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Westerbeke Diesel 12b Two Operator's Manual


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    TECHNICAL MANUAL                  WESTERBEKE                1oTWO  128TWO           MARINE DIESEL ENGINES            WMD 3 KW  60 HERTZ           WMD 24 KW  50 HERTZ      MARINE DIESEL GENERATORS                     PUBLICATION 33403                       EDITION TWO                         JUNE1993j   rv WESTERBEKE            WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK       j    150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA          TEL 5088237677 FAX 5088849688  WEBSITE                           IMPORTANT                   PRODUCT SOFTWARE NOTICEProduct software of all kinds such as brochures  data operators and workshop manuals parts listsand parts price lists and other information    specifications   provided   from  sources   other  thanWesterbeke is not wi thin Westerbeke s control and accordingly is provided to Westerbeke customers only as a courtesy and service    WESTERBEKE CANNOT BE RESPONSIBLE FOR THECONTENT   OF   SUCH   SOFTWARE   MAKES   NO  WARRANTIES    WITH RESPECT THERETO INCLUDING THE  OR COMPLETENESS THEREOF AND WILL IN NO EVENT BELIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED INCONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OFSUCH SOFTWAREFor example components and subassemblies incorporated inWesterbekes products and supplied by others such as engineblocks fuel systems and components transmissions electrical components pumps and other products are generally supported by their manufacturers wi th their own software andWesterbeke must depend on such software for the design ofWesterbekes own product software Such software may be outdated and no longer accurate       Routine changes made byWesterbekes suppliers of which Westerbeke rarely has noticein advance are frequently not reflected in the  until after such changes take  customers should also keep in mind the time spanbetween printings of Westerbeke product software and theunavoidable existence of earlier noncurrent    editions   in   the   field     Addi tionally   mostWesterbeke   products    include         that frequently do not include complete  sum product software provided wi th Westerbeke  from Westerbeke or other suppliers must not and cannot be relied upon exclusively as the definitive authority onthe respective product It not only makes good sense but isimperative that appropriate  of Westerbeke orthe supplier in question be consulted to determine theaccuracy and currency of the product software being consultedby the  INDEXGENERAL  Introduction   Operation  Installation    OVERHAULOTHER OVERHAUL  Marine Engine Electrical System  Cooling System External  Transm iss ionsGENERATOR SETSSERVICE BULLETINS                      INTRODUCTION  IMPORTANT  THIS MANUAL IS A GENERAL GUIDE TO THE INSTALLATION STARTUP  OPERATION AND MAINTENANCE OF YOUR WESTERBEKE MARINE DIESEL ENGINE  THE INFORMATION IT CONTAINS IS VITAL TO THE ENGINE I S DEPENDABLE  LONG TERM OPERATION         READ IT         KEEP IT IN A SAFE DRY PLACE          KEEP IT HANDY FOR REFERENCE AT ALL TIMES  FAILURE TO DO SO WILL INVITE SERIOUS RISK NOT ONLY TO YOUR  INVESTMENT BUT YOUR SAFETY AS  THE DIESEL      The diesel engine closely resembles the gasoline engine inasmuchas the mechanism is essentially the same   Its cylinders are arrangedabove its closed crankcase its crankshaft is of the same general typeas that of a gasoline engine it has the same sort of valvescamshaft pistons connecting rods lubricating system and reverse andreduction gear     Therefore it follows to a great extent that a diesel enginerequires the same preventative maintenance as that which any intelligent operator would give to a gasoline engine      The most  are proper maintenance of the fuel lubr icating and coolingsystems   Replacement of fuel and lubricating filter elements at thetime periods specified is a must and frequent checking for contamination i e water sediment etc  in the fuel system is alsoessential   Another important factor is the use of the same brand ofnhigh detergent diesel lubricating oil designed specifically fordiesel engines     The diesel engine does differ from the gasoline engine howeverin the method of handling and fir ing its fuel     The carburetor andigni tion systems are done away wi th and in their place is a   the Fuel Injection Pump  which performs the function ofboth     Unremitting care and attention at the factory have resulted in aWesterbeke engine capable of many thousands of hours of  What the manufacturer cannot control however is the treatment it receives in service This part rests with youORDERING PARTS    Whenever replacement parts are needed always include the completepart description and part number see separate Parts List    Be sureto include the engine I s model and ser ial number  Also be sure toinsist upon Westerbeke factory packaged parts because nwill fitparts are frequently not made to the same specifications as  GENERATOR SETS    Westerbeke diesels are used for both the propulsion of boats andfor generating electrical power  For generator set applications alldetails of this Manual apply except in regard to certain portions ofthe Installation Operation and Maintenance sections       is provided in the section titled Generator SetsSection T                                  2                       INSTALLATION    FOREWORD          Since the boats in which these engines and generators    are used are many and varied details of engine installation    are equally so    It is not the purpose of this section to    advise boatyards and engine installers on the generally well    understood and well developed procedures for installation of    engines However the following outline of general procedure    is included because it is valuable in explaining the func    tions of each component the reasons why the precautions to    be watched and the relationship of the installation to the    operation of the engine   There are details of the installa    tion which should have a per iodic check and of which the    operator should have a thorough understanding to insure good    operating conditions for the engine and correct procedure for    its  OF EQUIPMENT    The engine is shipped from the factory mounted securely and properly crated Accessory equipment is shipped in a separate small boxusually packed with the engine crate    Before accepting shipment from the transportation company thecrate should be opened and an inspection made for concealed damageIf either visible or concealed damage is noted you should require thedelivering agent to sign Received in damaged condition Also checkcontents of the shipment against the packing list and make sure noteis made of any discrepancies This is your protection against loss ordamage Claims for loss or damage must be made to the carrier not toJ H Westerbeke  AND LIFTING     The engine is fitted with lifting rings     Rope or chain slings should be attached to the rings and theengine lifted by means of tackle attached to this sling The liftingrings have been designed to carry the full weight of the  auxiliary slings are not required or desired     CAUTION   Slings must not be so short as to place the enginelifting eyes in significant sheer stress        Strain on the enginelifting eyes must not be in excess of 10 from the vertical A spacerbar must be placed between the two lifting eyes if supported by valvecover studs     The general rule in moving engines is to see that all equipmentused is amply strong and firmly fixed in place      Move the engine alittle at a time and see that it is firmly supported          of accidents by avoiding haste Do not lift from the propeller coupling or pry against this with crowbar as you may distortthe coupling     In some cases it may be necessary to lift the engine in other thanthe regular horizontal position     It may be that the engine must belowered endwise through a small hatchway which cannot be made largerIf the opening is extremely restricted it is possible to reduce tosome extent the outside clearances such as generator cooling pipingwater tank filters mounting lugs etc      This accessory  be removed by a competent mechanic and special care should be                                  3taken to avoid damage to any exposed parts and to avoid dirt    The parts which have been removed should be returned toposition as soon as the restriction has been passed    In case it is necessary to hoist the engine either front endupwards or reverse gear end upwards the attachment of slings must bedone very carefully to avoid the possibility of damage to the parts onwhich the weight may bear It is best if special rigging work be doneby someone experienced and competent in the handling of heavy  BOLTS    It is recommended that bronze or stainless hanger bolts ofappropr iate size be used through the engine flexible mounts     Lagscrews are less preferred because their hold on the wood is weakenedevery time they are moved whereas the lag bolt stays in position andthe nut on top is used to tighten the engine down or is removed topermit the engine to be lifted The bolt itself stays in position atall times as a stud and the bond between the bolt and the wood isnot weakened by its  FOR ENGINE     A good engine bed contributes much toward the satisfactory operation of the engine The engine bedmust be of rigid construction andneither deflect nor twist when subjected to the engine weight or theposition the boat may have to takeunder the effects of rough seasThe bed must keep the engine withinone or two thousandths of an inchof this position at all times    Ithas to withstand the forward push                               Aof the propeller which is appliedto the propeller shaft to thethrust washer bearing in the engineand finally to the engine bolts andeng ine bed     In fiberglas hulls we recommend that similar wooden str ingersas in wooden hulls be formed andfitted then glassed to the hullsecurely This allows hanger boltsto be installed firmly in woodthus reducing noise and                                                      B     Preformed fiberglas engine bedswhen used should be of  to properly support the engine and should be well glassed tothe hull when installed     The temptation to install the engine on a pair of fiberglas angleirons should be resisted Such construction will allow engine vibrations to pass through to the hull      Flexible mounts require a firmfoundation against which to react if they are to do their job Whenpossible follow bed design An and avoid bed design Sn                                  4    Supports between the bed stringer and extending out from thestringers out to the hull may be required for proper support and toaid in the absorption of  COUPLING    Each Westerbeke Diesel engine is regularly fitted with a  connecting the propeller shaft to the engine    The coupling must not only tr ansmi t the power of the eng ine toturn the shaft but must also transmi t the thrust ei ther ahead orastern from the shaft to the thrust bear ing which is built into thereduction gear housing of the engine This coupling is very  for accurate fit    For all engine models a propeller halfcoupling bored to shaftsize for the specific order is supplied   The coupling either has akeyway with set screws or is of the clamping type    The forward end of the propeller shaft has a long straight keywayAny burrs should be removed from the shaft end    The coupling shouldbe a light drive fit on the shaft and the shaft should not have to bescraped down or filed in order to get a fit     It is important thatthe key be properly fitted both to the shaft and the coupling     Thekey should fit the side of the keyway very closely but should nottouch the top of the keyway in the hub of the coupling    If it seems difficult to drive the coupling over the shaft thecoupling can be expanded by heating in a pail of boiling water    Theface of the propeller coupling must be exactly perpendicular to thecenterline or axis of the propeller shaftPROPELLER    The type and size of propeller varies with the gear ratio and mustbe selected to fit the application based upon boat tests To utilizethe full power of the engine and to achieve ideal loading conditionsit is desirable to use a propeller which will permit the engine toreach its full rated RPM at full throttle under normal loadALIGNMENT OF ENGINE    The engine must be properly and exactly aligned with the propellershaft   No matter what material is used to build a boat it will befound to be flexible to some extent and the boat hull will change itsshape to a greater extent than is usually realized when it is launchedand operated in the water    It is therefore very important to checkthe engine alignment at frequent intervals and to correct any errorswhen they may appear    Misalignment between the engine and the propeller shaft is thecause of troubles which are blamed often on other causes      It willcreate excessive bearing wear rapid shaft wear and will in manycases reduce the life of the hull by loosening the hull fasteningsA bent propeller shaft will have exactly the same effect and it istherefore necessary that the propeller shaft itself be     One particularly annoying result of misalignment may be leakage oftransmission oil through the rear oil seal    Check to make sure thatalignment is within the limits prescribed    The engine should be moved around on the bed and supported on thescrewjacks or shims until the two halves of the couplings can bebrought together without using force and so that the flanges meet                                  5evenly all around    It is best not to drill the foundation for thefoundation bolts until the approximate alignment has been     Never attempt a final alignment with the boat on land The boatshould be in the water and have had an opportunity to assume its finalwater form   I t is best to do the alignment wi th the fuel and watertanks about half full and all the usual equipment on board and afterthe main mast has been stepped and final rigging has     Take plenty of time in making this alignment and do not besatisfied with anything less than perfect results    The alignment is correct when the shaftcan be slipped backward and forward into thecounterbore very easily and when a feelergauge indicates that the flanges come  at all points     The two halves ofthe propeller coupling should be parallelwithin 0001 inches perinch diameter ofcoupling A    In making the final check for alignmentthe engine half coupling should be held inone position and the alignment with the propeller coupling tested with the  in each of four posi tions rotated90 between each position This test will also check whether the propeller half coupling is in exact alignment on its shaft         Thenkeeping the propeller coupling in one position the alignment shouldbe checked rotating the engine half coupling to full position each 90from the next one    The engine alignment should be rechecked after the boat has beenin service for one to three weeks and if necessary the    It will usually be found that the engine is no longer inalignment This is not because the work was improperly done at firstbut because the boat has taken some time to take its final shape andthe engine bed and engine stringers have probably absorbed somemoisture It may even be necessary to realign at a further period    The coupling should always be opened up and the bolts removed whenever the boat is hauled out or moved from the land to the water andduring storage in a cradle The flexibility of the boat often puts avery severe strain on the shaft or the coupling or both when it isbeing moved In some cases the shaft has actually been bent by thesestrains   This does not apply to small boats that are hauled out ofthe water when not in use unless they are dry for a  SYSTEM    Exhaust line installations vary considerably and each must bedesigned for the particular installation The prime requirements areto provide an outlet line with a minimum of restrictions and arrangedso that sea water rain water and condensation cannot get back intothe cylinders of the engine    The sea water supply line feeding raw cooling water into thesystem must be routed so as to prevent a siphoning of raw waterthrough this line into the exhaust system filling the