Alternator . ............................... .37         Piston Pin ................................ 14
Camshaft ................................ .30            Timing Gear .............................. .13
Crankshaft Bearing ........................ .31          Timing Gear Backlash ....................... 11
Cylinder Head Assembly ..................26-36           Transmission .............................. 10
Cylinder Head ............................ .33           Valve .................................... .13
Diagram External Parts .................... .34          Engine Inspection and Repair .............. .15
Diagram Lubrication ....................... .39          Camshaft .................................20
Dipstick . ................................. 16          Connecting Rod ............................22
Drive Pulley and Shaft ....................28,29         Connecting Rod Bearing .................... .15
Engine Adjustments .........................30           Crankshaft and Crankshaft Bearing ........... .23
Engine Tuning ............................ .38           Crankshaft Gear ...........................24
External Parts Diagram .................... .34          Cylinder Block . ........................... .15
Filter Air Intake ........................... .41        Cylinder Head ............................ .15
Flywheel . ................................ .32          Heat Shield ............................... 17
General Information ....................... .39          Hot Plug ............................... 16,17
Idle Gear ................................. 17           Oil Seal ................................. .24
Injection Pump . ........................... .35         Piston, Piston Pin, Piston Ring ................21
Internal Parts ...........................28,29          Piston Ring Gap ...........................22
Lubrication Diagram . ...................... .39         Ring Gear ................................24
Oil Filter ................................ .34          Rocker Arm ...............................20
Oil Pan ................................. . .33          Tappet and Push Rod . ...................... .19
Oil Pipe and Strainer ...................... .33         Timing Gear . ..............................24
Oil Pump ................................ .32            Valve, Valve Seal ........................... 17
Piston and Connecting Rod . ...............25-27         Valve Seat ................................. 18
Piston Rings ............................25-31           Valve Spring .............................. .19
Pump Oil ................................ .33            Engine Specifications ....................... .4
Pump Water .............................. .40            Engine Troubleshooting ..................... 6
Push Rod ................................ .33            Flywheel ................................ .30
Solenoid ................................. .35           Front Oil Seal ............................ .32
Starter ..................... ............. .37          Fuel Filter ............................... .48
Thermostat ............................. 36-41           FuelInjection Pump ...................... .48
Timing Gear Case ......................... .32           Fuel Lift Pump ........................... .48
Transmission ............................. .38           Fuel System ............................. .43
Tuning the Engine ......................... .38          Gasket Location ...........................72
Water Pump .............................. .36            Glow Plugs .............................. .49




                                             Engines & Generators

                                                    78
                    INDEX
Governor ................................ .43
Idler Gear ............................... .30
Injection Pump Fuel ...................... .48
Injection Testing .......................... .49
Injection Timing ...........................52
Metric Conversion Chart .................76,77
Nut and Bolt Tightening Specifications ........73
Oil Pressure .......... ·................... .50
Oil Seal ........ : .........................32
Overhaul Testing ...........................5
Parts Identification .........................2
Pump Raw Water ...................... .41,42
Raw Water Pump .......................41,42
Rocker Arm Bracket Assembly .............. 33
Schematic Wiring .......................... 60
Siphon Break ..............................3
Specifications Engine ........................4
Standard Torque Specifications ............74,75
Starter Motor ............................ .54
Tachometer ...............................62
Tappet and Head Gasket .................. .33
Timing Injection .......................... 52
Tools and Test Gear ........................73
Torque Data .............................. 70
Transmission ............................. 10
Valve Clearance ...........................51
Warning Lights .......................... .53
Wiring Diagram ........................... 61
Wiring Schematic ......................... 60




           '"" WESTERBEKE
                 Engines & Generators

                      79
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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.