Westerbeke Diesel 55d Four Operator's Manual
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I i INDEX Governor 43 Idler Gear 30 Injection Pump Fuel 48 Injection Testing 49 Injection Timing 52 Metric Conversion Chart 7677 Nut and Bolt Tightening Specifications 73 Oil Pressure 267 50 Oil Seal 32 Overhaul Testing 5 Parts Identification 2 Pump Raw Water 4142 Raw Water Pump 4142 Rocker Arm Bracket Assembly 33 Schematic Wiring 60 Siphon Break 3 Specifications Engine 4 Standard Torque Specifications 7475 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 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 2636 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 2829 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 1617 Idle Gear 17 Oil Seal 24 Injection Pump 35 Piston Piston Pin Piston Ring 21 Internal Parts 2829 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 2527 Valve Seat 18 Piston Rings 2531 Valve Spring 19 Pump Oil 33 Engine Specifications 4 Pump Water 40 Engine 6 Push Rod 33 Flywheel 30 Solenoid 35 Front Oil Seal 32 Starter 37 Fuel Filter 48 Thermostat 3641 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 oet eauivalent AND METRIC CONVERSION DATA Inches inx 254 Millimeters mmx 0394 Inches Feet Itx 305 Meters mx 3281 Feet Miles x 1609 Kilometers kmx 0621 Miles DISTANCE EQUIVALENTS 1 Degree of Latitude 60 Nm 111120 km 1 Minute of Latitude 1 Nm 1852 km VOLUME Cubic Inches inx 16387 Cubic Centimeters x 061 in Imperial Pints IMP ptx 568 lfters lx 176 IMP pt Imperial Quarts IMP qtx 1137 lfters Lx88 IMP qt Imperial Gallons IMP galx 4546 Uters lx 22 IMP gal Imperial Quarts IMP qtx 1201 US Quarts US qtx 833 IMP qt Imperial Gallons IMP galx 1201 US Gallons US galx 833 IMP gal Fluid Ounces x 29573 Millilfters x 034 Ounces US Pints US ptx 473 lfterslx 2113 Pints US Quarts US qtx 946 lfters lx 1057 Quarts US Gallons US galx 3785 Liters lx 264 Gallons MASS267WEIGHT Ounces ozx 2835 Grams gx 035 Ounces Pounds Ibx 454 Kilograms kgx 2205 Pounds PRESSURE Pounds Per Sq In psix 6895 Kilopascals kPax 145 psi Inches of Mercury Hgx 4912 psi x 2036 Hg Inches of Mercury Hgx 3377 Kilopascals kPax 2961 Hg Inches of Water Hox 07355 Inches of Mercury x 13783 H20 Inches of Water fi0x 03613 psi x 27684 H20 Inches of Water H20x 248 Kilopascals kPax 4026 H20 TORQUE PoundsForce Inches inIbx 113 Newton Meters Nmx 885 inIb PoundsForce Feet ItIbx 1356 Newton Meters Nmx 738 ItIb VELOCITY Miles Per Hour MPHx 1609 Kilometers Per Hour KPHx 621 MPH POWER Horsepower Hpx 745 Kilowatts Kwx 134 MPH FUa CONSUMPTION Miles Per Hour IMP MPGx 354 Kilometers Per Liter KmlKilometers Per lfter KmILx 2352 IMP MPG Miles Per Gallons US MPGx 425 Kilometers Per Liter KmlKilometers Per lfter KmILx 2352 US MPG TEMPERATURE Degree Fahrenheft oF OC X 18 32 Degree Celsius OC OF 32x 56 UQUID WEIGHTS Diesel Oil 1 US gallon 713 Ibs Fresh Water 1 US gallon 833 Ibs Gasoline 1 US gallon 61 Ibs Salt Water 1 US gallon 856 Ibs WESTERBEKE Engines Generators 76 AdobeUCS 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 kg267m lb ftN267m256f marking Nominal XDitchM6 x1 0509 0612 361a5046 x 125 1120 1429 1934 2339 3664 4372 1735 28202353 x 15 2338 3558 4168 x 125 5684 79119 87130 4050 86077747 x 175 3595 73109 81122 376156415099 76495280 11964M14 x 15 85127 117176 126189 76115 111166 118177 118177 171265 180271 8534 1280211571 2657616x2 112167 166249 172257 12440 18661116867 25301A bolt with an asterisk 1is used for female screws of soft material such as cast iron WESTERBEKE Engines Generators J5 AdobeUCSM 6 X NUT AND BOLT TIGHTENING METHOD 1 Carefully waSh the nuts and bolts to remove all oil and grease 2 Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts 3 Tighten the nuts and bolts to the specified torque snug torquewith a torque wrench CENTER LINE LINE l D 4 Draw a line ABacross the center of each bolt 5 Draw another line CDon the face of each of the parts to be clamped TItis line should be an extension of the line ABCOINCIDING LINE G 6 Draw another line FGon the face of each of the parts to be clamped TItis line will be in the direction of the specified angle Qacross the center Eof the nut or bolt 7 Use a socket wrench to tighten each nut or bolt to the point where the line ABis aligned with the line FGExample Specified Angle and Tightening Rotation A B C D E 30267 1112 ofa tum 60267 16 ofa tum 90267 14 ofa tum 180267 112 ofa tum 360267 One full tum E Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts TOOLS AND TESTING GEAR COMPRESSION GAUGE ADAPTER ptl 15 U VALVE GUIDE SEAL SmlNG TOOL IS REAR OIL SEAL SmlNG TOOL WITH DRIVE HANDLE FRONT DlL SEAL SmlNG TOOL WITH DRIVE HANDLE CONTACT THE WESTERBEKE CORPORATION FOR INFORMATION ON THESE AND OTHER SPECIAL TOOLS Engines Generators 73 AdobeUCSWith PTO providedQring control lever TORQUE DATA Kgm IbIIrI 0812 5887 GASKET LOCATION LOCATIONS WHERE GASKETS ARE USED Gasket joint bolt Corrugated washer 225225 18 Gasket water outlet pipe Oil seal crankshaft front Oring Oil pump I plug Engines Generators 72 Gasket exhaust silencer BLOCK AND OTHER COMPONENTS Dont remove boltfrom connecting rod 1 t 170 190 11230 1374 IApplV engine oilI Apply Locktite No262 to set up side of stud DATA Kgm IbHCOOLING FAN AND WATER PUMP To cylinder head t Engines Generators 71 AdobeUCSI 1929 I 137 2101 CYUNDER HEAD ANoCYUNDER HEAD COVER TORQUE DATA Kgm IbH7090 506 650WESTERBEKE Engines Generators 70 CYUNDER BLOCK AND OTHER COMPONENTS i 1525 I 1801 25 35 1BO 0812 ALTERNATOR SERVICE 7 Install the spacer and the fan Then push the pulley lockwasher and nut onto the shaft Tum the nut a few turns 8 Place an oversized Vbelt around the pulley and fasten the pulley in a vise OVERSIZEO INSTALLING THE PULLEY AND THE FAN NUT 9 Use a torque wrench to the tighten the nut TORQUE 3526750 Ilrtt 47 68 Nm10 Carefully install the brushregulator 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 brushregulator assembly cover 16 Install the Phillips screw for the brushregulator assembly cover TORQUE 25 351b267tt 28 51 Nm17 Install the capacitor 18 Install the tenninal nuts 19 Install the jumper 20 Install the last terminal nut INSTALL ALTERNATOR 1 Install the alternator screws and washers 2 Connect the wiring leads 3 Put the belt on the alternator crankshaft and coolant pump pUlleys 4 Adjust the alternator belts tension see DRIVE BELT ADJUSTMENT under ENGINE ALTERNATOR SPECIFICATIONS Battery Vollage 12 von Maximum Speed 13500 RPM Cutin Speed Max 2000 RPM at excMax 1500 RPM at l2Reg Set Vollage 147Votts Ambient Temp 2OC 26710OC Ground Negalive Engines Generators 69 MANDO ALTERNATOR SERVICE ANGERS TESTING THE ROTOR ASSEMBLE ALTERNATOR 1 Carefully press the front bearing inta the front housing pushing agajnst the bearings outer raoe using a hearing driver Lock the bearing in place with screws TORQUE 25 351lrin 28 40 NmFRONT BEARING ASSEMBLY BEARING HOUSING BEARING LOCKING SCREWS FRONT BEARING ASSEMBUNG THE BEARINGS 2 Place the rotor pulley end upon the bed of an arbor press on two steel blocks 3 Press the front housing and bearing assembly down onto the rotor shaft Press against the bearings inner race only using a sleeve driver Take care to insure that the rotor leads clear the steel blocks SLEEVE DRIVER FRONT HOUSING AND BEARING ASSEMBLY ROTOR INSTAlliNG THE FRONT HOUSING ON THE ROTOR ASSEMBLY 4 Install the rectifier assembly into the rear housing 5 Insert the Phillips screw and tighten it RECTIAER ASSEMBLY 6 Assemble the front and rear housings as follows a Put the siator winding in the front housing with the stator leads away from the front housing and the notches in the stator laminations aligned with the four throughbolt holes in the housing b Align the scribe marks you made in the stator and front and rear housings during disassembly c Slip the rear housing into place over the rotor shaft 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 35267 651b267ft 40267 73 NmNOTE If the front housing is new the throughbolt will not be tapped Engines Generators 68 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 outof255round bore in the mounting foot If possible correct slightly damaged threads using a tap Replace the housing if necessary e If the housings are to be reused clean them in solvent and dry with compressed air S Clean and inspect the rotor shaft bearings NOTE Do not use a solvent on the rear rotor bearing since it is serviced as a unil wilh Ihe rOIOr a The bearings should be wiped clean with a lintfree cloth containing a moderate amount of commercial solvent Do not inunerse a bearing in solvent or use pressurized solvent or air b Check the bearings for obvious damage looseness or rough rotation Replace a bearing if any doubt exists as to its condition NOTE If the rear rolor bearing needs replacement repoce the entire rolor 6 Inspect the belt pulley for rough or badly worn belt grooves or keyway and for cracks or breaks Remove minor burrs aild correct minor surface damage replace a badly worn or damaged pulley 0 FRONT FRONT BEARING 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 3A ohm reading or lit test lamp should be observed HOUSING b Check the resistance from each lead I 2 and 3to the laminations 4There should be no continuity if the insulation is good e Inspect the stator windings for signs of discoloration A discolored winding should be replaced d If a winding shows a high resistance or an open circuit between any two of the three winding terminals or