muffler andengine cylinders This line should be routed at least 12 inches above                                  6the water line and an antisiphon break installed at the top of itsloop   This loop should be high enough above the water line so as notto be below it at various angles of heel when under sail    Lines feeding raw cooling water to stuffing boxes if installedmust be installed so as to prevent siphoning of water back into theengine exhaust and engine cylinders as above    Most exhaust systems today use a water lift type muffler such asthe Westerbeke HydroHush     In most installations there is a dryinsulated high loop after the engine manifold and before the mufflerto prevent water flowing backwards into the engine during cranking      It is essential not to hang too much weight in the form ofexhaust   system   components  rigidly    from  the   engine   it is permissible to directiy connect a pipe nipple and a                                       water jacketed exhaust elbow                                       which two components weigh about                                       8 pounds 4 kg    If there are                                       more components to be rigidly                                       connected to each other than                                       will weigh 8 pounds then a                                       flexible exhaust section must be                                I      installed between the manifold                                   outlet and these exhaust system                                     components                                                         ENCINE INSTALLATIONS WITH EXHAUST MANI            FOLDWATER INJECTED ELBOW MINIMUM OF 6            INCHES ABOVE VESSEL WATER LINE                                                                                                                                        12min                                                            48                                                            max                                                             I                                                             I                                                             IENCINE INSTALLATIONS WITH EXHAUST MANIFOLDWATER INJECTED ELBOW AT OR BELOW                     JVESSEL WATER LINE    The exhaust system must be supported or suspended independently ofthe engine manifold usually using simple metal hangers secured to theoverhead    All dry portions of the exhaust system can be constructed of common black iron pipe and should be wrapped in sui table  to keep surface temperatures as low as possible    Many installations use flexible rubber exhaust hose for the water                                                      7cooled section of the exhaust line because of the ease of  flexibility Provide adequate support for the rubber hose to prevent sagging bending and formation of water pockets      The exhaustline must be at least as large an ID as the OD of the exhaustelbow hose attachment nipple     It should be increased in size by12 ID for every 10 feet beyond the first 10 feet    Always arrange the rubber hose section so that water cannotpossibly flow back into the engine Also make sure that entering seawater cannot spray directly against the inside of the exhaust  excessive erosion will occur   The use of brass or copperis not acceptable for wet exhaust systems as the combination of saltwater and diesel exhaust gasses will cause rapid deterioration of  EXHAUST GAS BACK PRESSURE    Back pressure must be measured on a straight section of theexhaust line and as near as possible to the engine exhaust manifoldThe engine should be run at maximum load during the  Setup should be as shown below1 For normally aspirated engines         Pressure Test       Mercury Test     Water Column         112 Max PSI      3 Mercury          392   For turbocharged engines          Pressure Test       Mercury Test     Water Column          075 Max PSI        112 Mercury     1912Checking The Back Pressure1 Exhaust elbow2 Exhaust line3 Transparent plastic hose part                          Exhaust                                                            Elbowly filled with  A may not exceed 39for normally aspirated engines and195 for turbocharged enginesWATER CONNECTIONS     Seacocks and strainers should be of the full flow type at leastone size greater than the inlet thread of the sea water pump      Thestr ainer should be of the type which may be wi thdr awn for cleaningwhile the vessel is at sea    Mount the strainer below the water lineto insure selfpriming     Water lines can be copper tubing or wirewound reinforced rubberhose    In any case use a section of flexible hose that will notcollapse under suction between the hull inlet and engine and betweenthe outlet and the exhaust system    This takes up vibration and per                                   8mits the engine to be moved slightly when it is being realigned Donot use street elbows in suction piping All pipe and fittings shouldbe of bronze  Use sealing compound at all connections to prevent airleaks The neoprene impeller in the sea raw water pump should neverbe run dryCOOLANT RECOVERY TANK    Your   Westerbeke diesel    isdesigned for and supplied wi th a        COOLANT                                                   FILL CAPremote coolant    recovery   tank                               COCKPITOnce the engine has been ini             TANK     j                                         RECOVERY tially filled via its pressure                   ALTERNATE                                                 MOUNTING                                                              cap occasional topping off can                    STRAP                                                 POSITIONSbe done    through the recoverytank     Coolant level can beeasily and frequently monitored           CABIN    Mount the recovery tank abovethe engine and inside the cabinwhere it will always be visible    Take care that the plastictubing between the engine and therecovery tank is led    so that itwill not chafe or kinkFUEL TANK AND FILTERS     Fuel tanks may be of fiberglas monel aluminum plain steel orterne plate    If made of fiberglas be certain that the interior isgel coated to prevent fibers from contaminating the fuel systemCopper or galvanized fuel tanks should not be used          It is notnecessary to mount the tank above the engine level as the fuel liftpump provided will raise the fuel from the tank     The amount of liftshould be kept minimum 6 feet being maximum     If a tank is  above the engine level it can be utilized in this positionGreat care should be taken to ensure that the fuel system is  so that airlocks are eliminated and precautions takenagainst dirt and water entering the fuel     A primary fuel filter of the water collecting type should beinstalled between the fuel tank and the fuel lift pump A  is available from the list of accessor ies     The secondary fuelfil ter is fitted on the engine between the fuel lift pump and theinjection pump and has a replaceable element     As the fuel lift pump has a capacity in excess of that required bythe injection pump the return is piped to the fuel tank and should beconnected to the top of the tank and the return extended down into thetank     To insure satisfactory operation a diesel engine must have adependable supply of clean diesel fuel    For this reason cleanlinessand care are especially important at the time when the fuel tank isinstalled because dirt left anywhere in the fuel lines or tank willcertainly cause fouling of the injector nozzles when the engine isstarted for the first timeFUEL PIPING     We recommend fuel hose or copper tubing together with sui tablefittings both for the supply line and the return line    Run the                                     9tubing in the longest pieces obtainable to avoid the use of unnecessary fittings and connectors The shut off valve in the line between the fuel tank and engine should be of the fuel oil type and itis important that all joints be free of pressure leaks    Keep fuel lines as far as possible from exhaust pipe for  to eliminate vapor locks    The fuel piping leading from the tank to the engine  always be securely anchored to prevent chafing   Usually thecopper tubing is secured by means of copper straps    The final connection to the engine should be through flexiblerubber hosesELECTRIC PANEL    The Westerbeke allelectr ic panel utilizes an electronic tachometer with a builtin hourmeter hourmeter only on  on the panel are a voltmeter water temperature gauge and oilpressure gauge  Each instrument is lighted   The allelectr ic panelis isolated from ground and may be mounted where visible  It is normally  EQUIPMENT    Most Westebeke engines are supplied prewired and with     Never make or break connections while the engine isrunning    Carefully follow all instructions on the wir ing  especially those relating to fusecircuit breaker requirements    Starter batter ies should be located as close to the engine aspossible to avoid voltage drop through long leads It is bad practiceto use the starter batter ies for other services unless they requirelow amperage or are intermittent   In cases where there are substantial loads from lights refrigerators radios depth sounders etcit is essential to have a complete separate system and to  current for this by means of a second alternator oralternator output splitter    Starter batteries must be of a type which permits a high rate ofdischarge Diesel starting    Carefully follow the recommended wire sizes shown in the wir ingdiagrams Plan installation so the battery is close to the engine anduse the following cable sizes         II       for distances up to 8 feet         110     for distances up to 10 feet         20     for distances up to 13 feet         130     for distances up to 16 feetMECHANICAL CONTROLS    The recommended practice is to have the stoprun lever loaded tothe run position and controlled by a sheathed cable to a pushpullknob at the pilot station The throttle lever should be connected toa Morse type lever at the pilot station by a sheathed cable    The transmission control lever may be connected to the pilot station by a flexible sheathed cable and controlled by a Morse typelever   The singlelever type gives clutch and throttle control withfull throttle range in neutral position The twolever type providesclutch control with one lever and throttle control with the other    Any bends in the control cables should be gradual    End sections                                  10at engine and transmission must be securely mounted    After linkagesare completed check the installation for full tr avel making surethat when the transmission control lever at the pilot station is inforward neutral and reverse the control lever on the  moved into the respective position     Some models do not require a stop cable because they have a fuelrun solenoid    Examples of such models are the WS8 and the WS2 20KWand ISKW generators     Check the throttle lever on the injection pump and insure thatfull    movement   of    the  lever   is   provided  by   the   cable                                  11                          FOR FIRST START    The engine for safety reasons is shipped dry  with lubricating oil drained from the crankcase and fluid from the  be sure to follow these recommended procedures  starting the engine for the first time    1 Remove the oil filler cap and fill the sump with diesel oilhaving an API spec of CC or better Refer to the technical data section of this manual for the proper amount of oil the sump shouldreceive    2 Fill the cooling system with a mixture of antifreeze and freshwater 5050 The mixture should be strong enough to protect   Open bleed petcocks to allow air to bleed from the systemwhile it is being filled    3 Fill the reverse gear to the highest mark on the dipstick withthe proper lubricant for     the model gear as specified in  Section of this manual Vdrives must be filled separately    4 Fill the fuel tank with clean 2 diesel fuel The use of 1is permissible but 2 is preferred because of its higher lubr icantcontent    5 Ensure that the battery is fully charged and the  is correctFUEL SYSTEM     The fuel injection system of a compression ignition engine dependsupon very high fuel pressure during the injection stroke to     Relatively tiny movements of the pumping plungers producethis pressure and if any air is present inside the high pressureline then this air acts as a cushion and prevents the  and therefore fuel injection from being achieved     In consequence it is essential that all air is bled from thesystem whenever any part of the system has been opened for repair orservicing    Selfbleeding units need only have the fuel brought to the fuelconnection on the engine      The system when activated will selfbleed    The selfbleeding feature of the engine will not bleed thevessels fuel system from the tank to the engine in all casesBLEEDING PROCEDURES BY MODELInitial Engine Startup Engine stoppage due to lack of fuel    a Insure that the fuel tanks is filled with the proper grade    of diesel fuel    b Turn the fuel selector valve to On Systems with more than    one tank insure that fuel returning is going to the tanks being    used                                  12     c Fill any large primary filterwater separator with clean     diesel fuel fuel that is installed between the fuel tank and     engineThe above procedures are basic for all initial engine startups or forrestarting engines stopping due to lack of fuelWESTERBEKE WIOTwo 3KW W13 44KW W21 77KW W27 llKW W33 12SKWThese units are selfbleeding1 Turn the ignition to the ON position Generators  PREHEAT          and    wait 2030 seconds2 Start the engine following normal starting  WS2 lSKW WS8 20KW W70 2SKW WIOO 32KW1   Open the bleed screw on the top inboard side of the enginemounted     secondary fuel filter one to two turns using a lOmm box wrench     Bleed Point A     This fuel filter is equipped with a hand     operated priming pump    with the palm of your hand pump this     primer with slow steady pumps until fuel free of air bubbles flows     from this bleed screw     Stop pumping and retighten the bleed     screw     NOTE An electric fuel pump is incorporated in the fuel system on     new model units which when activated by turning the ignition on     Generator  Preheat will bleed the filter of air through Bleed     Point A2   With bleed screw A tightened continue to pump the hand primer     operate the electric fuel pump several more times so as to bleed     and prime the fuel injection pump3   Loosen the four injector line attaching nuts at the base of each     injector Bleed Point B one to two turns with a 16mm open end     wrench   Place the throttle in the full open position and crank     the engine over with the the starter until fuel spurts by the nut     and injector lines Stop cranking and tighten     each of the four nuts and proceed with normal     starting procedure                                                   Electric Fuel Pump                          A                                   13PREPARATION FOR STARTING1   Check water level in expansion tank    It should be 12 to 1 in     below the top of the tank when cold    If remote plastic recovery     tank is used the level should be at the cold mark2   Check the engine sump oil level3   Check the transmission fluid level4   See that there is fuel in the tank and the fuel shutoff is open5   Check to see that the starting battery is fully charged all     electr ical connections are properly made all circui ts in order     and turn on the power at the battery disconnect6   Check the seacock and ensure that it is openSTARTING THE ENGINE COLD1   Check to see that the ft stopft lever if incorporated is in the     ftrunft position Place the throttle in the full run position and     the gear lever in the neutral position2   Engines with keyswi tches   Turn the swi tch to the ON posi tion     This energizes the instrument panel electric fuel pump and injec     tion pump fuel solenoid3   Preheat for 15 to 20 seconds     Panels with keyswitches  Push in on the key to activate the pre     heat and hold in panels with pushbuttons     Panels with pushbuttons   Push in on the preheat button to acti     vate preheat and hold it in     Generators Depress preheat switch and hold4   Start the engine     Panels with keyswitches While continuing to hold the key pushed     in for preheat turn the key to the start position     Panels with pushbutton start Continuing to hold the preheat but     ton in press the start button     Generators  Continuing to hold preheat depressed depress start     swi tch5   Start   Once the engine starts release the keyswitch push     buttons and return the throttle immediately to near the idle     position 1000  1500 RPM     Generators   Release the start toggle switch only   Continue to     hold the preheat toggle switch depressed until oil pressure shows     20  25 PSI then release the preheat toggle     Check for proper oil pressure and insure that there is raw water     coolant discharge with the exhaust6   If the engine fails to start in 20 to 30 seconds of cranking     discontinue the starting and allow the starter to cool for a                                   14     preiod of time at least     twice   that   used   when cranking    Then     repeat steps 3 through 5     CAUTION Excessive cranking can damage the starter as well as     fill the exhaust muffler and that portion of the system between     the muffler and engine with raw cooling water possibly getting it     back into the engineSTARTING THE ENGINE WARMIf the engine is warm and has only been stopped for a short timeplace the throttle in the par tially open position and engage thestarter as above eliminating the preheat stepNOTE preheat must be depressed on generator           units whenever   it isbeing startedNOTE   Always be sure that the star ter pinion has stopped  again reengaging the starter  otherwise the flywheel ringgear or starter pinion may be  use of the cold starting aid beyond the time periods statedshould be avoided to prevent damage to the aidNEVER under any circumstances use or allow anyone to use ether tostart your engine    If your engine will not start then have aqualified Westerbeke marine mechanic check itWHEN ENGINE STARTS1   Check for normal oil presure immediately upon engine starting Do     not continue to run engine if oil pressure is not present within     15 seconds of starting the engine2   Check Sea Water Flow    Look for water discharge with the exhaust     Do this without delay3   Recheck Crankcase Oil   After the engine has run 3 or 4 minutes     subsequent to an oil change or new installation stop the engine     and check the crankcase oil level This is important as it may be     necessary to add oil to compensate for the oil that is required to     fill the engines internal oil passages and oil filter    Add oil     as necessary Check oil level prior to each days operation4   Recheck Transmission Fluid level    This applies only subsequent     to a fluid change or new installation   In such a case stop the     engine after running for several minutes at 800 RPM with one shift     into forward and one into reverse then add fluid as necessary     Check fluid level each day of operation5   Check Expansion Tank Water Level      This is done stopping the     engine     and removing the fresh water       fill cap from the      tank    To remove the cap press down on it     with the palm of the hand and twist the cap  until                                    15     the resistance of the safety stops is felt    Slowly release palm     pressure from the cap and allow any pressure built up in the     system to escape     Take care not to be scalded or burned by     escaping stearn or water Leave the cap in this position until all     pressure is released Then press the cap firmly downward to clear     the safety stops and continue turning it until it can be lifted     off     Add coolant as needed to bring the level to within one half inch     of the top of the fill neck     NOTE Systems with metal remote expansion tanks    Coolant level     should be checked at this tank and the level maintained about one     half to three quarters full   The fill cap on the engine should     not be removed to check the system as coolant will be lost when     this cap is removed     NOTE Engines equipped with the plastic coolant recovery tank     The level in the tank should be checked and coolant added as     needed  The engine fresh water cooling system is filledfull when     this recovery tank is used and this tank collects coolant from the     engine through expansion as the engine reaches operating tem     perature 170  190 F and returns this coolant to the engine     through contraction as the engine cools         WARNING The cooling system is pressurized when the engine         is at operating temperature or overheated and the pressure in         the system must be released with caution as the filler cap is         removed    It is advisable to protect the pands against         escaping stearn or water as the cap is turned6   Warmup Instructions As soon as possible get the boat underway     but at reduced speed until water temperature gauge indicates     l30l50F    If necessary engine can be warmed up with the     transmission in neutral at 1000  1500 RPM7   Reverse Operation    Always reduce   engine to idle speed when     shifting gears   However when the   transmission is engaged it     will carry full engine loadSTOPPING THE ENGINE1   position shift lever in neutral   Remove load from generator2   Idle the engine for 2 to 4 minutes to avoid boiling and to dissi     pate some of the heat3   Engines equipped with stop handles  Pull the handle out and hold     until the engine stops completely     Engines stopped by means of the throttle lever Move the throttle     to idle and apply added pressure to move the throttle below idle     and in to shut off     Engines with keyswitch shut off Just turn the key off                                   16     NOTE Be sure to place the stop handles and throttle levers into     the run position4   Turn off the keyswitch  Some models do not use the stop lever as     they are equipped with a fuel solenoid or electric fuel pump which     shuts off the fuel supply when the keyswitch is turned to the OFF     position5   Close the seacock6   Disconnect power to system with battery  PRECAUTIONS1   Never run engine for extended periods when excessive overheating     occurs as extensive internal damage can be caused2   DO NOT put cold water in an overheated engine    It can crack the     cylinder head block or manifold3   Keep air intake silencer free from lint etc4   Never Race a Cold Engine as internal damage can occur due to ina     dequate oil circulation5   Keep the engine and accessories clean6   Keep the fuel clean    Handle it with extreme care because water     and dirt in fuel cause more trouble and service life of the     injection system is reduced dramatically7   Do not allow fuel to run low because fuel intake may be uncovered     long enough to allow air to enter the injection system resulting     in engine stoppage requiring system bleedingB   Do not be alarmed if temperature gauges show a high reading     following a sudden stop after engine has been operating at full     load   This is caused by the release of residual heat from the     heavy metal masses near the combustion chamber     Prevention for     this is to run engine at idle for a short period before stopping     it   High temperature reading after a stop does not necessar ily     signal alarm against restarting   If there is no functional dif     ficulty temperatures will quickly return to normal when engine is     operating     NOTE Oil and water temper ature instruments will remain at or     near their last reading when the panel power is shut off with the     engine                                   17                       TEN MUST RULESIMPORTANT                        IMPORTANT                      IMPORTANT for your safety and your engines      1      Keep this Manual handy and read it whenever in doubt    2      Use only filtered diesel fuel and check lube oil level daily    3      Check cooling water temperature frequently to make sure it is            190 or less    4      Check engine coolant prior to each days use    5      Investigate any oil leaks immediately    6      Check transmission lubricant prior to each days useNEVER     6      Race the engine in neutral when cold    7      Run the engine unless the gauge shows proper oil pressure    8      Tamper with the injection pump    9      Use cotton waste or fluffy cloth for cleaning or store fuel            in a galvanized container    10      Subject the engine to prolonged overloading or continue to            run it if black smoke comes from the exhaust                                    18                             ATTENTION    After you have taken delivery of your engine it is important thatyou make the following checks right after the first fifty hours of itsoperation    Note   Transmissions generally require fluid change after thefirst 25 to 30 hours of operation   Refer to the Transmission Sectionof this manual for detailsFIFTY HOUR CHECKOUT INITIALDo the following1 Retorque     the    cylinder     headbolts2 Retorque    the    rocker    br acketnuts   and   adjust     valve     Change fuel filter elements4 Change engine lubricating oiland oil filter5 Check for fuel and lubr icatingoil leaks Correct if necessary6 Check cooling system for leaksand inspect water level7 Check    for     loose    fittingsclamps connections nuts boltsvee belt tensions etc       Pay particular attention to loose enginemounts and engine mount fittingsThese could cause misalignment8 Check conditions of zinc anodein engine heat exchangerDAILY CHECKOUTDo the fOllowing1 Check the sea water strainer if one has been installed2 Check water level in cooling system3 Check lubricating oil level in sump     Fill to highest mark ondipstick4 Check fluid level in transmission      Fill to highest mark ondipstick with proper fluidSEASONAL CHECKOUT MORE OFTEN IF POSSIBLEDo the following1 Check generator alternator and sea water pump V belts forproper tension2 Check water level in battery3 Change oil in sump See Note4 Replace lubricating oil filter Figure 2 See Note5 Fill sump with diesel lubricating oil to highest mark on dipstickRefer to Specification page for proper quantity of oil        Do Not                                                                 Overfill but be sure the proper amount of oil is placed in the sumpSee Note                                      19    CAUTION   The use of different brands of lubricating oils during    oil changes has been known to cause extensive oil sludging and may    in many instances cause complete oil starvation6 Start engine and run for 3 or 4 minutes    Stop engine and checkoil filter gasket for leaks Check oil sump level This is importantas it may be necessary to add oil to compensate for the oil that isrequired to fill the engines internal oil passages and oil filterAdd oil as necessary See NoteIMPORTANT NOTEIT IS MANDATORY THAT THE CHECKS 3 4     5 AND 6 BE ATTENDED TO WHENTOTAL OPERATING TIME REACHES 150 HOURS   IN SOME INSTANCES THIS TOTALIS REACHED BEFORE END OF SEASON7 Clean Air Filter if supplied     Most models have an air silencerthat does not require cleaning8 Check engine for loose bolts nuts etc9 Check sea water pump for leaks10 Clean pr imary filter bowl and screen    If filter bowl containswater or sediment filter bowl and secondary fuel filter need becleaned more frequently11 Replace secondary fuel filter element12 Change the fluid in the transmission    Refer to the  of this manual for  Fresh Water Cooling System The use of a 5050 solution of antifreeze and fresh water is recommended for use in the fresh watercooling system year round       This solution may require a  of antifreeze depending on the areas winter climate    Should more antifreeze be needed drain an approximate amount fromthe engine block and add a more concentrated mixture      Operate theengine to insure complete circulation throughout the system Recheck2 Lubrication System     With the engine warm drain ALL the lubricating oil from the oil sump      Remove and replace the oil filterplace some paper towels and a plastic bag around the filter to catchthe oil while removing it    When installing the new oil filter be sure to apply a smallamount of oil on the sealing Oring at the base of the filter    Fillthe sump with the correct amount of oil for your engine model Use anoil wi th an API Spec CC    Run the engine and check for proper oilpressure and insure that there are no leaks    Do not leave old eng ine lubr icating oil in the sump over thewinter layup period Lubricating oil and combustion deposits combineto produce harmful chemicals which can reduce the life of internalengine parts3 Transmission    Drain the lubricant from your transmission andorVdrive   Refill with the proper lubricant to the full mark on  dipstick Run the engine and shift the transmission intoforward and reverse onetwo times      Stop the engine and check  oil level add lubricant as needed Check for leaks4 Fuel System    Top off your fuel tanks with 2 diesel fuel Fueladditives should be added at this time to control algae and conditionthe fuel   Care should be taken that additives used are compatible                                  20with primary  used in the system Change the elementin your primary fuel  if it contains one andor cleanthe separator sediment bowl     Change the fuel filter elements on the engine and bleed the fuelsystem as needed      Start the engine and allow it to run for 5 to10 minutes to insure that no air is left in the fuel system and checkfor any leaks that may have been created in the fuel system dur ingthis servicing and correct as needed5 Sea Water Circuit      Close the thru hull sea cock    Remove the rawwater intake hose from the sea cock      Place the end of this hose intoa 5gallon bucket of clean fresh water       Before starting the enginecheck the z inc pencil found in the pr imary heat exchanger on theengine and clean or replace it if required Clean your sea strainerif one is installed on the inside of the hull     Start the engine and allow the raw water pump to draw the freshwater through the system       When the bucket empties stop the engineand ref ill the bucket wi th an antifreeze solution slightly strongerthan needed for winter freeze protection in your area     Start the engine and allow all of this mixture to be drawn throughthe raw water system Once the bucket empties stop the engine Thisantifreeze mixture should protect your raw water circuit from freezingduring winter layup as well as providing corrosion protection     Remove the impeller from your raw water pump some antifreeze mixture will accompany it so catch it in a bucket             Examine theimpeller   Acquire a replacement if needed and cover gasket       Do notreplace the impeller back into the pump until the Spring commissioning6 with a clean cloth lightly soaked in oil place it in the openingof the intake manifold so as to block it closed         DO NOT shove thecloth out of sight into the intake manifold         If you cannot see itnext Spring and you attempt to start your engine you may need theassistance of a servicing dealer       Make a note to remove this clothpr ior to star tup    The exhaust through hull can be closed in thissame manner7 Disconnect the propeller shaft coupling from the transmission      Ifthe boat remains in the water during winter storage this need not bedone      This is a good time to check the security of the coupling to thepropeller shaft     Insure also that the coupling set screws are tightand wired so as not to loosen      The engine alignment to the propellershaft should be checked in the spring when the boat is placed back inthe water and the mast stepped and the rigging tuned8 Controls and Linkage       Check the security of control connectionsto the engine and transmission       Lubricate these controls and insurethat they move freely     Engines with pUlltype shutoff levers shouldbe left in the run position during winter storage9 Starter Motor       Lubr ication and cleaning of the starter dr iveplnlon is advisable if access to the starter permits its easy removalInsure that the battery connections are shut off before attempting toremove the starter Take care to properly replace any electrical connections removed from the starter10 Removing