indicates poor insulation between the windings and the laminations the stator must be replaced 8 Check the rotor assembly as follows NOTE If slip rings need 10 be replaced you must replace the entire rotor a Visually inspect for physical defects such as dam255aged shaft threads worn or damaged bearing areas burned or pitted slip rings or scuffed pole fingers b Measure the winding resistance across the slip rings APlace the ohmmeter leads on the edges of the slip rings not on the brush contact surfaces The correct winding resistance at 70 80260 F 21 27260 Cis 41 to 47 ohms c Minor burning or pitting of the slip ring surfaces can be removed using a croCus cloth Thoroughly wipe the slip rings clean afrer polishing removing all grit and dust dCheck for a grounded slip ring or rotor winding by measuting the resistance from each slip ring to the rotor body or pole finger BAn open circuit should be indicated in both cases for a good rotor o e If the windings are defective or physical damage cannot be corrected replace the rotor assembly 9 Use a commrcial capacitor checker to test the capacitor for capacity shorts leakage and series resistance INTERNAL CIRCUIT WIRING Engines Generators 67 AdobeUCSMANDO ALTERNATOR SERVICE BEARING DRIVER BEARING LOCKING SCREWS FRONT BEARING HOUSING 16 Remove the rectifier assembly by removing the Phillips screw and lifting out the assembly RECTJRER ASSiMBLY RECTIFIER REMOVAL CLEAN AND TEST ALTERNATOR COMPONENTS 1 Inspect and test the brushregulator assembly The brush set may be reused if the brushes are 14 in 6 mmor longer The brushes must not be oil soaked cracked or gt9Oved Test for continuity between I and 2 and 3 and 4 using 3 test lamp or an ohmmeter These checks will indicate a good brushregulator assembly replace the complete assembly if necessary TESTING BRUSH ASSEMBLY 2 Inspect and test the diodetrio assembly 3 Using a commercial diode tester a 12volt DC test lamp or an ohmmeter check the resistance between each of the three diode terminals and the indicator light stud light stud DIODE TERMINAL DIODE TRIO ASSEMBLY b Reverse the tester leads and repeat the resistance checks c A very low resistance should be indicated in one direction and a very high resistance should be indi255cated 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 dioderectifier bridge as follows 3 Using a commercial diode tester check for continuity from each of three terminals to the ouput terminal TERMINAL OUTPUT RECTIFIER DIDOES b Reverse 267the tester leads and repeat Step 3 c Continuity should exist in only one direction and all diodes should check alike d Perfonn the same continuity checks between the three terminals and strap ground terminal This should show continuity in only one direction through the diodes and all diodes should check alike e If any diode appears to be defective replace the rectifier assembly Engines Generators 66 the rotor the WESTERBEKE 51A MANDO ALTERNATOR DISASSEMBLY AND TESTING FAN HOUSING EXCITER TERMINAL I COVER SENSING TERMINAL GROUND TERMINALE TESTING THE OUTPUT CIRCUIT REAR HOUSING ASSEMBLY COVER TERMINALP 1 Connect the positive voltmeter lead to the output terminal B and connect the negative lead to the ground terminal E on the alternator 2 Wiggle the engine wiring harness while observing the voltmeter The meter should indicate the approximate battery voltage and should not vary If no reading is obtained or if the reading varies check the alternator output circuit for loose or dirty connections or damaged wiring NOTE Prior to any alternator testing inspect the entire alternator system wiring for defects Check all connections for tightness and cleanliness panicuarly battery cable clamps and battery terminals Inspect the alternator drive belt for excessive wear and replace if necessary Also adjust for proper belt tension A WARNING A failed alternator can become very hot Do not touch until the alternator has cooled down A WARNING Before starting the engine make certain that everyone is clear of moving parts Keep away from sheaves and belts during test procedures A WARNING Multimeters and DC Circuits DC and AC Circuits are otter mixed together in marine applications Always disconnect shore power cords isolate DC and AC converters and shut down generators before performing DC testing No AC tests should be made without proper knowledge of AC circuits REFER TO THE WIRING DIAGRAMS FOR THE ABOVE WIRING HARNESS CONNECTIONS TESTING THE EXCITATION CIRCUIT 1 Connect the positive lead to the excitation terminal R on the alternator and the negative lead to the ground terminal E on the alternator 2 Tum the ignition switch to the on position and note the voltmeter reading The reading should be 13 to 25 volts see illustration3 If the reading is between 75 and 11 volts the rotor field circuit probably is shorted or grounded Disassemble the alternator and test the rotor as described under CLEAN AND TEST ALTERNATOR COMPONENTS in this section 4 If the reading is between 60 and 70 volts the rotor field circuit probably is open Remove the regulator and inspect it for worn brushes or dirty slip rings Replace the brushes if they are less than l4in 6 mm long If the brushes and slip rings are in good condi255tion disassemble the alternator and test the rotor as outlined under CLEAN AND TEST ALTERNATOR COMPONENTS in this section Engines Generators 63 TACHOMETER METER The meter used in propulsion engine instru255ment 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 68 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 130148 volts DC The following are procedures to follow when a fault in eitheiof the two circuits in a meter Hour meter Inoperative Oteck for the proper DC voltage between and terminals L Voltage present meter is defective repair or replace 2 VolIllge not present trace and electrical con255nections for fault Jump 12 volts DC to meter terminaJ to verify the Inoperative Check for the proper AC voltage between tachometer input terminal and terminal with the engine running L Voltage present attempt adjusting meter through calibra255tion access hole No results repair or replace meter 2 AC voltage not present check for proper alternator DC output voltage 3 Check for AC voltage at tach terminal on alternator to ground 4 Check electrical connections from tachometer input ter267 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 a With a handheld tach on the front of the crankshaft pulley retaining nut or with a strobetype tach read the front crankshaft pulley pm at idle b Adjust the tachometer with a SmaIl PbilIips type screw255driver 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 neededNOTE Cumn model tachometers use a coarse adjustmen dial 10 set the tachometer 10 the crankshaft pulley rpms The calibrating screw is then used for fine tuning TERMiNAl TACHOMETER CHECK New In a new installntion having new insrrumen panels the tachometer may not always be comctly calibrated 10 the engines rpm This calibration should be checked in all new instal1ntions 1 Warm up the engine to normal operating temperature Remove any specks on the crankshaft pulley with a clean cloth and place a piece of suitable reflecting tape on the pulley to facilitate use of a photoelectric type tachometer 2 Start and idle the engine 3 Aim the light of the tachometer onto the refiecting tape to confirm the engine speed Check the instrument panel tachometer reading Adjust the tachometer in the panel by using the instrument coarse adjustment to calibrate the instrument reading to the closest RPM that the photo tach is showing Then use the fine calibration adjustment to bring the instrument to the exact reading as the photo tach WESTERBEKE Engines Genellltors 62 AdobeUCSHOH Ij 1 1 1 aAll NOTE An onoff swiIh should be installed in this circuft to disconnect the slllrterflOm the battel in an emergency and when leaving theboat Twelve volt engine sIllrte typically dtaw 200 to 300 amps when etanking A switch with a continuous tating of 175 amps at 12 vac will normally serve this function but a swiJch must never be used to make the sIllrter circuit WIRING DIAGRAM IWfA Q II flQSURC mID 1 AdobeUCS II vot Y n 225 Ii IJ n n ft SUIT i i lJJ 1101101 SIlIrCti WIRING SCHEMATIC STAIIT m S1ARTCA r J I 1 PItHtAl rSOl CB 225 i AtT 04 02 61 J GLOWLGS ALttRNA10R LIH PUMP P 1 1 1 1 1 1 1 1 1 1 1 J TH IIK WIR AT 2 IS InIUUD AIID SHOULD BE INSUUlD ANtl ONLY 225 4 THE GRAY IRE AT lUG 2 IS UMusro UD SHOULD lit INSULAlD AOKIUL ANEL OIIU rJ TO ALT I TeRM I rUL InUl UJ I I I I U1 0 IIDU difcH XI 1 1 lACora 225 VOLTMUtA 1 GAUGE I lESf n 1 I I lQBP 1 ONl I I MIIV6i I ADMIRAL PANEL CAPTAIN PANEL 4 LT BLU fl4 PINK 0 RO 14 BRN pRESTOI ITE 72 AMP AI T 4 8RN GRA 1114 PINK 414 LT 8L It I YfjRSAl PROPUI S I Wr PR STO ITF 51 AMP A 51 AMP AI TERNATOR STNOARO AllERtiA10R ON TilE 638 01 63C Il i IB IT 826 IT 1086 D 10SC UN 225 WIRING SCHEMATIC 39144 AtD sruuW 19 OPT IONAI AI IERNATORS256 101 IOA ltsT1I ALHRNAlORi AVAIAnqM 1H no rv ue ty liB II UB ty nRD I WESTERBEKE Englnes Generators 60 AdobeUCSwire AdobeUCSthe positive ONE TWO MOTOR Field Coil Inspection 1 Check for insulation between one end brushof the coil and yoke 2 Check for continuity between both ends brushesof the coil 3 Check the poles and coil for tightness FIELD COIL TEST STARTER ADJUSTMm AND REASSEMBLY A CAUTION IJeforB installing thl1lDUghly clean the stalter flange and mollJltfng SIIrfates reml1w alillil old paint aad