the injectors from the cylinder head and squirting somelight lube oil down the injector hole into the cylinders is notnecessary for the few months the engine is laid up for the winterHowever if you anticipate a longer layup period 12 months                                     21please follow through with this procedure        It will prevent theadher ing of the piston rings to the cylinder walls   Insure that youhave the proper hardware to replace the sealing washers for the injectors and return line connections11 Spares This is a good time to look over your engine and see ifexternal items such as belts or hoses may need replacing come    Check over your basic spares ki t and order i terns noton hand or replace those items used during the winter layup such asfilters and zincs12 Batteries If batteries are to be left on board during the winterstorage per iod insure that they are in a state of full charge andwill remain that way to prevent them from freezing If not it wouldbe wise to remove  OILS    Lubricating oils are available for Westerbeke Diesel engines whichoffer an improved standard of performance to meet the requirements ofmodern oper ating conditions such as sustained high speeds and ternperatures    Use a good brand of oil that has an API Service Spec of CC orbetter    Use the following chart to select the proper viscosity of oil foryour Westerbeke engine             Ambient Temperature          Viscosity                Above 80 F             SAE 30 or 1030                30  80 F              SAE 20 or 1030                Below 30 F             SAE 10 or 1030                                   22     ENGINE OVERHAULThe following sections contain  relating to the proper operation character istics of the major components   and  systems  of   the   eng ineIncluded   are  disassembly   rework   andreassembly instructions for the guidanceof suitably equipped and staffed mar ineengine service and rebuilding facilitiesThe necessary procedures should be undertaken only by such facilitiesAddi tional operating character istics areincluded in the Operation Section of thismanualAny replacements should be made only withgenuine Westerbeke partsGeneral Specifications    32Engine Cylinder Head  37Engine Crankcase  47Lubrication System  60Fuel System  65Governor System  77Maintenance  81Technical Data  85                    23WESTERBEKE 10 Two  12BTwo PROPULSION              Right Side               Left Side                  24WESTERBEKE WMD 3KW GENERATOR                  Side          Left Side             25                                                   DIMENSIONAL DRAWINGS                                                   Westerbeke 10Two  12BTwo                 EXHAUST CONN INPT                     I                 AW WATE OUT                                     fUEL 1 NLET                    27 FfMILf                                                                                      r                                                                                    1075                                                                        1957                                                                                    l                                                    24 KW  3 KW GENERATOR                                                                                        11581            FlAW   WATER OUT         iD HOSC      VEL INLET 27NPT                                                                                  075                                                                        2150                                                                    I37                                      2000                                       2850                                                              4G                                                                    I                                                                   1                            625                  Dimensions are subject to change                                                              26                                  ENGINE NUMBER1 The engine serial number is stamped on the ID plate attached to the exhaust manifold2 The engine serial number is stamped as shown below       Engine number 1001  COOOThe engine block serial number will also be found stamped in the block on a flange justbelow the number two injectorThe generator serial number is found stamped in the outside housing of the generator onthe left side when viewed from the front of the engine                                               27                              SECTIONAL VIEWS OF ENGINE1    Longitudinal cross section                    1     2          3    4        S                                                                       13          16               17                                                                      27                    20   21              23   24        2S1   Fresh water pump         10   Push rod             19   Crankshaft plate2   Water outlet fit        II   Tappet               20   Front bearing housing3   Exhaust valve            12   Camshaft             21   Gear case4   Intake valve             13   Oil pump             22   Oil drain plug5   Oil filler cap           14   Piston               23   Oil pan6   Rocker arm shaft         15   Connecting rod       24   Oil screen7   Rocker cover             16   Crankshaft pulley    25   Rear plate8   Cylinder head            17   Crankshaft           26   Flywheel9   Cylinder block           18   Crankshaft gear                                              282    Lateral cross section                    221   Exhaust manifold     9   Cylinder head      16   Fuel filter2   Rocker cover        10   Piston             17   Ring gear3   Push rod            11   Starter            18   Oil level gauge4   Rocker arm          12   Rear plate         19   Oil filter5   Exhaust valve       13   Water drain hose   20   Oil screen6   Glow plug           14   Crankshaft         21   Oil pan7   Nozzle holder       15   Cylinder block     22   Oil drain plug8   Intake pipe                                       29                           GENERAL                                            Vertical 4 cycle OH water  Chamber                             Swirl type chamberNumber of Cylinders                            2Bore x stroke                                  65 mm 256 in x 68 mm 268 inTotal Displacement                             451 cc 2752 ciCompression Ratio                              251Firing Order                                   1 2Engine Performance                             95 HP at 3000 RPM  10 Two Model                                               120 HP at 3600 RPM  12BTwo ModelDry Weight      Propulsion                               205 Pounds      Generator                                308 PoundsFuel                                           2 Diesel FuelFuel Injection Pump                            Bosch M TypeGovernor                                       Centrifugal weight typeNozzle                                         Throttle typeFuel Injection Pressure                        160 kglcm 2Lubrication System                             Forced Lubrication trochoid pumpOil Pump                                       Trochoid TypeEngine Oil Capacity Limit upperlower        28 liters  l 8 litersCooling Water Capacity                         Approx 16 liters in engine properStarter                                        Solenoid operated overrunning clutch                                               cranking type 12V  09 KWAlternator                                     12 Volt  35 ampGlow Plug                                      Sheathed plug quick heat type                                          30                                        PERFORMANCE CURVESThis performance shows the values under standard ambient conditions  760 mmHg temperature 20 0 C humidity 65                              10 Two and 12BTwo Propulsion Engine                                                                                                          TORQUE                                                                                                          L BFT                                                          i   I                                                                    I           I           I      HORSEPOWER                                                                               I     I     COINT         I    1 I                                                             I   I                                                                                                050   F U E LeO N SUM P T ION                                                          I   lrl                   I          045                                                                                                            LB PER HPHR                                     o Ililj040                                      1400         2000                      3000            3600                                                              RPM                             WMD 3 KW Generator Model 60 Hertz                             WMD 24 KW Generator Model 50                            Ratings                                   Deratings             EngineModel      Volts     AmS   Hertz     Phase        Wire          PF         KW                                   RPM      Start30612   120       25       60                     2             10          30            35 each 1000 ft    1800     Remote                                                                                              above sea level30613   120240   251125   60                     3             10          30            1 for each 100 F     1800     Remote                                                                                              above 85F ambient24512   220       10       50                     2             10          24            10 for continuous    1500     Remote                                                                                              duty                                                                and remedies for general engine trouble are listed as   PROBABLE CAUSE          REMEDYHard Starting1 Slow cranking    a Viscosity of engine oil    Use oil of lower viscosity        high    b Battery discharged         Charge battery    c Battery is old             Replace battery    d Poor connection of         Clean terminals and cable connectors        battery terminal    e Faulty starter             Overhaul or replace starter    f Faulty starter Bendix      Check starter amperage draw Replace        drive                      or repair starter if necessary2 Injection system trouble    a Air in fuel system         Allow system to self bleed    b Fuel filter clogged        Replace fuel filter element    c Injector pressure low      Adjust injector pressure    d Nozzle injection failure   Clean or replace nozzle    e Lack of pressure from      Overhaul or replace injection pump        injection pump    f Injection timing too       Check and adjust injection timing        early                           propulsion 25 BTDC                                        Generator 25 BTDC3 Engine    a Lack of compression        1 Improper valve          Adjust valve clearance           clearance        2 Incorrect contact of    Lap valves to head           valve seat        3 Seizure of valve stem   Replace valve and valve guide        4 Valve spring broken     Replace valve spring        5 Leakage from cylinder   Replace gasket           head gasket        6 Piston ring sticking    Replace piston and piston ring        7 Worn piston rings and   Repair as needed           cylinder    b Glow plug burned           Replace glow plug    c Insufficient operating     Adjust time per temperature Check        time for glow plug         connections and solenoid    d Incorrect setting of       Set to starting position full open        throttle lever    e Governor spring out of     Correct spring        position                                   32SYMPTOMS  PROBABLE CAUSES              REMEDYLack of Power1 Lack of compression                 See Lack of Compression under                                        Hard Starting2  Improper adjustment of     injection system     a Improper injection timing Adjust injection timing     b Injectors misfiring       Overhaul or replace injectors     c Low injector pressure     Check injector nozzle and adjust                                   injector pressure3  Lack of fuel     a Air in fuel system        Check connections and fuel tank     b Filter clogged            Replace filter     c Fuel tank contaminated    Clean tank and replace filters4 Lack of intake air             Check air intake for obstruction5  Overheating     a Lack of cooling water     Replenish water check for leaks     b Vbelts loosened          Adjust or replace     c Heat exchanger clogged    Clean     d Improper injection timing Correct injection timing     e Lack of engine oil        Replenish engine oil check for                                   leaksExcessive Oil Consumption1 Oil      leakage    a      Faulty oil seals           Replace   oil seals    b      Gear case gasket damaged   Replace   gasket    c      Gear case bolts loosened   Tighten   bolts    d      Drain plug loosened        Tighten   plug    e      Oil pipe connector         Tighten   connector bolt             loosened       f   Rocker cover gasket        Replace gasket             damaged       g   Rocker cover bolts         Tighten bolts             loosened2 Oil      up    a      Piston ring end gaps       Correct ring positions             incorrectly positioned       b   Connecting rod tilted or   Replace connecting rod             distorted       c   Wear of piston ring        Replace ring       d   Wear of piston and         Replace piston and rebore cylinder             cylinder3 Oil      down    a      Faulty stem seal           Replace stern seal    b      Wear of valve and valve    Replace valve and valve guide             guide                                        33SYMPTOM                             REMEDYNoise or Abnormal Sound1 Crankshaft or main bearing    a Excessive wear of bearing   Replace bearing and grind crankshaft    b Excessive wear of crank    Grind to proper undersize         shaft    c Bearing melted              Replace bearing and check oil line2 Connecting rod and connecting    rod bearing    a Wear of connecting rod      Replace bearing and grind crank pin         big end bearing    b Wear of crank pin           Grind crank pin    c Connecting rod bent         Straighten or replace3 Piston piston pin and piston    ring    a Wear of cylinder            Rebore cylinder to oversize and                                    replace piston    b Wear of piston pin          Replace piston pin    c Seizure of piston           Replace piston    d Piston ring worn or         Replace piston ring        damaged4 Valve mechanism and other    a Wear of camshaft            Replace camshaft    b Excessive valve clearance   Adjust valve clearance    c Wear of timing gear         Replace gear    d Wear of water pump          Replace bearing        bearing                                    34                      ADJUSTMENT OF VALVE CLEARANCE1   Remove the rocker cover In loosen the rocker arm lock nut fI2      and while turning the adjusting screw fI3 measure and adjust the      valve clearance with a thickness gauge between the valve stem and      rocker arm position A      1      32   With the No 1 cylinder at TDC on compression stroke adjust the      clearance of the intake and exhaust valves of the No 1 cylinder      Then with the No 2 cylinder at TDC on compression stroke      adjust the clearance of the intake and exhaust valves of the      No2 cylinder3   To posi tion the No 1 cylinder for TDC of compression stroke      align the timing mark on the gear case with that on the      crankshaft pulley     position No 2 cylinder at TDC of its      compression stroke by rotating the crankshaft 1704   After    the     adjustment      securely      tighten    the      rocker    arm    nut   while      holding     the    adjusting      screw from rotating      Note The cylinder head      holddown bol ts should be      torqued before the valve      adjustment is made      Valve   Clearance    both      intake  and   exhaust      engine cold           025mm                                     35                 CYLINDERHEAD BOLT TIGHTENING TORQUENote The cylinder head bolts when being torqued should be broken free onequarter toonehalf tum then torqued to the value given and in the proper order as  Torque                             253  289Ibft                             35  40 kgm                                         36                CONSTRUCTION AND SERVICING OF CYLINDER HEADCylinder HeadThe cylinder head is made of a cast iron and has great rigidity andexcellent cooling property  It is of the overhead valve type and theintake port and exhaust port are of crossflow type and the valveseats and guides are  chamber and glow plug are provided at the lefthand side of thehead to insure complete fuel combustion and better engine  Head GasketThe cylinder head gasket ismade of airtight and  and has stainlesssteel grommets in the cylinderbore area     The gasket iscoated wi th sealant on bothsides except where the cylinder bore periphery is to prevent oil and water  no gasket sealantis needed during assemblingAn   engine  model   markstamped on the upper side of                            is        c                                      C   Ethe   gasket  cylinder   head            side to help insure  and Valve SpringThe intake valve has a large diameterhead to increase the intake effic iency  Both the intake and exhaustvalves are steel and the exhaust valvehas a welded special  head to withstand a higher heat                          Stem sealThe upper part of the valve guide isprovided with a valve stern seal to                           Valve guideprevent oil leakage into the cylinderThe valve spring is made of a highrigidity valve spring steel       Thespr ing spr ing retainer and retainerlock of the intake valve are identicalto      those of   the exhaust valve                                     37Combustion ChamberThe combustion chamber is of a swirl chamber type   The swirl chamberis made of a heatresisting steel and is pressed into the cylinderhead   The swir I chamber should not be disassembled because it ismachined wth the head after being pressed into the cylinder headRocker Arms and Rocker ShaftRocker arms are made of a special cast iron   Rocker shaft is made ofbar steel and the surface is cemented     Oil to the rocker arms androcker shaft is supplied through the rocker cover oil holeRocker CoverThe rocker cover is made of aluminum diecast and the upper part isprovided with an oil passage to supply oil to the rocker section via asupply tube from the front cam bearingThe cover is also provided with a fill port for engine oilServicing the Cylinder    Remove the exhaust manifoldb   Remove the oil pipe from the cylinder headc   Remove the fuel return lined   Remove the fuel injection lines from the injectorse   Remove the injectorsf   After removing the glow plug lead wire remove the glow plugg   Remove the rocker coverh   After removing the rocker shaft holddown bolts remove the rocker      arms rocker shaft and rocker support assembly    After removing      the rocker assembly pullout the push rodsi   Loosen   and   remove   the   cylinder   head   bolts   in   the   illustrated      order                                        38                                                        m       10                                                                o                                                    Q           9                                                    1                                            JO8 6                                                                                                       4                                                            o        0j   Remove the head gasket etck   Using a valve spr ing compressor compress the valve spr ing and      remove the retainer spring and valve   Keep the removed valves      and related parts in order by each     Check the cylinder   head   for     visible   water   leakage      or   damage      before cleaning2    Prior to inspection and repair clean each part carefully and      remove oil scale carbon and paint3    Clean oil holes with compressed air and make sure they are not       HeadCheck   the cylinder   head  forcracks damage and water leakagebefore cleaningMake sure the oil passage is  the bottom of the cylinderhead for any warpage   Check asillustrated   using  a  straightedge and thickness gauge                                     39Valve GuideCheck the clearance from valve stem tovalve guide and if it exceeds theservice limit replace the valve guide        145 155and valve    When replacing a valvewi th its stem worn also replace thevalve guide                                                Valve guideTo replace the valve guide use apress and remove the worn guide bypressing it out from the underside ofthe head out through the topTo install a new guide press it into the cylinder head from the upperside obtaining the illustrated dimension  After installing the valveguide check the valve stem to guide clearance and if the clearanceis less than the standard value ream the guide to achieve the  SeatCheck the valve seat for any damage andincorrect contact and if     as   illustrated       lap the valve and seat withlapping compoundIf the valve seat surface recedes morethan the service limit replace thecylinder head    The receding of thevalve seat surface can be checked bymeasuring the installed height of the valve springCAUTION  Check the valve guide for any wear     before       cor recting   thevalve seat  If necessary replace the guide         Amm         Bmm        Cmm         237       217        25                            A                                                                                                                            rIValveIf the thickness T of the valve headexceeds the service limi t replace thevalveIf the top end A of the valve stemsurface in contact with the rocker armis worn or dented repair or replace                                                           40Valve SpringCheck for cracks and damageMeasure the free length and load of the spring if defective replaceCheck the squareness of     the spring       if excessively tilted             replace                                                svri1Ce gage                                                  plate  Rocker Arms and Rocker ShaftI f the rocker arm par t in contact with the valve is excessively worn or damaged replaceAlso check the adjusting screwand if the surface in contactwith the push rod is  replaceCheck the ID of the rocker armbushing and the 00 of therocker    shaft    rocker    area and if theclearance is excessive replacethe rocker arm assemblyPush RodCheck the push rod for    bending and wear at both ends                and if defective  and    Clean thoroughly each assembly part prior to assembly2   When   assembling   apply   oil    to    sliding          and   rotating     parts                                        41Securely install the valve stern seal into the valve guide     Note   The valve stern seal is not reusableCoat the valve stern wi th eng ine oil and insert it into the valveguide   Then install the retainer wi th the redpainted end of thevalve spring at the retainer side compress the spring with a  and install the retainer lockInstall the rocker arm rocker shaft and rocker bracket          Wheninstalling apply engine oil to the bore of the rocker arm bushingThe cylinder head gasket iscoated wi th sealant and thereis no need of applying anyadditional sealantTighten   the   cylinder  headbolts in the illustrated orderto the specified torqueInstall the rocker arm andshaft assembly on the top ofthe cylinder head and tightenthe bolts to the     the   glow   plug  andtighten     to    the    the nozzle holdergasket  and  install andtighten the nozzle holderassembly to the    Replace the gaskets and washers with new ones and apply sealant     to specified areas2   When installing the injectors do not turn the body side but turn     the retaining nut                                    42Install the glow plug lead wireAdjust    the   valve   clearanceWith the piston Gf each cylinderat   the   top   dead   center  ofcompression    stroke   insert  afeeler gauge between the valvestem tip and the rocker arm faceand   adjust   to   the  specifiedclear ance cold by use of theadjusting screw                                     43                                  of  crankcase is of the fulljacket type made of cast iron alloy andformed integral with the cylindersThe main bearing is of the bushing type made of special copper alloywith back metal and is flashplated        The crankshaft thrust isreceived and maintained by the front bearing  crankshaft is a highcarbon     steel         and     the   ma1nbearings and connecting rodjournals     are       to    increase  thewear    resistance        Thebalancer is formed integralwith the  and Ring GearThe flywheel is designed to provide a great inertial efficiency and tominimize torque variation    The ring gear is shrinkfitted to theflywheel and gear teeth are  to increase  to wearPiston Piston Pin and Piston RingThe piston is made of special light alloy and is elliptic and taperedgetting smaller upward to provide the best contact with the  piston pin is a hollow special alloy steel pin and is  the surface The piston pin is pressed into the connectingrod and fixed by use of a special fitting toolEach piston is provided with four piston rings three  and one oil ring    No 1 ring and oil ring are hard chromeplated on the surface in contact with the cylinder                                     44connecting RodThe connecting rod is a high carbon steel forging and the rod is ofIsection and the big end is of hor izontally split construction toincrease rigidityThe piston pin is pressed into the small end of the rod    The connecting rod bear ing is made of special copper alloy with back metaland is  GearsAll the timing gears arespur gears     The camshaftgear   is   driven   by  thecrankshaft   gear   and  thegovernor gear is dr i ven bythe camshaft  camshaft is a high carbon steel forging and is formed integralwi th the cam for the injection pump and the cam lobes and journalsare  camshaft is supported in machined holes in the crankcase   Thefront journal is provided wi th an oil hole to supply oil intermi ttently to the cylinder head and rocker armsCamshaft thrust is received by the front side of the crankcase and bya surface provided in the timing gear front coverThe rear end of the camshaft is provided with a slot to drive the oilpumpTappet and Push RodThe tappet is tubular and is surface                                Tappettreated on the bottom surface and therod receIvIng area      The tappet isinstalled offset from the cam center and                                                             as the cam rotates thus preventing uneven wear of the bottom of thetappetThe push rod is made of bar steel and                1  Offsetboth ends are specially hardened                                  45Oil PanThe oil pan is made of sheet metal and is provided with an oil drainhose attached to the sump oil drain boss                                 46                 DISASSEMBLY AND INSPECTION OF  SystemRemove engine electrical    Mar k leads for  35 amp       DC   alternator    anddrive beltRemove starter motorRemove the glow plugsCooling SystemRemove sea water pump mounting bracket thermostat housing                              thermostat pump drive belt hoses and primary heat  exhaust manifold with idle stop                ontrol   fuel solenoid assembly generator modelFuel SystemRemove electric fuel pump and engine mounted fuel filter assemblyRemove high pressure liner from injection pump to  fuel return line from injectors and to injection pumpRemove injectors and sealing  HeadRemove rear lifting eye and rocker box cover with oil supply lineRemove rocker arm assembly and push rodsRemove   cylinder   head    hold    down   bolts       and   lift   cylinder   head       fromblockLift tappets out of block with use of a magnetic pencilRemove the oil pan and gasketRemove transmission       damper    plate      and    bellhousing    generator          seegenerator sectionRemove the flywheel and backplate                                           47Remove the oil pumpLoosen the front crankshaft pulley nut and remove the front pulleyRemove the front gear case cover and gasketAfter removing the governor weight assembly remove the snap ring andthen the governor gearDraw the camshaft and gear from the  the sleeve crankshaft gear and plateRemove the connecting rod caps and draw the pistons and connectingrod assembly through the top of the block     Keep the rod caps andbearings in order by cylinder so that there will be no mixing  Markthe rod and cap on one sideRemove the front bearing housing from the crankcaseDraw out the crankshaft    from   the    crankcase   hole   Be careful   notdamage the main  of Piston and Connecting RodSet the piston and connecting rod assembly on the body of a specialtool as illustrated insert the push rod of the tool into the pistonpin hole and remove the piston pin by pressing it out with the aid ofa hydraulic press Do not use the guide of the tool when removing thepiston pinCAUTION1   Be sure to use hydraulic press when removing the piston pin         Do     not attempt to hammer it out   If an excessive pulling force        is     required to remove the piston pin due to adhesion replace           it     wi th a new one   Do not apply the load of more than 3000          kg     6600 lbs to the pin setting tool                                    482   When setting the piston and connecting rod on the tool body be     sure that the small end of the connecting rod is placed properly     on the receiving area of the tool body                    a 925                                                     PuSh rod                                                            Identification mark                                                                Tool body      1 Body      2Guide      3 Push    Check the crankcase for signs of water leakage oil leakage and     damage before cleaning it2   Pr ior to inspection and repair clean each par t    and remove the     dust oil carbon deposits and water scale3   Clean the oil galler ies by applying compressed air and be sure     that the holes are not clogged and are clean and  the crankcase for cracksand   damage    If     the crankcaseCheck the water jackets for presence of water scale and rustand clean as needed                                    49Using a cylinder gauge measure the cylinder bore at three   in X and Y directions and if necessary rbore the cylindersto   oversize   or   replace      the   block   if   beyond   repair                                              XXis th thrust  Piston Pin and Piston RingCheck the piston for   evidence of seizure   streaks and wear             and ifdefective replaceMeasure the 00 of the piston and if excessive wear is foundreplace   If the piston to cylinder wall clearance is  the cylinder to the next oversize or replace the piston  Thepiston 00 should be measured at the lower part of the skirt acrossthe thrust facesWhen an oversize piston is usedfinish the cylnder bore oversize aswell    First measure the  of the oversize piston to beused diameter in the thrust directionat the lower part of       the pistonskirt rebore the cylinder so thatthe clear ance between the piston andthe cylinder wall will be the valuespecified in the data section andfinally cross finish by honingMeasure    the    piston   ring   sideclearance and if necessary replacethe ring    If the clearance is stillexcessive with a new ring replace  piston ring end gap and ifthe end gap is excessive replace thering                                     50To measure push the ring with a piston into the least worn partskirt of the cylinder as illustrated and measre the end gap usinga feeler gauge                                      r                                 PistonIf the clearance between the piston pin and piston or the bore of thesmall end of the connecting rod is excessive