IUI Starter perflJrmanCB largely depends I1n the quality 111 the wiring Use wire 111 suffi255cient size aIJd grade between the battery and starter and fully tigttBn to the rellllnal 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 gapto between 05 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 05 mm increase the number of adjusting washers inserted 2 Greasing Whenever the starter has been overhauled apply grease to the following parts a Armature shaft gear and reduction gear b All bearings c Bearing shaft washers and snap rings d Bearing sleeves e Pinion f Sliding portion of lever A CAUTION Never Slllear the starter fitting terminals bnIshes I1r cJlRlllutatl1r with grease 3 After reassembly check by conducting a noload test again GEAR WASHER SNAP RING mm MAX PINION SHAFT END PLAY I Engines Generators 57 MOTOR STARlER INSPECTION 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 Inspecting Tbe Annature L Checkthe aonature with a growler tester If its short circuited repIace the 8IlllllIDre Also check for insulation between the and its shaft If poorly insulated repIace the armaIlIre ARMATURE CHECK 2 Measure the commutator OD and the depth of undercut Repair or repIace4t if the service limit is exceeded Also check the comm1i1ator outside surlace for dirtiness and rouglmess If rough polish the commutator with fine aocus cloth CRIICUS CLOTH Brush and Brush Holder Inspection 1 Check the brushes If worn out beyond the service limit replace the brushes Brush Height StlJlUiard 17 nun 0669 inlimit 6 nun 0236 inBRUSHES 2 Check the brush spring tension A weak or defective spring will cause excessive brush wear replace the springs if suspect BRUSH HOLOER ASSEMBLY 3 Check for insulation between the positive brush holder and holder base If poorly insulated replace the holder assembly Also check the brush holders for proper staking CoIlUlUllDr OD StJuulJzrd StiuuIIlrd 387 nun 1523 inl267 ce limit 10 nun 0039 in Engines Generators 56 MOTOR AT11IACTION lEST COIINECTDR OFF 4 Return test With a battery connected to the solenoid ter255minal M and to the starter body manually pull out the pinion fully The pinion must return to its original position when released from holding by hand 3 Holding test With a b8ttery connected to the solenoid ter255minal 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 OFF STARIER DISASSEMBLY L Discon the wire from the solenoid terminal M 2 Loosen the two screws fastening the solenoid Remove the solenoid assembly 3 Remove the two long through bolts and two screws fas1rning the brush holder Remove the rear bracket 4 WlIh the brushes pulled away from the armature remove the yoke and brush holder assembly Then pull the armature out 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 the pinion shaft end play adjustmeDt will come off PINION STARTBI II011IR WEAR CfflPING LEVER SPRING RETURN TEST 7 Pull out the reduction gear lever and lever spring from the front bracket 8 On the pinion side pry the snap ring out and pull out the 9 At each end of the armature remove the ball bearing with a bearing puller It is impossible to replace the ball bearing pressfitted in the front bracket Ii that bearing has worn off replace the front bracket assembly TERMINALM NOTE Jnspect ceOJl and replace if necessary brush COTTU1UJer solenoid Ql77U2ture elc See the Jollawing pages Engines Generators 55 MOTOR DESCRIPTION The sttuter can be roughly divided into the following sections 225 A motor section which generates a drive power 225 An ovemmning clutch section whicb transmits an arma255lUre tmque preventing motor overrun after starting 225 A switch section solenoidwhicb is operated wben actu255ating the overrunning clutch through a lever and whicb supplies load current to the motor The starter is a new type small lightweight and is called a highspeed starter The pinion shaft is sep3I8Ie ftom the motor shaft the pinion slides only on the pin255ion 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 mech8ism switch and overrunning clutch inner circuit are identical to conventional ones ADIISIMENT AND REPAIR If any almormaIity is found by the following tests the starter should be disassembled and repaired Piaion Gap Inspection 1 Connect a battery 12Vbetween the starter terminaI S and the starter body and the pinion drive should rotate out and stop I A cAIJID IlI1rtI1t apply battery wtage tor over 10 267 tIII1lImIoIIsI 2 tightly push the pinion bsck and measure the return stroke called pinion gap3 If the pinion gap is not within the standmd range 05 to 20 mmadjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the number of shims increases GENTLYPUSH BACK 152D PlalOaGAP NoLoad Test 1 Connect the ammeter voltmeter and battery to the starter as illustrated 2 When the switch is closed the pinion must protrude and the starter must run smoothly at 3000 rpm or moreIf the current or starter speed is out of specification disas255semble the starter and repair it rI SAnERY 1 A CAUTION Use thick wires as muth as possible and tighten el8ry tetminal SllCursly This is a solBloid shift255type starter whlth makes a rotating sound loudsr than that of a dITBCtdri18 type stalter When dllfflcting starter rotation at the pinion tip be careful not to come In contact wfth the pinion gsar whent protrudes SOLENOID Perform the following tests If any test result is not satisfactory replace the solenoid assembly 1 lnspect the solenoid for continuity between terminals and and between terminals S and the body and M and the body There should be no continuity found between terminals S and M Continuity will be found between terminals S and the body and terminaI M and the body MUlTIMETER NOTE Disconnect the wire from terminal M 2 Connect a battery to the solenoids terminal S for and M for Have a switch in the lead and close it The pinion drive should extend fully out A CAUTION Do not apply battery current for mote than 10 seconds when testing the solenOid 1WESTERBEICE i Engines Generators 54 5 AdobeUCSENGINE ADJUSTMENTS INJECTION TIMING Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made 1 Remove the injection pipe of the No1 cylinder 2 Remove the delivery valve holder of the injection pump of the No 1 cylinder and then pull out the delivery spring 3 With the spring left removed install the delivery valve holder oelivery valve holder Injection pump 4 Slowly tum the crankshaft pulley clockwise at the same time continue to feed the fuel When the fuel stop flowing out from the No1 deliv267 ery valve holder stop turning the crankshaft This crank angle position is the starting point of injection 5 In the condition at Step 4above confirm what degree the groove mark of the crank pulley is at when seen by the timing mark provided in the timing gear case When the value is out of the range of the normal injection timhg adjust it accordingly Injection timing I BTDC 16267 Note The injection timing varies according to the specifica267 tions of the machine 6 Adjust the injection timing with a shim between the injection pump and the cylinder block Shim is available in the following 9 types and iden267 tification mark is stamped or imprintedon the top face Identification mark of shim and its thickness mmMark Thickness Mark Thickness Mark Thickness 2 02 5 05 8 08 3 03 6 06 10 10 4 04 7 07 12 12 Note For each of the injection pumps of three cylinders the shim adjustment is made at the same time When a shim is missing while overhauling the engine and the shim thickness is unknown assemble the engine with provisional shim inserted After assembling the engine check the injection timing and adjust the shim until the normal injection timing is obtained Reference To add the 01 mm shim thickness corresponds to the 1 degree of crankshaft angle advance Injection pump Cylinder block Engines Generators 52 ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT The valve clearance must be adjusted every 500 operating hours or whenever the valve rocker is abnormally noisy Valve adJustment should only be done when engine is cold Cold engine valve clearance is OOI5in O4OmmVALVE CLEARANCE NOTE The cylinder head bolts have been tightened with the Angular 1ightening Method Thereore it is not necessary to retighten the cylinder head bolts before adjusting the valve elearanees ADJUSTMENT PROCEDURE f CRANK PULLEY 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 outon the timing gear case cover 2 Remove the cylinder head cover and check to see if cylin der No1 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 NO1 COMPRESSION 3 In accordance with the conditions of cylinder No1 mea255sure and adjust if required the clearance of the valves marked with eiiher or 225 in the table below Cylinder No 1 2 3 4 Valve arrangement I E I E I E I E When No1 cylinder is at TOe 225 225 225 225 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 clearance of the other valves A CAUTION The rocker ann is made of diecast aluminum Therefore be careful not to tighten the adjusting screw to excess Adjusbnent of Injection Timing The injection timing may not be readjusted Take care not to forget to insert a shim in the mounting surface when reassembling the injection pump after disassembly i Engines Generators 51 AdobeUCS5 AdobeUCS6 FUEL SYSTEM THE IJRING GASKET ONlY NESJS ro BE FIEPACED IF IT SHOWS SlSNSOFWEAR Changing the Fuel Filter Element Refer to the illIIstratWn above L Shut off the fuel supply 2 Ibm the fuel filter bowl to remove 3 Pull the filter eIemeut SlIaight down and off 4 InsJecl both Orings and replace if worn 5 Wipe the Orings with clean fuel and snap the new filter up into place over the small Oring 6 Clean off the filter bowl and threads The bowl can be profilled with fiicJScrew the bowl inta place when the Oring contacts the bousing TIghten the bowl fumly by hand 7 TIle keyon preheat sequence will allow the lift pump to fill the fuel filter 8 Run the engmes and inspect for leaks FUBINJECTION PUMP The fuel injeCtion pump is a very important component of the diescJ engine requiring the utmost care in handling The fuel injection pump bas been thoroughly benchtested and the owneroperator is cautioned not to attempt to service it If it requires servicing remove it and take it to an authorized fuel injection pump service facility Do not attempt to disassemble and repair it 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 FROM PREHEAT NOZZLE ASSEMBLY Inspection and replacement Place the removed nozzle in the clean light oil disas255semble it into the nozzle body and the needle valve and clean them thoroughly Then check to see if the valve moves smoothly in the body When it does not move smoothly repair or replace the nozzle Injection pipe Leak off pipe DISASSEMBLY Packing Injection pump Hetsheld L EvAlGasket 225 fdP tWESTERBEKE EngInes Generators 48 AdobeUCSFUEL SYSTEM Reassembly of fullload stopper Install the fullload 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 1When 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 shaft2Install the set spring securely to the groove of the pin connecting the floating lever with much care to its assembling direction 3Confirm that each lever moves by its dead weight before installing the start spring 4After assembly confirm that each lever moves smoothly And also confirm that each spring operates properly WESTERBEKE Engines Generators 47 AdobeUCSFUEL SYSTEM STRUCTURAL DRAWING OF GOVERNOR Start spring Set spring Snp pn Guide tever I t Control link Floating fever Link plate Copnut l Flyweight WESTERBEKE Engines Generators 46 AdobeUCSFUEL SYSTEM REASSEMBLY OF CONTROL LEVER RELATED PARTS Lever Main spring Protrusion Bush Apply loctite NoSO to the peniphery 1Put the lever main springthrough 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 2Put the return spring ofthe control lever through the shaft of the Iever main the bushes Assemble the bush of the lever main springfirst and then the control lever bush Note When assembling the bushes apply Loctite 601to the periphery of the bushes 4Hook both ends of the return spring control leversecurely to the protrusion and the pin of the lever main Assemble the control lever Assemble the Oring to the groove of the bushes control leverfirst and then assemble the washers and the control lever before tightening up the control lever with a nut kgm ft IbsI Control lever tightening torque 112 18 90 130Control lever aring Bush Spring washer Notes 1 TIghten the control lever after locking the control lever firmly Do not tighten the control lever after locking the main spring lever2 After assembly confirm that the control lever moves smoothly i Ellfllnes Generators 45 AdobeUCS2 3 2 3 AdobeUCSFUEL SYSTEM GOVERNOR 1 The adjustments of the 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 Governor cover Main spring lever 267S Guide lever Timing gear esse Tensioner lever Angleich Sleeve Fulload stopper Shifter WESTERBEKE Engines Generators 43 AdobeUCSplate 8 SYSTEM 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 PART NO 11885 TO TRANSMISSION COOLER Heat Exchanger Service After approximately 1000 hocrs of operation remove clean and pressure test the engines heat exchanger A local automotive radiator shop should be able to clean and test the heat Engines Generators 41 A CAUTION any Df the VIIJIBS hare IIml uff tire Impeller hey IIIDSf be fDrmd fD pment IIIDCkageln tire cooling 111 They DflBn can be fDtmd In tire heat mhanger HAW WATER PUMP PART NO 11361 RAW WATER PUMP THERMOSTAT ASSEMBLY SYSTEM WATER PUMP Seal unit DISASSEMBLY Body Cover 1 Loosen the set screw 2 Remove the cover Note The cover is applied with sealant TB1207BWhen re255moving the cover much care should be267 taken not to deform it by applying an excessive force to it center Cover Setscrew Impeller Seal unit Impeller Seal unit Bearing unit REASSEMBLY Cover Bearing unit With a hole in the bearing unit set in line with one in the body lock the bearing unit with a setscrew kg267m ft IbsSet screw tightening torque 0812 60 90Cover Impeller Seal unit 1 Apply BELCO bond No4 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 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 Screwlock 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 mm inStandard 053 217 00209 00854 2 Play in the water pump ball bearing mm inStandard Limit 0008 0010 00003 0000402 000793 Tightening allowance between center and the bearing shaft mm Standard 0026 0061 0001 00024Engines Generators 40 SYSTEM Valve opening pressure lkgtcm2 140 PSIOil filter Oil gallery Valve opening pressure 45kgcrn 640 PSI1 I H jectiO pump h LGJllton iii Oil pan Pressure feeding Non pressure feeding LUBRICATING OIL CIRCULATION DIAGRAM Body Oil pump 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 267the pump cover mm inStandard Limit 0040 0085 00016 00033015 00059Clearance between the periphery of the outer rotor and the pump body mm inStandard Limit 010 0185 00039 0007304 00157Clearance between the inner rotor and the outer rotor mm inStandard Limit 017 0006702 Engines Generators 39 AdobeUCSENGINE ASSEMBLY NOTEThe exhaust manifold which was disassembled from the cylinder head should be inspected before reassembly a Remove the exhaust elbows from the lower surface of the manifold Clean and inspect for cracks and defects Replace as needed b Remove the exhaust nipples elbows and plugs from the manifold and heat exchanger c Remove water connectors from the ends of the manifold Be sure to note the proper location and arrangement of each for proper alignment d Examine all parts for defects corrosion and wear and replace as needed f Flush out the coolant recovery tank and clear its hose passage Set aside to reinstall on the boat HEAT EXCHANGER Install the heat exchanger replace the heat exchanger zinc and aUach new hoses with new clamps to the cooling system Refer to the COOLING SECTION in this manuall for HEAT EXCHANGER SERVICE MARINE TRANSMISSION 1 Assemble the damper plate to the flywheel 2 Reinstall the marine transmission and fill with ATF Dextran III NUIE Some transmissions such as the Borg Warner Velvet Drive require oil coolers Oil coolers should be cleaned pressure tested and repainted at engine overhaul The transmission oil cooler hoses should also be inspected Refer to the text on Heat Exchangers ENGINE TUNING OPERATION After reassembly the engine must be tuned This will ensure that the engine operates at its maximum efficiency Fill the engine cooling system with antifreeze mixture and the engine oil sump with lube oil API spec CF or CG41 Mount the engine on a test bench and connect the fuel lines 2 Connect the electrical wiring Refer to the WIRING DIAGRAM 3 Connect the air intake line to the air cleaner 4 Connect the exhaust pipe 5 Manually operate the fuel feed pump to feed fuel to the engine 6 Bleed the fuel lines of air 7 Crank the engine with the starter nonignition operationfor about twenty seconds This will prelubricate the engine internal components B Start the engine and allow it to run at 750 to BOO rpm for five minutes 9 Remove the cylinder head cover while the engine is running 10Check that the engine oil is continuously circulating from the oil pump to the valve rockers through the cylinder head If there is no oil circulation or if the oil circulation is sluggish stop the engine and make the appropriate repairs or adjustments Reinstall the cylinder head cover 11 Increase the engine speed to 1500 rpm to do the engine warmingup operation 12Check the engine for oil fuel coolant and air intake leakage 13 Check for abnormal noise and odor 14Check for abnormal electrical charging 15 Check the engine fastening parts for looseness 16 When the engine coolant temperature reaches 75260C 167260For more increase the engine speed to 2000 rpm and allow it to run for twenty seconds This will give the engine the essential runin operating time 17Adjust the engine operation speed to the specified value 1BStop the engine to complete the tuning procedure Refer to the following pages for details of subassemblies These sections also include Wiring Diagrams Engine Specifications Torque Diagrams Starter Motor Alternator Raw Water Pump and a detailed Section Adjust the Valve Clearance Refer to the ENGINE ADJUSTMENTS section in this manual Engines Generators 38 ENGINE ASSEMBLY Air inlet pipe 1 Apply sealant TB1207Cto the surface in which the air inlet pipe is installed 2 Install the air inlet pipe to the cylinder head cover and tighten it to the specified torque Tightening torque Cylinder head cover Exhaust manifold kgm ft Ibs0812 6090I Air inlet pipe Assemble the gasket to the cylinder head install the exhaust manifold along the stud bolts and tighten it to the specified torque kgm ft IbsTightening torque 1929140210I Gasket Exhaust Starter Install the starter to the flywheel housing and tighten it to the specified torque kg267m ft IbsTightening