replace the piston pinassembly or connecting rod  RodUsing a connecting rod aligner measure the bend and distortion of therod and if excessive bend or distortion is found repair or replaceAfter installing the connecting rod on the cr ankshaft measure thethrust clearance and if the clearance is excessive replace the rodassembly                                                   twist theak       J       c         I        I J r                                                      the crankshaft journals and pins for damage and seizure    Alsomeasure the crankshaft 00 and if wear is exceSSlve finish thecrankshaft to the next undersize and replace the main bearing and connecting  rod   bearing  with   new  parts   of  the   same  undersize                                                                  51CAUTION     Correct the bend before grinding     the crankshaft Finish each fillet     to the illustrated RMeasure the crankshaft end playand if it exceeds the specifiedvalue replace the front mainbearing housing      To measurethe   end   play   install   thecrankshaft   and   main   bearinghousing   install    the   gearsleeve and pulley tighten thenut and then apply a dial gaugeto the end of the crankshaftMain bearing and connecting rod bearingCheck the bearing surface for flaking melting seizure and  and if defective replaceWith each main bearing and connectingrod bearing installed in the crankcase bear ing housing and connectingrod measure the 10 of the bearingsThen   measure   the   00   of    thecrankshaft   journals  and   pins    andcalculate the oil clearanceIf the oil clearance    is not wi thinthe   specifications    replace   thebearingI f the standard oil clear ance is notobtained even with the new bearinggrind the crankshaft undersize andinstall a bear ing of the same undersize                                    52To replace the main bearing use the special tool Bearing InstallerPart Number 337421   To remove the main bearing install      the guide ring to the installer      body as illustr ated   To pull the      main bearing out of the bearing      housing push it from the front                                                                                               side to the rear side    To remove      the main bearing at the rear of the                                                           Fo fmnt bring      crankcase remove the oil seal and      then push the bear ing inward from      the rear side of the crankcase                                                 Bearing Installer2  To install the main bearing assemble the main bearing installerbody and guide ring as illustrated and press in the bearing in thesame direction of removalSince the front bearing is to installed 25mm inside from the reference surface at the bearing installation side use the furnished tooladapter ring                                                                                                                                                              Marking      1 Guide ring          4 Bearing housing front      2 Main bearing           or crankcase rear            I Bearing installer             3 Guide ring      3 Bearing installer                                     2 Main bearing               Removing the Main Bearing                              Installing the Main    Install the main bear ing so that the oil hole of the bear ing     aligns with that of the crankcase   Set the oil hole position of     the main bearing to the mark line stamped on the collar of the     installer body and then press the bearing in while aligning the     oil hole with that of the crankcase After setting do not turn     the tool or bearing   Be sure that the butting part of the main     bearing is in the illustrated position2    Before installing the bear ing apply eng ine oil to the outside      surface of the bearing  Be sure to use a press to install the      bearing Install the bearing squarely                                                          53Timing GearsCheck each gear for incorrect wear and damage and ifdefective  the clearance between the camshaft journals both front andrear and the shaft hole in the crankcase and if the clearance isexcessive replace the camshaft or crankcaseIf the cam face is damaged or the cam lobe is worn in excess of theservice limit replace the camshaftCheck the slot for driving the oil pump for any wear and if the wearis excessive  the bottom of the tappet the surface contacting the cam andreplace the tappet if the bottom is excessively cracked spalled orstreakedPush RodReplace if the wear at both ends  the push rod on a surface plateand measure the bend in the centerand if it is excessively bent overthe   standard   value   repair   orreplace                                  54                       ASSEMBLY AND    Clean each part thoroughly     Especially clean carefully oil     holes bearings bearing lower holes and inner wall of cylinders2   Be careful not to mix nuts and bolts       Metric and SAE bolts     are used on various engine assemblies3   During assembly recheck clearances and insure parts are being     assembled in their proper order and facing in the correct direc     tion in relation to the engine block eg pistons piston     rings bearings and bearing caps4   Apply lubr icating oil to moving parts dur ing assembly  Insure     that moving parts when assembled on the engine rotate or slide     and are not subject to binding or excessive tension5   If there are mating marks scr ibed dur ing disassembly              reference     them correctly for assembly6   Use new gaskets lockwashers orings etc7   Tighten the bolts and nuts on important parts of engine to spe     cified torques using a reliable torque wrench8   Use liquid sealants when required on nuts               bolts and gaskets     Refrain from using tape  of Piston and Connecting RodAssemble the piston and connecting rod in the following manner usingthe special tool Piston Pin Setting Tool Part Number 335821   Insert the piston pin into the push rod of the tool and screw the     guide fully into the push rod2   Insert the push rod piston ring and     guide   assembled  in   the  preceding                                                                     Push rod     paragraph into the piston pin hole of     the piston and further into the small     end of the connecting rod   Make sure     that the front mark arrow on the top   Arrow mark on                                              piston head     of the piston and the identif ication     mark of the connecting rod face in the          Piston     same direction Apply engine oil suf                                      Tool body     ficiently to the piston pin surface     and inside the small end of the con     necting rod                                  553   Set the piston connecting rod and tool assembled in the pre     ceding paragraph to the tool body   To set lign the notch of     the guide with that of the body and insert the assembly into the     tool body   Then turn the guide 90 degrees   After setting be     sure that the small end of the connecting rod securely rests on     the receiving part of the tool body   Also check that the front     mark arrow on the top of the piston and the identification mark     of the connecting rod are facing upward4   With the piston set on a hydrau     lic press press the piston pin     into the piston   The hydraulic     pressure should be between 500     1500 kg 1100  1300 Ibs    If     the pin requires a greater or     lesser   pressure  replace   the     connecting rod or piston and pin     assembly    The pin is pressed     into a prescribed position by     the guide   After the installa     tion is completed turn the push     rod 90 degrees align the notch     of the guide with that of the     tool body and remove the piston     and connecting rod assembly from     the tool  installing the piston and connecting rod verify that the pistonpin is equally pressed in against the center of the rod    If the pinhas been installed unequally correct it   In such a case check  of Piston RingsSince piston rings differ in shape fromone another they must be installed as                      paying attention to     the         posi tion and direction  They must beinstalled so that the manufacturers                                                                                                           rJNo2mark and size mark face the top of thepiston                                                           No3Insert the crankshaft into the crankcase   Apply engine oil to the main                Ibearings and journals and take care not                   Oilringto damage the main bearingInstall   the   front   bearing   housing                                    56                                                          Bearing housing                                                    Pulley                  Install     the   crankshaft    plate    cr ankshaft gear and sleeve   Install    the cr ankshaft plate wi th the cham    fered side directed toward the rear of    the eng ine crankshaft gear wi th the                    stepped side directed toward the front       Nut                                                                                                                                               rP Sleeve     of the engine and sleeve with the                     nCrankshft    chamfered square end toward the front                          gear                                                Washer    of the engine                                                  Stopper plata    Temporarily     install    the     sleeve    stopper washer and crankshaft pulley    and after tightening the nut check    the cr ankshaft end play    I f the end    play is excessively larger than the    specified value recheck the bearing    housing      Also   verify    that   the    crankshaft gear and sleeve are pro    per ly installed   After checking the    end play loosen the nut and remove    the pulley and washer    Insert the piston and connecting rod   assembly into the cylinder install    the connecting rod cap and tighten to    the specified torque        Insert the    bol ts at the connecting rod side and    tighten the nuts from the cap side    When   inserting   the piston    use a                                                  piston ring compressor and be sure                                                  j    that the front mark arrow on the                                             h o                                                                                      l                                                                                                 piston head and the identification                                                             mark    on  the   connecting   rod   are    directed   toward   the front of the    engine    Also make sure that each    piston ring end gap is not in the    direction of thrust of the piston or    in line with the piston pin and that    the adjacent ring end gaps are at    least 90 degrees apart    Key the camshaft gear to the camshaft    and   insert  the camshaft into the    crankcase   Make sure that the mating    mark of the crankshaft gear aligns    with that of the camshaft gear as    illustrated Apply oil to the bearing    surfaces when installing                                        57 Install the governor gear andinstall a snap ring onto the shaftThen install the governor weightassembly and sliding shaftInstall the gear case with governor linkage assembled     In thiscase attach a gasket coated with a        good br and of sealant to the gearcase before  the crankshaft pulley   Donot    forget    to   install   thecrankshaft spacer stopper washerand   crankshaft    pulley  washerInsure   these   washers  maintaintheir positios when installing and tightening the front pulley nutTorque the front pulley nut i6 the proper  the oil pump  the  the flywheel and tightenthe bolts to the specified torqueInstall the oil screen and oil panInsert the tappets                                               dll lObeInsert the push rods into the tappet hole centerInstall the cylinder head assemblySee Cylinder Head    the   injection     pumpassembly and fuel lines      SeeFuel SystemInstall the oil filter     I f theoil pressure     swi tch and oilpressure sender have not beeninstalled yet apply sealant totheir threads and install themUse    the proper     socket   forinstalling   the    oil   pressureswi tch Install the fuel filter assemblyand    electric    fuel    pump                                      58Install the fresh water pump and drive pulleyInstall the starter and alternator           See Electrical SystemInstall the alternator belt             Adjust   the   tension   of   the   belt   byadjusting the    the   thermostat   housing    sea water     pump   bracket and  the primary heat  and related hosesAttach   the  idle   stop    fuel run  wir ing harness   Insureharness is properly supported andprotected from chafing and heatInstall the damper plate adapterand     transmission       Generatoruni ts    refer to text on gener atorremoval and installation                                         59                            LUBRICATION  lubr icating system is of fullforce type using a trochoid gearpump with a fullflow oil filter   The oil pump is driven through theOldhams coupling located at the rear end of the camshaft     The oilfrom the oil pump is regulated by a check valve filtered by thecartridge type oil filter and supplied to each part of the enginethrough oil galleries in the engine blockl    Oil Filter                                 72    Relief Valve                                   93    Oil Pump4    Dipstick5    Pickup Line6    Oil Pressure Switch7    Oil Ffll CapB    Rocker Arm                    13   t9    Rocker Shaft10   Camshaft11   Crankshaft12   Sump13   Oil Line to Rockers                            2                            1                            6                            4                            2                                    60Engine Oil1   Engine oil to be used      Use HD eng ine oil heavyduty oil API spec of CC and change      the oil every 100 hours of operation initially at 50 hours2   Changing of engine oil      To change the engine oil warm up the engine    Shut it down and      then remove the oil dr ain hose from its suppor t br acket at the      front of the engine   Two wrenches are needed to do this one to      hold the fitting on the hose and the other to unscrew the      securing cap   Lower the hose into a container large enough to      hold the oil and allow the sump to drain A pump may be used to      draw the oil out through this hose   When the sump is completely      drained reposition the drain hose on its support bracket and      replace the hose capplug and tighten securely      Refill the engine oil sump with the correct amount of oil as spe      cified in the data section of this manual      NOTE Check the oil level reading on the oil sump dipstick      Allow a few minutes after adding the new oil for it to settle      into the oil sumpOil FilterThe oil filter is an easytohandle cartr idge type    filter with thefilter body and element formed integralIf the element has been contaminated or clogged and the oil  before and after the element has become more than about1 kgcm 2  the builtin relief valve opens to allow the oil to flow toeach part of the engine wi thout passing through the oil filter element   Therefor e it is impor tant to check and change the oil regularly The filter interior requires no cleaning The filter must bereplaced with a new one every 100 hours of operation initally at50 hoursRemoval and Replacement of Oil FilterIf it is difficult to remove the filter by hand use a special  available or wrap a Vbelt around itTo install tighten the oil filter fully by hand             Tightening torque   11 to 13 kgmConfirm that the Oring is properly fitted in the Oring grooveApply a thin coat of engine oil to the Oring    Prior to installingthe filter on the engine run the engine after filling with oil andcheck for pressure and leaks  Check the oil level after shutting theeng ine off and add oil to br ing the level up to the full mar k asneeded                                     61Oil