torque 95115687832I For starter motor disassembly and repair refer to the starter motor section in this manual Alternator 1 Tighten the adjustment plate together with the water pump and then install them temporarily 2 Install the bottom of the alternator to the timing gear case and then tighten it temporarily with bolts and nuts 3 Install the fixing bolts onto the top of the alternator through the adjusting plate temporary pump Drive pulley and belt 1 Install the drive pulley to the water pump and then tighten it up 2 ft IbsTightening torque 08 12 60 90I 2 Set the drive belt to each pulley Drive belt tension should be very tight about 12 deflection at midpoint For alternator disassembly and repair refer to the MANDO ALTERNATOR SECTION in this manual Engines Generators 37 ASSEMBLY ADJUST THE VALVE CLEARANCE Refer to the ENGINE ADJUSTMENTS section in this manual EXTERNAL PARTS Righthand SideEXTERNAL PARTS Lefthand Side 11Dipstick 9Water Pump 12Oil Filter 110Thermostat and Water Outlet Pipe 13Injection Pump 111Cylinder Head Cover 14Injection Pump HouSing Cover 112Exhaust Manifold 15Fuel Pipe 113Starter 16Leak Off Pipe 114Generafor 17Fuel Hose 115Pulley 18Injection Pipe 116Belt jJ 314Front hanger and rear hanger Dipstick Oil filter them to the specified torque shown below 1 Insert the dipstick kg267m ft IbsTightening torque 1929 140210I 2 Rear hanger IOFront hanger v WESTERBEKE Engines Generators 34 11113the the AdobeUCSENGINE ASSEMBLY Oil pump assembly Install the oil pump assembly to the cylinder block PrO not provided kg267m ft IbsTIghtening torque 1929140210I Cylinder block Front oil seal Install the front oil seal to the timing gear case Installation is made according to the L n dimension shown in the figure mm inL dimension I 602 608 2370 2384Front oil seal TIming gear case with governor Install the timing gear case to the cylinder block 1 Put the link plate of the governor incorporated in the gear case through the connecting hole of the injection pump in advance 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 kgm ft IbsCase tightening torque 19 29 140 210I Governor cover 4 Assemble the gasket and the governor cover to the top of the gear case and then tighten them 267to the specified torque kg267m ft IbsCover tightening torque 08 12 60 90Flywheel housing Install the flywheel housing to the cylinder body kg267m ft IbsTightening torque 42 56 300 400I Flywheel Lubricate bolts with engine oil Tighten a little at a time in the sequence shown in the illustration Tightening torque kgm ft Ibs90 110 650 800 Apply engine oil WESTERBEKE Engines Generators 32 AdobeUCSq Front 151 2st Ojl 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 connect255ing rod bearings with engine oil Position the piston front mark towards the front of the engine Use the piston ring compressor to compress the piston rings Use a hammer grip to push the piston in until it makes contact with the crank pin At the same AdobeUCSENGINE ASSEMBLY Installation of retainer After applying engine oil to the lip of the oil seal install the retainer Apply sealant Tighten bolts on the retainer to the specified torque in the order as shown in the figure left kg267m ft IbsTightening torque 08 12 60 90I D Camshaft assembly 1 Apply engine oil to the inside of the bearing of the cylinder block and then install the camshaft assembly Note When installing the assembly care should be taken not to damage the bearing 2 After installation of the snap ring to the outside of the front bearing check to see if the camshaft rotates smoothly Cam gear and sleeve 1 Install the cam gear to the camshaft so that the tim255ing point a dot mark comes to the front side 2 With the flyweight installed tighten the cam gear with a lock nut kg267m ft IbsTightening torque 7090510650I Cam gear Timing pOlnt Sleeve Flyweight 3 Apply engine oil to the shaft of the sleeve and the slide of the flyweight 4 With the lip of the sleeve placed in the cavity of t flyweight insert the shaft of the sleeve into the til255end of the camshaft Note Check to see if the sleeve moves smoothly Idle Gear Install the idler gear shaft with the oil hole facing up255ward Lubricate the shaft with oil Install the idler gear Align the timing marks as shown in the illustration Install the thrust collar and tighten the bolts to the specified torque kg267m ft lb Tightening torque 21 31 152 224Idle gear Engines Generators 30 AdobeUCSENGINE 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 Eiglne Hangers Engines Generators 29 Reassembly Steps 1Crankshaft 2Piston Assembly 3Rear Seal Retainer 4Camshaft 5Cam Gear 6Idler gear and Shaft 7J 011 Pump Assembly 8TIming Gear Case 9Flywheel Housing 10Flywheel 11Crank Pulley 12Oil Pipe 13Oil Strainer 14Pan 15Tappets 16Cylindar Head Gasket 17Cylinder Head Assembly 18Push Rods 19Rocker Bracket Assembly 20Engine Hangers 11ENGINE ASSEMBLY INTERNAL PARTS 121 Engines Generators 28 r I i I I I I washer AdobeUCSENGINE ASSEMBLY CYUNDER HEAD ASSEMBLY Valve Stem Oil Seal Glow plug 7Ii 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 Nozzle holder Seat Valve insert Split collar 5e Spring seat 4I Valve spring 3dj INSTAlLER 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 Intake and Exhaust Valve Springs Install the valve springs with their painted end the close pitched endfacing down PORTION Engines Generators 26 AdobeUCSENGINE ASSEMBLY GENERAL INFORMATION 225 Be careful not to mix bolts and nuts Metric and SAB bolts are used on various engine assemblies 225 During assembly recheck clearances and insure that parts are being assembled in their proper order and faCing in the correct direction in relation to the engine block such as pistons piston rings bearings and bearing caps 225 Apply lubricating oil to moving parts during assembly Insure that moving parts when assembled on the engine rotate or slide and are not subject to binding or excessive tension 225 If there are mating marks scribed during disassembly reference them correctly for assembly 225 Use new gaskets lockwashers Orings packings and seals 225 Tighten the bolts and nuts on important parts of the engine to specified torques using a reliable torque wrench 225 When required use liquid sealants when required on nuts bolts and gaskets Refrain from using tape sealants 225 Most gaskets and many bolt washers are asymmetrical make certain they are positioned properly Torquing Hardware Prevent mechanical damage by running fasteners down in three stepsII2 213 and III torque Exceptions are bolts and rocker arm shaft fasteners The former are torqued as indicated The latterrocker shaft 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 Oil based PERMATEX 2 and its mGH TACK equivalent are excellent all purpose sealers They are effective in just about any joint in contact with coolant raw water oil or fuel A light coating of oil or LIQUID TEFLON can be used on rubber gaskets and orings LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil filter assembly Coat both surfaces of the oil pan gasket with high temp RED SllJCONE SEALER When installing gaskets that seal around water coat both sides with WHITE SILICONE GREASE Do not use sealant when installing a new gasket mGHCOPPER ADHESIVE SPRAYS are useful for hold255ing a gasket in position during assembly Specialized gasket sealers such as HYLOMAR work well in applications requiring nonhardening properties HYLOMAR is particularly effective on copper cylinderhead gaskets and resists fuel oil and water NOTE TAPE SEALANTS should be used on pipe plugs and fitting that connect water cookmt passages Bolts and Fasteners Lightly oil head bolts and other fasteners as you assemble them Bolts and other plugs that penetrate the water jacket should be sealed with PERMATEX 2 or mGH TACK When assembling the flywheel coat the bolt threads with LOCTITE blue LITInUM based grease is waterproof ideal for water pump bearings and stuffing boxes Antiseize compounds and thread locking adhesives such as LOCTITE protect threaded components yet allow them to come apart when necessary LOCTITE offers levels of lOCking according to the job Heavily oil all sliding and reciprocating components always use clean engine oil PISTON AND CONNECTING ROD Piston Pin Snap Ring 1 Use a pair of snap ring pliers to install the piston pin snap ring 2 Check that the piston moves smoothly on the piston pin Piston Ring SNAP RING PLIERS 1 Use a piston ring installer to install the three piston Install the piston rings in the following order 1Oil ring 22nd compression ring 31 st compression ring The marked side of the two compression rings be facing up The undercut side of the second compression ring will be facing down As the oil ring has no any facing mark it may face in either direction 2 Lubricate the piston ring surfaces with engine oil 3 Check that the piston rings rotate smoothly in the piston ring grooves I st 2 st Engines Generators BOil 25 AdobeUCSENGINE INSPECTION AND REPAIR Runout of crankshaft Replace if beyond limit Standard 0025 0001Crankshaft gear mm inLimit 005 0002Check the crankshaft gear visually for damage and any other defects Oil seal When the lip of an oil seal is found defective replace it with a new one Installation Use the crankshaft front oil seal installer to install the crankshaft front oil seal 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 Ring Gear Installation REMOVING THE RING GEAR 1 Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the gas burner to exceed 200267C 390267F2 Use a hammer to install the ring gear when it is heated TIMING GEAR Uneven wear of idle gear shaft mm inNominal Limit 450 1771701 00039Clearance between idle gear bushing and shaft mm inStandard Limit 0025 0085 0001 0003302 00079Engines Generators 24 ENGINE INSPECTION AND REPAIR Connecting267 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 If worn beyond the limitsreplace Crank journal 2 Check the connecting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Tighten the connecting rod and the bearing cap to the specified torque Tightening torque Fm1NG THE LOWER BEARIIIG kg267m ft Ibs7585 5461Clearance between bearing and crank pin inside di267 ameter with bearing installed and without Clearance Standard 0035 0073 00014 00029mm inLimit 010 00039 mm inStandard Limit 600 236225986 23567Crank pin mminStandard Limit 490 19291 4887 19240When 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 inStandard Limit Clearance 0029 0072 011 00011 Generators 23 ENGINE INSPECTION AND REPAIR Clearance between piston pin and piston pin hole Piston ring gap mm inStandard 0002 0012 000008 000047With 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 mminStandard Limit 1st 02035 compression ring 00079 0013815 2nd 03505 ring 00138 00197Oil ring 0204 10 00079 between piston ring groove and ring Measure 267clearance at several places on the If worn beyond the limit replace the rings or piston mminStandard Limit 1st 0085 0105 02 compression ring 00033 00041000782nd 0050 0085 compression ring 00020 00033015 Oil ring 0030 0070 0005900011 ROD AND CONNECTING ROD BEARING Torsion and parallelism of connecting rod If worn beyond the limitrepair or replace Per 100 mm 394Standard Torsion 005 005 0002mminLimit 02 00079015 00059Clearance between small end pin hole of connecting rod and piston pin inside diameter of bushing Clearance Inside diameter mm inStandard Limit 0008 0020 00003 0000825 09843005 00020MEASURING CONNECTING ROD BUSHING INNER DlAMmR W PISTON PIN Engines Generators 22 AdobeUCS AdobeUCS643 613 AdobeUCSENGINE INSPECTION AND REPAIR 5 Apply light pressure to the valve while turning it to fit the valve seat insert 6 Check that the valve contact width is correct 7 Check that the valve seat insert surface is in contact with the entire circumference of the valve 8 Clean the head and valves to remove the abrasive compound and metal particles VALVE SPRING Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination If the measured value exceeds the specified limit the valve spring must be replaced Valve Spring Inclination Valve Spring Tension Standard 18 00709mm inLimit 25 00984Use a spring tester to measure the valve spring tension If the measured value is less than the specified limit the valve spring must be replaced Valve Spring Tension at 299 mm Standard 170 37479mmin1 Limit 150 33069Set Length f J VALVE 225225 ilNrValve Spring Free Length Use a vernier caliper to measure the valve sprng free length If the measured value is less than the specified limit the valve spring must be replaced mm inStandard Limit Exhaust and Intake 421 400 Valve Spring Free TAPPET Cam Follower or Valve LifterAND PUSH ROD TAPPET Inspect the tappets for excessive wear damage and any abnormalities Use a micrometer to measure the tappet diameter Tappet Diameter mm inStandard 20967 20980 082547 082598Use a dial indicator to measure the clearance between the tappet and cylinder body tappet travelling bore mm inStandard Limit Tappet and Tappet 0020 0054 008 Travelling Bore 000079 r c WESTERBEKE Engines Generators VALVE SPRING TESTER 19 AdobeUCS AdobeUCS1 A B AdobeUCSB AdobeUCSX X AdobeUCSENGINE DISASSEMBLY Piston and Connecting Rod Connecting rod Piston and connecting rod 1 Turning the crankshaft position the piston to be removed at the bottom dead center 2 Loosen the cap nut of the connecting rod and then remove it 3 Give another rotation to the crankshaft to position the piston at the top dead center 4 With the handle of a hammer placed at the bottom of the connecting rod push the piston assembly upward out of the cylinder block Notes 1 Before removing the piston scrape the carbon deposit off the cylinder wall 2 When pushing out the piston assembly care should be taken not to damage the cylinder wall 3 Attach a tag with a cylinder number to the removed caps and bearings to keep them in order Piston ring 4r 1 ri Piston 1 Conrod bolt The drawing267out ofthe conrod bolt must be limited to only when rod 7 Snap rn9 5Bearing 3Piston ring Remove the piston ring with a ring pliers Brass bar Piston pin 1 Remove the snap rings with a commercially avail267 able tool 2 With a brass bar attached to the piston pin push it out by hammering it lightly Note Keep the pistons piston pins and connecting rods in order for each cylinder Engines Generators 14 AdobeUCSENGINE DISASSEMBLY 5 4 3 2 1 Timing gear 1 Remove the idle gear and the idle gear shaft 2 Pull out the sleeve from the tip end of the cam shaft Rear hanger Cylinder head ASM Valve mechanism Head bolt M123 1 Before disassembling the valve mechanism remove the connector glow plug and nozzle holder as255sembly 2 Compressing the valve spring remove the split col255lar spring seat valve spring and valve lllA G lo wr 1 appHed wfih sealing agent Do not pull them out Nozzle holder 35 locationst Hot plug F1I Split collar 410 11 Spring seat 151 lSI Seat valve insert 256 t Remove the lock nut of the cam shaft gear and then remove the flyweight assembly and the cam gear Camshaft 1 Remove the snap ring which holds down the front bearing of the cam shaft from the ring groove of the cylinder block 2 Pull out the cam shaft from the cylinder block together with the bearing Snap ring Engines GelJerstors 13 PARTS DiSassembly Steps 11 Rocker Bracket Assembly 21 Push Rods 31 Rear Hanger 41 Front Hanger 51 Cylinder Head Assembly 61 Cylinder Head Gasket 71 Tappets 81 Oil Pan 91 Oil Strainer 101 Oil Pipe 111 Crank Pulley 12Flywheel 131 Flywheel Housing 14111ming Gear Case 15Oil Pump Assembly 16Idler Gear and Shaft 171 Cam Gear 181 Camshaft 19Rear Seal Retainer 20Piston Assemblies 211 Crankshaft 00 nat pull out this bolt t 191 ENGINE DISASSEMBLY 111 Rocker bracket Push rod 1 Remove the rocker bracket assembly M6 x 1 5 bolts and 6 nuts2 Pull out the push rods 8 pesnuts 6 Cylinder head 1 Remove the rear and front hangers 2 When removing the cylinder head bolts loosen them slowly a little at a time starting with the outside working in a circular pattern inward 3 Remove the cylinder head assembly and the head gasket 4 Pull out the tappet from the cylinder body E19ines Generators 12 AdobeUCSENGINE DISASSEMBLY Injection pump MEASUREMENTS 1 Align the hole of the fuel cut lever with the hole of the governor cover and then insert a pin 6into tliis hole to hold the fuel cut lever PRIOR TO MAIN ENGINE DISASSEMBLY 2 Check to see if the pin groove of the control link is at the center of the injection pump 3 Remove the injection pump and then take out the shim NOTE Fuel cut lever Pin6 Governor cover Control link I Injection pump 1 center position nection pump rack pm 1 Mark each injection pump as to which cylinder it was removed from 2 Do not reuse the shim replace it with the same thickness that was removed Injection pump ASM Shim Cylinder block Backlash oftiming gear STANDARD CRANK GEAR 004 IDLER GEAR 00017CAM GEAR 003 IDLER GEAR 00012IDLER GEAR END PLAY STANDARD 0058 0115 00023 END PLAY STANDARD 0058 0208 00023 00082 WESTERBEKE Enginds Generators 11 mm inLIMIT 02 0007902 00079mm inLIMIT 02 00079mm inLIMIT 03 disconnect AdobeUCSENGINE PROBLEM PROBABLE CAUSE KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles a Overheated cylinder a See OVERHEATING LOW OUTPUT b Carbon deposits in cylinder b Clean 2 Too early injection timing 2 Correct 3 Too high injection pressure 3 Correct 4 Improper fuel 4 Replace wnh proper fuel KNOCKING WITH DARK SMOKE 1 Poor compression 1 See LOW COMPRESSION HARD STARTING 2 Injection pump malfunctioning 2 AdjustRepair 3 Improper nozzle a Poor spray a Clean or replace nozzle b Poor chattering b Repair or replace nozzle c drip c Repair or replace nozzle d Nozzle needle valve seized d Replace INTERMITTENT 1 Fuel clogged 1 Clean or replace EXHAUST SOUND 2 Water mixed in fuel 2 Replace fuel OVERHEATING 1 Vbelt slackening or slippery wnh oil 1 Adjust replace or clean 2 Damaged water pump 2 Replace 3 Lack of coolant 3 Add 4 Low oil level or poor oil quality 4 Add or change 5 KnOCking 5 See KNOCKING 6 Moving parts seized or damaged 6 Replace 7 Defective thermostat 7 Replace LOW OIL PRESSURE 1 Wom Bearings 1 Engine overhaul replace bearings 2 Relief valve malfunction 2 Overhaul oil pump 3 Clogged oil cooler 3 Repair 4 Diesel dilution of the oil 4 Injection pump repair I engines Generators 9 AdobeUCSENGINE PROBLEM PROBABLE CAUSE SMOKY EXHAUST emWHmSH OR PURPUSH conI 225225 d Worn valve stem and valve guide d Replace e Low engine oil viscosity e Replace f Excessive oil pressure f Correct 3 Injection timing is too late 3 Adjust 4 Insufficient compression 4 See LOW COMPRESSION HARD STARTING BLACKISH OR DARK GRAYISH 1 Engine body troubles a Poor compression a See LOW COMPRESSION HARD STARTING b Improper valve clearance b Adjust 2 Insufficient intake air air cleaner clogged2 Clean air cleaner 3 Improper fuel 3 Replace with proper fuel ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING OR NOISE 1 