PumpThe oil pump is of trochoidtype and is mounted at therear of the crankcase  Theoil filter is attached tothis oil pumpThe oil pump incorporates arelief valve which when thedelivery   pressure  becomesmore    than   35   kgcm 2 relieves excess pressure bypassing oil back into theoil sumpWhen    disassembling      the oil pumppay attention to the following itemsI   Apply engine oil to the rotating parts before assembling2   After assembling check that the pump shaft turns smoothly3   Measure the clearance between the outer rotor and the pump body      using a feeler gauge and if the clearance is excessive replace      the rotor assembly or the pump body or both4   Measure the clearance between the outer and inner rotors using a      feeler gauge and if the clear ance is excessive replace the      rotor assembly5   To check the clear ance between the rotor and cover inser t the      rotor into the pump body and apply a straight edge across the      body face   If the clearance does not conform to the standard      replace the rotor assembly or body                                   626   Assembling the oil pump      a   Install    the rotor            assembly in the oil            pump body      b   Install the oil pump            shaft to the crankcase            with its lug properly            fi tted in the slot in            the camshaft      c   Replace   the   Oring            with a new one and            install    the    pump            cover   Apply oil to            the Oring and install            it squarely on the 0            ring grooveOil Pressure SwitchThe oil pressure swi tch is located at the rear right side of thecrankcase and when the lubricating system pressure becomes lower than18 to 23 PSI dur ing normal oper ation this swi tch oper ates an alarmbuzzer When the alarm sounds check the oil pressure and water temperature gauges on your instrument panel      NOTE The alarm can also be activated by an overheat switch      which will activate the alarm should the operating temperature of      the engine reach 205 F      Should the oil pressure be low stop the engine and  the oil pressure switches and if they do not meet the specifications replace them      NOTE Generator units have a twoprong oil pressure and water      temperature switch which interrupts the circuit for the fuel run      solenoid when tripped thus shutting down the generator automati      cally                                     63Checking Oil Pressure1   Warm up the engine2   Remove the oil pressure sender     and connect a mechanical oil     pressure gauge instead3   Set the eng ine speed at 3000     RPM   and   measure  the   oil     pressure  If the oil pressure     is less than the specifica     tion check the lubricating     system     Oil pressure          Greater tnan 35 kgcm 2          50 lbin 2  at 3000 RPM     NOTE  Insure   proper oil   is being used   that meets temperature     requirements     and  the    API   Spec    of  CC   or   better                                    64                                FUEL SYSTEMFuel from the fuel tank is brought to the engine by the aid of  electric fuel pump    Note  A filterwater separatoris recommended to be installed in the fuel supply line between thefuel tank and the connection to the electric fuel pump     Fuel passesthrough the electr ic pump to the eng inemounted fuel f il ter and thento the high pressure injection pump The injection pump delivers thefuel through high pressure lines to each inj ector       The injectorsspray the fuel into the engines combustion chambers where it ignitesFuel not used is returned to a fitting on the injection pump where itcombines with unused fuel from the injection pump and is returned tothe fuel tankFuel Filters Engine MountedThe fuel filters are easy to handle cartridge type and constructed ofpaperOne filter element is located in the base of the electr ic fuel pumpand the other is located in the filter housing adjoining the electricpump   Note   Both elements should be replaced after the ini tial50 hours of engine operation and then every 200 hours or once a seasonas neededChanging the Fuel FiltersThe fuel filter element located in the electr ic fuel pump can beremoved by undoing the base of the pump    A 17 rom wrench 5 rom thickshould be used to undo the base   Turn the base clockwise to replaceFuel will spill from the pump when the base is removed so be preparedto catch it   Remove the base and filter element    Install the newelement insure the sealing gasket in the base cover is in good condition and the round magnet is in the center of the cover  filter element in the cartridge is a paper type and to remove itunscrew the knurled retainer ring and drop the ring and lower housingoff the filter bracket     Fuel will spill from the housing so beprepared to catch it   The filter element is then withdrawn from thefilter bracket Two Orings are located in this bracket and should bereplaced as needed   One seals the lower housing and the other sealsand holds the filter element in placeReplace the filter element and the lower housing and retainer ring andtighten the retainer ringCaution When threading the retainer ring onto the bracket take carenot to cross thread it    It should thread easily onto the bracketuntil the lower housing contacts the sealing Or ing   Hand tightenonly                                    65Bleed the air from the electric fuel pump and this filter cartridge bysimply turning on the keyswitch generator  depress preheat switchfor 30 to 40 seconds then start the unit and check for leaksFuel PumpIn a  transistor type12 volt DC fuel pump the  of the pump plunger is controlledby a transistorized circuitThe   oscillator   section   diodes and resistorsWhen the transistor circuit is closedand the solenoid coil is excited asucking   force  acts  on   the  plungerforcing it down against the spring forceand the fuel pushing up the deli veryvalve that leads into the plungerWhen the transistor circuit is openedthe plunger is pushed back upward by the                   1  Diaphragm          6 Plunger                                                           2  Oscillator         7   Outlet valvespr ing force forcing the fuel out of                     3  Solenoid coil      8 Springthe outlet port and at the same time                      4 Filter             9   Inlet valvethe inlet valve opens and the fuel                          5 Filter coverenters the lower chamber                                               Fuel  and Reassembly of the Electric Fuel Pump for CleaningSince this tr ansistor ized fuel pump is of a totally enclosed typeonly the cover filter and plunger assembly require cleaningUsing a 17 rom wrench remove the cover 1 as illustrated Then thecover gasket 2 magnet 3 and filter 4 can be removed from thepump body        I Cover             4 Filter        6   Spring retainer    10   Plunger spring        2 Cover gasket      13 Body         7   Washer             11   Plunger        3 Magnet                              8   Dring             12   Plunger tube                Removal of Filter               9   Valve              13   Body                                                            Removal of Plunger                                           66Replace the filter as neededCheck the cover gasket and if damaged replace it         Clean the magnetand cover thoroughlyTo remove the plunger first remove the spring retainer 6 from theplunger tube 12    Then remove the washer 7 Oring seal 8valve 9 plunger spring 10 and plunger 11 from inside the tubeWash these parts in clean diesel oil and remove the oil and other contaminants using compressed airCAUTION THE TUBE 12 HAS VERY SMALL WALL THICKNESS BE CAREFUL NOTTO DEFORM THE TUBE DURING REMOVAL OF THE PLUNGER AND THE  HANDLE THE    PLUNGER   TO    PREVENT   IT   FROM BEING   DENTED   OROTHERWISE    To assemble install the plunger plunger spring valve Oring      and washer in that order and finally secure them with the      retainer so that they will not come out2   Install the filter element and then the magnet and gasket in the      base cover and tighten the cover with a 17 mm wrench to the ends      of the slotted stopServicing and Checking the Electric Fuel Pump1   Changing the FilterAfter the first 50 hours of operation and thereafter every 200 hoursremove the lower cap of the pump using a 17 mm wrench and replace thefilter element2   Checking the Electric Fuel Pump OperationTurn on the ignition switch generator  preheat     The pump shouldproduce a clicking sound   If the pump does not produce any operatingsound check with a DC voltmeter to determine that 12 volts is beingsupplied to the pump   If 12 volts is being supplied to the pump andthe pump still does not make any operating sound replace the fuelpump assembly If 12 volts is not present at the pump check the unitcircuit breaker electrical connections and switch                                   673   Checking the Discharge Rate of the      Fuel PumpCheck the discharge rate as illustratedThe pump must deliver over 200 cc 422pints    of    fuel    in   15 secondsFuel Injection PumpThis fuel injection pump is a doublebarrel pump installed in thecylinder block and consists of pump element plunger assembly delivery valve tappet and smoke set device  The pump is mounted at thefront right side of the cylinder block and delivers the fuel underpressure when the pump cam rotation pushes the plunger up  through a fixed stroke1   Control of Injection RateThe fuel injection rate is increased or decreased by chang ing therelative position of the plunger lead and plunger barrel The plungeris rotated by the control pinion installed on the outer periphery ofthe plunger barrel The lower flange of the plunger fits in the slit of this plnlon andthe rotation of the pinion is transmitted directly to the plungerThis control pinion is driven by engine power through the  weights operated through centr ifugal force governor sleeveand throttle linkage    Therefore when the fuel rack moves to theright the amount of fuel injected decreases and when the fuel rackmoves to the left the fuel increases                                                          1 Delivery valve holder                                                          2 Delivery valve seat      Q                                                  3 Control rack                                                          4 Pump body      j                                                 5 Tappet                                                         6 Stopper                                                          7 Delivery valve spring                                                         8 Delivery valve                                                                9 Air vent screw                                                        10 Plunger barrel                                                   iJ   11 Lock pin      iJ                                                12 Control pinion                                                          13 Plunger                                                       14 Union bolt                                                         15 Upper seat                                                         16 Spring                                                        17 Lower seat                                                         18 Return spring                                  682   Smoke SetA smoke set is installed to control the maximumfuel injection rateThe stopper is held by a spring in the illustrated position      Thisposition is the smoke set position      To start a cold engine thethrottle lever is pulled fully toward the maximum number of rotationand the control rack is moved by the governor lever in the directionof the arrow overcoming the spr ing force of the stopper thus  injection  The fuel injection rate between the two barrelsis adjusted by the plunger barrel which rotates on the adjusting platewith cam mechanism located on the opposite side of the control rack                                                               Spring        Adjusting plate   Plunger barrel                                                            Lever3   Delivery ValveIn addition to the function                to deliver the fuel into the injector lineafter the fuel pressure has                 increased sufficiently high the deliveryvalve has another important                 function to prevent nafterdripn from thenozzle tip after completion                of injectionWhen the fuel pressure above the plunger has dropped at the completion ofinjecting the delivery valve pistonmoves to close the delivery valve seatbut at that time the compressed fuelstill remains in the line which resultsin the afterdrip from the nozzle tipTo prevent this afterdripping thedelivery valve piston sucks back thefuel remaining in the injection linebefore the delivery valve is seated                                                           During injection   End of injectionthus reducing the fuel pressure in theinjector line almost to zero                                                 69Disassembly of the Fuel Injection Pump1   Remove the fuel injec      tion lines and return      lines2   Loosen    the    injection      pump mounting bolts and      lift the pump assembly      out    of    the    engine      block      position the      throttle arm about half      open to position the      fuel rack ball joint at      the notch in the block      for removal3   Record the thickness and quantity of pump adjusting shims      in      order to facilitate adjustment at the time of reassembly4   Disassembly of the Fuel Pump      CAUTION      Do not recklessly try to disassemble the fuel injection pump      Pump adjustment requires a test bench and acquired skill Avoid      disassembly and adjustment of the pump when this equipment and      knowledge are not available      Before disassembling close the fuel inlet and outlet and clean      the exterior of the pump      Fill a container with clean diesel oil and put disassembled parts      in it      Keep in order the disassembled parts except those to be replaced      so that they may be reassembled in their original positions and      that no mixing with other parts will occur      a   Remove the deli            very valve            holder      Take            out   the   valve            spring     valve            and Oring      b   Take   out   the            gasket and valve            seat                                     70      c   Straighten the tappet guide pin lock plate push in the tap            pet slightly pull off the guide pin  using a needle nose            pliers and take out the tappet      d   Remove the spring and upper seat      e   Remove the pinion      f   Draw out the plunger barrel upward from the pump housing            Keep the removed plunger barrels and plungers in sets            Never mix plunger and barrel assemblies      g   Remove the cotter pin washer return spring and smoke set            and pullout the control    Delivery Valve Seat                                                             Delivery VIIlveCheck the contact surface of the delivery valve seat and if not showinggood contact replace the deliveryvalve The delivery valve should showa   slight   resistance   when   beingwithdrawn from the valve body when theother hole is closed off wi th one ISfinger2   Plunger BarrelCheck the plunger for seizure damageand rust Also check that the plungerslides smoothly when it is lubricatedwith diesel fuel and inserted into thebarrel   If the plunger is found not           Barelto slide smoothly into the barrelreplace the assembly   The repair ofthe plunger is not permitted it mustbe replaced                                    713   Control Rack and PinionReplace the rack and pinion         whoseteeth are worn or damaged4   TappetCheck the outer periphery of tappetroller and shaft for wear and damageand if defective    Partial Assembly of Fuel Injection Pump Assembly      a    Insert the plunger barrel with the notch properly aligned             with the dowel pin of the pump housing      b    Install the Oring to the delivery valve holder      c    Install the spring seat gasket and valve assembly to the             valve holder and temporarily install this to the pump             