Badly worn bearing 1 Replace bearing and grind crankshaft 2 Badly worn crankshaft 2 Grind crankshaft 3 Melled bearing 3 Replace bearing and check lubrication system CONNECTING ROD AND CONNECTING ROD BEARING 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace PISTON PISTON PIN AND PISTON RING 1 Worn cylinder 1 Rebore cylinder to oversize and replace piston 2 Worn piston pin 2 Replace piston 3 Piston seized 3 Replace piston and rebore cylinder 4 Piston seized and ring worn or damaged 4 Replace piston and rings VALVE MECHANISM 1 Worn camshaft 1 Replace 2 Excessive valve clearance 2 Adjust 3 Worn timing gear 3 Replace 4 Worn fan pulley bearing 4 Replace ROUGH OPERATION INJECTION PUMP SYSTEM 1 Uneven injection 1 Adjust injection or replace paris 2 Control rack manunctioning 2 Disassemble check and correct injection pump 3 Worn delivery valve 3 Replace 4 Inadequate injection nozzle spray 4 Replace injection nozzle GOVERNING SYSTEM 1 Governor lever manunctioning 1 Check governor shaft and correct operation 2 Fatigued governor spring 2 Replace continuedv WESTERBEKE Engines Generators 8 ENGINE PROBLEM PROBABLE CAUSE LOW OUTPUT ooMOVERHEATING 1 Low coolantlevel 1 Add coolant 2 Loose 2 Adjust or replace Vbelt 3 Incorrect injection timing 3 Adjust injection timing 4 Low 6 Add engine oil EXCESSIVE OIL OIL LEAKAGE CONSUMPTION 1 Defective oil seals 1 Replace oil seals 2 Broken gear case gasket 2 Replace gasket 3 Loose gear case attaching bolts 3 Retighten bolts 4 Loose drain hose 4 Retighten hose 5 Loose oil pipe connector 5 Retighten oil connections 6 Broken rocker cover gasket 6 Replace gasket 7 Loose rocker cover attaching bolts 7 Retighten attaching bolts OIL LEVEL RISING 1 Incorrectly positioned piston ring gaps 1 Correct ring gap positions 2 Displaced or twisted connecting rod 2 Replace connecting rod 3 Worn piston ring 3 Replace ring 4 Worn piston or cylinder 4 Replace piston and rebore cylinder OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace a valve and valve guide EXCESSIVE FUEL ENGINE BODY mOUBLES CONSUMPTION 1 Noisy knocking 1 See KNOCKING 2 SmokY exhaust 2 See SMOKY EXHAUST 3 Moving parts nearly seized or excessively worn 3 Repair or replace 4 Poor compression 4 See LOW COMPRESSION HARD STARTING 5 Improper valve timing 5 Adjust 6 Improper valve clearance 6 Adjust INSUFFICIENT INTAKE AIR 1 Air intake obstructed 1 Remove obstruction NOZZLE mOUBLES 1 Seized nozzle 1 Replace 2 Worn nozzle 2 Replace IMPROPER FUEL Replace with proper fuel FUEL LEAKS Find fuel leaks SMOKY EXHAUST WHmSH OR PURPLISH 1 Excessive engine oil 1 Correct oil level 2 Excessive rise of oil into combustion chamber a Poor piston contact a Check b Seized piston ring b Replace or clean c Excessive clearance c Replace or correct Engines Generators 7 AdobeUCSENGINE The following chart describes certain problems relating to engine service the probable causes of these problems and the to overcome these problems This chart may be of assistance in determining the need for an engine oveIhaui PROBLEM PROBABLE CAUSE lIARD STARTING lOW CRANKING SPEED 1 Engine oil viscosity too high 2 Rundown battery 3 Worn battery 4 Battery terminals loosely connected 5 Defective slarter DEFECTIVE INJECTION SYSTEM 1 Airtrapped in fuel passage 2 Clogged fuel fmer 3 low injection pressure 4 Inadequate spray 5 Injection pump delivering insufficient fuel 6 Injection too earty MAIN ENGINE TROUBLES 1 low compression a Incorrect valve clearance b Inadequate conlact of valve seat c Valve stem seized d Broken valve spring NOTE The engines electricol system is protected by a 20ampere 1IIl11IJJo1 reset circuit breaker The preheat solenoid is mounted on the same bracket 1 Replace engine oil less viscous oil 2 Recharge battery 3 Replace battery 4 Clean terminals and correct cables 5 Repair or replace slarter 1 Bleed air from fuel system 2 Clean or replace filler 3 Adjust injection pressure 4 Clean or replace nozzle 5 Repair or replace injection pump 6 Adjust injection timing a Adjust valve clearance b lap valve c Replace valve and valve guide d Replace valve spring e Compression leaks through cylinder head gasket e gasket I Piston ring seized I Replace piston and piston ring g Worn piston ring and cylinder g Overhaul engine 2 Burnt glow plug 2 Replace glow plug 3 Faulty glow plug operation 3 Correct lead wire connection 4 Incorrect governor lever position 4 Set lever to slarting position LOW OUTPUT LOW COMPRESSION See HARD STARTING INJECTION SYSTEM OUT OF ADJUSTMENT 1 Incorrect injection timing 1 Adjust injection timing 2 Insufficient injection 2 Repair or replace injection pump 3 low injection pressure 3 Check injection nozzle and adjusl pressure INSUffiCIENT FUEL 1 Airtrapped in fuel system 1 Check and retighten connector 2 Clogged fitter 2 Clean or replace filter 3 Contaminated fuel tank 3 Clean lank INSUffiCIENT INTAKE AIR 1 Clogged air cleaner 1 Clean or replace air cleaner Engines Generators 6 FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Genenilly the time at which an engine should be overhauled is determined by various conditions such as lowered engine power output decreased compression pressure and increased fuel and oil consumption The lowered engine power output is not neoessarily due to trouble with the engine itself but is sometimes caused by injector nozzle wear or injection pump wear The decrease in compression pressure is caused by many factors It is therefore necessary to determine a cause or causes on the basis of data produced by periodic inspection and maintenance Oil analysis on a seasonal basis is a good means of monitoring engine internal wear When caused by worn cylinders or piston rings the following symptoms will occur 1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption 4 Hard engine starting 5 Noisy engine operation These symptoms often appear together Symptoms 2 and 4 can result also from excessive fuel injection improper injec255tion timing and wear of the injectors They are caused also by defective electrical devices such as the battery alternator starter and glow plugs Therefore it is desirable to judge the optimum engine overhaul time by the lowered compression pressure caused by worn cylinders and pistons plus increased oil consumption Satisfactory combustion is obtained only under sufficient compression pressure If an engine lacks compression pressure incomplete combustion of fuel will take place even if other parts of the engine are operating properly 1b detennine the period of engine overhaul it is important to measure the engine compression pressure regu255larly At the same time the engine speed at which the mea255surement of compression pressure is made should be checked because the compression pressure varies with engine rpm The engine rpm can be measured at the front end of the crankshaft NDlE To test engine compression see the ENGINE ADJUSTMENT section of this manual ASSEMBLY 1 Wash all parts except for oil seals Orings rubber sheets etc with cleaning solvent and dry them with pressure air 2 Always use tools that are in good condition and be sure you understand how to use them before perfonning any job 3 Use only good quality lubricants Be sure to apply a coat of oil grease or sealant to parts as specified 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5 Ant time the engine is assembled new gaskets and Orings must be installed OVERHAUL CONDITIONS Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in Thereafter it decreases gradually with the progress of wear of these parts When decrease of compression pressure reaches the repair limit the engine must be overhauled The engine requires overhaul when oil consumption is high blowby evident and compression values are at minimum or below 558 FOUR COMPRESSION PRESSURE DISASSEMBLY 441 PSI 304 MPaNORMAL AT CRANKING SPEED OF 250 RPM 441 PSI BETWEEN CYLINDERS 1 Before disassembly and cleaning carefully check for defects which cannot be found after disassembly and cleaning 2 Drain water fuel and oil before disassembly 3 Clean or wash the engine exterior 4 Do not remove or disassemble the parts that require no disassembly 5 Perform disassembly in a proper order using proper tools Keep disassembled parts in order Apply oil when neces255sary Take special care to keep the fuel systern parts from intrusion of dust and dirt 6 Parts must be restored to their from which they were removed at disassembly This means that all parts must be set aside separately in groups each marled for its component so that the same combination or set can be reproduced at assembly 7 Pay attention to marks on assemblies components and parts for their positions or directions Put on marks if necessary to aid assembly S Carefully check each part or component fore any sign of faulty condition during removal or cleaning The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning ALTERNATOR INSPECTION When rebuilding the engine the alternator should be cleaned and inspected The housing can be wiped off with a solvent and the alternator terminal studs should be cleaned with a wire brush Make certain the studs are tight and clean the wiring connections that connect to the wiring harness Thm the rotor pulley by hand It should tum smoothly Depending on when the alternator was last serviced the brushes may need replacing If the alternator is at all suspect send it to a service shop for testing and overhaul For additional information on alternators refer to the ALTERNATOR and MANDO SERVICE in this manual WESTERBEKE Engines Generators 5 SPECIFICATIONS 558 ENGINE SPECIFICATIONS Engine Type Displacement Combustion Type Combustion System Bore Stroke Max Angle of Max Angle of Rring Order Direction of Propeller Shaft Compression Aspimtion Engine Speed Fuel Dimensions inches mmEngine Only Weight Air Row Diesel water cooled four cycle four cylinder inline overhead valve type 133 cubic inches 2179 literIndirect injection Swirl chamber 335 x 378 incheS85 x 96 mmNotto exceed 14 Not to exceed 30 for 30 minutes 1342 when viewed from flywheel Right hand direction of rotation 2151 Naturally Aspirated Idle speed 8501000 RPM CruiSing Speed 20002500 RPM No load speed 3200 RPM neutral15 US gph running at 2500 RPM approxwhen the propeller used allows the engine to tum at 3000 RPM at full open throttle underway in forwam 233 inches Width 186 inches Length 270 inches 448 Ibs 2032 kgs592 mm472 mm687 mmEngine 116 cfm 33 cmnEngine Cooling 200 cfm 56cmmTUNEUP SPECIFICATIONS Compression Pressure Valve Timing Intake Opens Intake Closes Injection Timing Nozzle Injector Pressure Valve Clearance engine cold441 psi 304 MPaOpen at 15 BTDC Close 29 ABDC Open at 40 BTDC Close 16 ATDC 16 BTDC 1920 psi 132 MPa00157 inches 04 mmELECTRICAL SYSTEM Starting Battery Battery Capacily DC Charging Altemator Starting Aid Starter Cold Cranking Amps Altemator Regulator Exhaust Elbow Exhaust Hose Size Exhaust Gas Flow Muffler Size min12 Vott negative ground 400 600 CCA min50 Amp rated bettdriven 12V Glow plugs 12V sheathed 12 von 18 KW solenoid 175 200 Amps Intema regulator buitt into altemator EXHAUST SYSTEM 45 elbow 30 10 hose 265 cfm at 3000 RPM 14 x 14 Fuel Fuel Injection Pump Injectors Fuel Rner Air cleaner Fuel Uft Pump General Operating Temperature Fresh Water Pump Raw Water Pump System Capaclly Sea Water Row at 3000 rpm Diesel fuel I catane rating of 45 or higherBOSCH PFR type Throttle type Primary full flow spinon element Replaceable paper carlridge Solid atate with extemal fitter COOLING SYSTEM Fresh watercooled with tube and shell type heat exchanger 170 190 F 77 88 CCentrifugal matal impeller type beltdriven Positive rubber impeller bendriven 725 US qts 80 85 gpm 302 321Ipmmeasured before discharging into water injected exhaust SYSTEM General Oil Rtter Sump Capeclly not including fitterOpemting Oil Pressu re engine hotOil Grade Oil Cooler General clutch Gear Ratio atandamForced bY Trochoid type pump Full flow spinon 8 US qts 43 85 psi 290 590 KPaAPI CF or CG4 SAE 30 15W30 Fresh water cooled TRANSMISSION ZF Marine Transmission case hamened helical gears with a servooperated multiple disc 1881 ZF25MPropeller 18 x 13P2blade RHor 18 x l1P 3 blade RHPropeller used should allow the engine to reach its full rated RPM 3000 000 100at full open throttle while underway in forwarc gearRuid Transmission Sump Capacity Automatic transmission fluid type Dexron II or III 075 US qts 079 Engines Generators 4 PRODUCT SOFTWARE Product software technical data parts lists manuals brochures and from sources other than WESTERBEKE are not within WESTERBEKES control WESTERBEKE CANNOT BE RESPONSIBLE FOR mE CONTENT OF SUCH SOF1WARE MAKES NO WAR255RANl1ES OR WITH RESPECT THERETO INCLUDING ACCURACY TIMEliNESS OR COMPLETENESS mEREOF AND WIUIN NO EVENT BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WIm OR ARISING OUT OF THE FURNISHING OR USE OF SUCH SOF1WARE WESTERBEKE customers should keep in mind the time span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE product software The product software provided with WESTERBEKE products whether from WESTERBEKE or other suppliers must not and cannot be relied upon exclu255sively as the definitive authority on the respective product It not only makes good sense but is imperative that appropriate ofWESTERBEKE or the supplier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer SERIAL NUMBER LOCATION The engines model number and serial number are located on a nameplate mounted on the side of the engines manifold The engines serial number can also be found stamped into I the engine blOck on the flat surface of the block just forward of the number one cylinders injection pump Take the time to enter this information on the illustration of the nameplate shown below as this will providea quick reference when seeking technical information andor ordering repair parts ORDERING PARTS Whenever replacement parts are needed always provide the engine modelnumber and serial number as they appear on the silver and black nameplate located on the manifold You must provide us with this information so we may properly identify your engine In addition include a complete part description and part number for each part needed see the separately furnished Parts ListInsist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment RAW WATER CODLING SYSTEM SiphonBreak For installations where the water injected exhaust elbow is close to or will be below the vessels waterline provisions must be made to install a siphonbreak in the raw water supply hose to the water injected exhaust elbow The siphon255break provides an air vent in the raw water cooling system to prevent raw water from filling the exhaust system and the engines cylinders when the engine is shutdown A CAUTION Failure to use a siphonbreak when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and possible flooding of the boat If you have any doubt about the position of the exhaust elbow relative to the vessels waterline under the vessels various operating conditions install a siphon255break This precaution is necessary to protect your engine The siphonbreak must be installed in the highest point of a hose that is looped a minimum of 20 inches 51cmabove the vessels waterline This siphonbreak must always be above the waterline during all angles of vessel operation to prevent siphoning NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphonbreak can result in catastrophic engine damage Consult the siphonbreak manufacturer for proper maintenance SIPHONBREAK WITH STAINLESS LOOP FOR 34 HOSE PART NO045368 SIPHON267BREAK PART NO 033327 flY WESTERBEKE Engines Generators 3 PARTS IDENTIFICATION INTAKEAIR AlTER OIL PRESSURE CAP CONNECTION THERMOSTAT ASSEMBLY RAW WATER DDREAR FRONT PREHEAT uNUU AIR INTAKEAIR FUEL UFT 2DACIRCUIT BREAKER Fua AlTER SHIFT lEVER Oll T1267 WATER INJECTED EXHAUST OIL COOLER SENOOR RIGHT SIDE Engines Generators 2 ElBOW 10 PLATE JfHIAT EXCHANGER REAR ANODE COOlER LEFT SIDE All THERMOSTAT AlTERNATOR fRONT PUllEY OIL All MOUNT AdobeUCSTABLE OF CONTENTS Parts Identification 2 Introduction 3 Engine Specifications 4 Testing for Overhaul 5 Alternator Inspection 5 Engine 6 Engine Disassembly 10 Engine Measurements 11 Prior to 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 View225 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 225 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 AdobeUCSThe exhaust AdobeUCSSAFETY INSTRUCTIONS 225 Do not wear loose clothing or jewelry when servicing equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in moving parts 225 Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at all times 225 Do not check fluid levels or the drive belts tension while the engine is operating 225 Stay clear of the drive shaft and the transmission coupling when the engine is runuing hair and clothing can easily be caught in these rotating parts HAZARDOUS NOISE I High noise levels can C81S8 hearing 225 Never operate an engine without its muffler installed 225 Do not run an engine with the air intake 225 Do not run engines for long periods with their enclosures open A WARNING Do not nt lin macIJinlll1 when ytlU are fIT pJysItal Incapacifatetl by fatigue ABYC NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC NfPA and USCG publications for safety codes and standards Follow their when installing your engine ABYC American Boat and Yacht CouncilSafety Standards for S1IaU Craft Order from ABYC 3069 Solomons Island Rd Edgewater MD 21037 NFPA National Fire Protection Protection Standard for Motor Craft Order from NfPA II Tracy Drive Avon Industrial Park Avon MA 02322 USCG United Slates Coast GuardUSCG 33CFR183 Order from US Government Printing Office Washington DC 20404 OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your 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 Councils ABYCstandards These standards are a combination of sources including the USCG and the NfPA Sections of the ABYC standards of particular interest are H2 Ventilation Pl Exhaust Systems P4 InboanI Engines E9 DC Electrical Systems All installations must comply with the Federal Code of Regulations FCREngines Generators iii AdobeUCSand any ventilation exists CALIFORNIA PROPOSITION 65 WARNING Exhaust gas from diesel and gasoline engines and some of its 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 and death Symptoms of Carbon Monoxide exposure can include Dizziness Nausea Headache Weakness and Sleepiness 225 Throbbing in Temples 225 Muscular Twitching 225 Vomiting 225 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 ivingsleeping quarters of your vessel They are inexpensive and easily obtainable at your local marine store Engines Generators SERVICE MANUAL 55BFOUR and 55eFOUR 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 AlMM Metn253f National Manufacturers Association AdobeUCS
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