housing Be sure to install the Oring properly      d    Install the control rack      e   Assemble    pinions   to   the                               Pinion            control rack with their center                                                                           Deep            deep teeth properly aligned                                     bottoms            with the aligning marks on the            control rack respectively      f    Install the spring upper seat             and spring                                                Control rack       Aligning marks      g   Assemble   the   plunger   and            spring lower seat and install            the assembly with the mark nL n            on the plunger     flange  facing   the      control   rack       side                                     72      h   Insert the tappet pay attention to            the shim inserted align the tappet            guide hole with the dowel pin hole of            the housing and insert the tappet            guide pin  Before inserting the tap            pet guide pin attach the lock plate            and bend it to lock after the guide            pin is installed      i   Install the smoke set stopper return            spring and washer    and install a            cotter pin      j   Tighten the delivery valve holder     to            30 1bft2   Installation and Adjustment of Fuel Injection Pump      a   To install the pump assembly            use     the  same    thickness            adjusting shim under the pump            as removed   Confirm that the            projection of the control rack            fits properly in the forked                        Control rack            end of the governor lever            The shim is available in nine                      Pump            types from 02 mm thickness            to 10 mm in increments of            01 mm                                                       AdjUsting      b   Connect the fuel feed hose and                             shim            bleed the injection pump by            turning on the keyswitch or            depressing the preheat switch generators      c   Confirm the injection timing        First remove the deli very            valve holder and after pulling out the delivery valve and            spr ing install the deli very valve holder only     Tur n the            crankshaft so as to bring 11 piston coming up on its            compression stroke      The injection time is the moment when            the fuel flowing from the outlet port of the valve holder            stops flowing     Compare this moment to the timing mark on            the crankshaft pulley on the front cover mark If the stan            dard    injection   timing   cannot be obtained    adjust by            increasing or decreasing the thickness of the adjusting            shim    As the shim thickness changes 01 mm the inj ection            timing changes about 1      Where the above operation cannot            be done the adjustment may be made without removing the            valve and spring In this case remove injection line 1 at            the injector side and slowly turn the crankshaft pulley nut            with a wrench The injection timing is the moment when the            fuel appears and swells at the end of the pipe and this is            about 1 later than the normal injection timing The injec            tion timing must be checked when the plunger is in the smoke            set      position     that    is    full    open   throttle                                     73Injector NozzleThe fuel from the fuel injection pumppasses through the fuel passage in thenozzle holder body and is  the nozzle into the  The excess fuel at the nozzleflows through the nozzle holder theupper nipple and the return line andreturns to the fuel tank                       I   Hexagon nut     7 Pressure pin                                                2   Packing ring    8 Distance piece                                                3   Washer          9 Retaining nut                                                4   Body           10 Nozzle                                                5   Shim washer    II Flange                                                6    of the Injector1   Remove the return line from      the injector upper attach      ment2   Remove the fuel injection      line from the injector3   Loosen the injector nut and      remove the assembly4   Disassemble    the         nozzle      holder   assembly     in      the      following manner      a   With the retaining            nut   held   in   a            vice remove the            nozzle holder            using a wrench on            the nozzle holder            body When            holding the            retaining nut in            the vice use an            aluminum or copper            plate between the            nut and the vice      b   Remove the shim            pressure ring            flange pressure pin and distance piece                                          74      c    Take out the nozzle from the retaining nut    If the nozzle             is too hard to remove lightly tap i t wi th a wooden piece             and remove taking care not to damage the needle  the nozzle for incorrect contact and damage and if  the nozzle assemblyCheck the pressure spring for damageAssembly of Nozzle and Injector Assembly      CAUTION   Before assembling put the parts in diesel oil and      clean them well DO NOT wipe the cleaned parts with cloth      When installing the nozzle holder body and retaining nut be sure      to tighten them to the specified torque      Inusfficient torque      will cause poor compression   If torqued excessively the nozzle      needle will drag affecting injection performance1   Install the nozzle     assembly     spacer   and   pressure   pin   to   the      retaining nut2   Install the shim spring and flange in the body and install them      to the abovementioned retaining nut and torque the retaining nut      to the specification3   Tighten the nipple gasket and  Test1   Injection Start Pressure Test      a   Measure the injection            start pressure using a            nozzle tester and if            out of standard make            adjustment   to  obtain            the specified pressure            by increasing or            decreasing the            adjusting shims            Adding shims increases            the pressure and            reducing shims            decreases the pressure      b   As the thickness of the            adjusting shim changes            01 mm the pressure changes about 10 kgcm 2  To change the            shim hold the retaining nut with a vice and remove the pump            body with a wrench   Tighten the retaining nut to the spe            cified torque                                      752   Injection Test      The chattering test intermittent      small amount injection test     is      considered as passed if intermi t      tent clear cut injection with sound      is obtained when the tester lever      is slowly oper ated   In this case      the injection must be straight in      the same direction as the nozzle       Good                 8ad      axis   Spray in different direc      tions or in sever al lines is not      acceptable Also a large coarse spray is not acceptable3   Afterdrip Test      In the preceding chattering test      if the fuel collects on the tip of      the nozzle and dripping occurs      after injection the nozzle must be      replaced because it is defective      A very small amount of fuel may                                             u u                                                                         LJ      collect on the nozzle tip This is     Good      8ad        Bad      caused by chattering and therefore      is not a defect4   Spray Condition Test      When the tester lever is operated fast abour 200 strokes per      minute the fuel must be sprayed in fine mist straight in the      direction of the nozzle axis Coarse spray is not  of the Nozzle Holder  the nozzle holder assembly to the cylinder head and tighten tothe specified torque    Replace the nozzle holder gasket wi th a newone                                   76                                 GOVERNOR  governor functions to keep the engine running at a constant speedby balancing the centrifugal force acting on the governor weights andthe governor spring tension     As the engine speed increases thegovernor weights 8 open to move the sliding shaft 6 forward andthe control rack of the injection pump is moved by the governorlever 5 in the direction of reducing the fuel injection rate    Atthe same time the governor spring 3 is pulled by the governorlever 5 until the spring force is balanced with the  of the governor weights thus maintaining the constant enginespeedIf the speed control lever 1 is pulled toward HIGH SPEED thegovernor spr ing 3 is pulled and the governor control rack is movedby the governor lever 5 toward increasing fuel injection rate toincrease the engine speed which is kept constant when the  of the governor weight is balanced wi th the governor spr ingforce                                                       9                         1                                                                        10                             3                             4                             5                             6            1   Speed control lever            2   Camshaft               8   Governor weight breather            3   Governor spring        9   Injection pump            4   Cam gear              10   Gear case            5   Governor lever        11   Air breather pump            6   Sliding shaft         12   Crankshaft gear            7   Idle gear             13   Crankshaft                                         77Governor  of the  governor lever is builtinside the gear case oneend of the lever in contactwith  the   injection  pumpcontrol rack and the otherend with the governor weightsliding shaftThe lever is held at thecenter by a shaft which isfitted to connect the shaftwith the control     Remove the alternator       bel t     See nCooling       Systemn 2    Remove the crankshaft       pulley nut then the       pulley3    Remove the fuel injec       tion pump   See nFuel       Injection pumpn4    Remove    the gear   case       bolts    then the   gear       case5    Remove    the   governor       spring6    Remove the nu t  washer       and spring lever and       remove   the     throttle       control lever from the       gear case7    Remove the nu t  washer       and spr ing lever then       the governor lever set       bolt and remove the       governor lever8    Remove   the   governor       weight   assembly   and       sliding shaft from the       pump camshaft                                   78Inspectionl   Governor Lever      Check the connections      of the governor lever      wi th the sliding shaft      and with the control      rack and if defective      replace2   Governor Spring      Check the spring for      deterioration and      breakage and if defec      ti ve replace  Do not      stretch the springGovernor WeightThe governor weight is installed on the governor gear in mesh with thecam gear   In order to improve the governor regulation the slidingshaft is provided with a stopperThe governor gear is fi tted in the gear shaft on the crankcase sideand is retained by a snap ringThe    shaft   is   made   hollow   to   receive   the   sliding         The governor weight can be disassembled by the same procedures as      for the governor lever                                    79Inspection1   Governor Assembly      a    Check the   weight   for   wear   and   damage   and   if   defective             replace      b    Check the operating part of the sliding shaft for damage and             see if the operation is smooth If defective       For reassembling reverse the order of disassembly and after the      reassembly is completed check that the operation is smooth                                        80                                ToolsTool No        Tool Name                                 Use 33582          Piston pin                       For drawing out or                setting tool                     pressfitting piston                                                 pin 33742          Bearing                          For drawing out or                installer                        pressfitting main                                                 bearing with ring                                                 adapter for front                                                 bearing 33584          Compression                      For testing com                gauge adapter                Straight type                without check                                               pression Mounts in                                                 place of glowplug                valve 5818 UNF                thread for gauge    33781          Compression gauge                For testing                with builtin                    compression                check valveIn addition to the above the following are needed     Common servicetools bearings puller valve seat cutter valve guide installer oilfilter wrench and other measuring instruments                                    81                        OVERHAULING  When to Overhaul the EngineUsually   the overhauling time of the engine is determined by reducedengine power decreased compression pressure and increased fuel andengine oil comsumptionBut the reduced engine power may be caused not only by the trouble ofthe engine itself but also by damaged nozzle or improper adjustment ofthe injection pump   For this reason it will be most advisable totake a compression check of the engine before undertaking  the decrease in compression pressure is caused by many fctorsand it is not so easy to find which factor is the cause Thereforethe cause for trouble should be determined on the basis of records ofregular inspection and maintenanceIf the trouble is caused by the wear of the cylinder and piston thefollowing symptoms will appear    1   Reduced engine power and decreased compression pressure    2   Increased fuel consumption    3   Increased consumption of lubricating oil    4   Poor engine starting    5   Increased noise from engine partsUsually two or more of the above symptoms appear at the same timeSymptoms 2 and 4 are caused by excessive fuel injection  timing and plunger and nozzle wear and they are alsoser iously affected by electr ical system trouble such as faulty battery alternator starter and glow plug      Therefore in order todetermine the overhauling time of the engine it is recommended to useas a guide the decrease of the compression pressure due to the wear ofthe cylinder and piston aand at the same time to take into consideration the oil consumption and other itemsThe compression pressure is the source of the explosive power of thediesel engine and without sufficient compression pressure  cannot be achieved even if other parts of the engine arenormalIn order to determine the overhauling time of the diesel engine it isimportant to measure the engine compression pressure regularly Sincethe compression pressure varies with engine RPM check the speed alsoThe engine RPM can be measured at the front end of the crankshaft                                  82Measuring Compression Pressure1 Remove the glow plug from    the   cylinder whose  com    pression pressure is to be    measured2 Install a pressure gauge    adapter in the screw hole    of the glow plug and con    nect a pressure gauge3 Turn the engine over wi th    the starter and when the    eng ine  speed  has   become    stabili zed   record    the    engine speed and pressure    gauge4 Measure the compression pressure of other cylinders in the carne    manner    CAUTION It is wrong to judge the status of the other cylinder by    measuring only one cylinder Be sure to measure both  of Engine Condition by Compression Pressure1 When the engine is new the compression pressure is a little high    because of the close fit between mating parts but after that the    pressure decreases gradually as the parts get worn2 When the compression pressure has decreased below the acceptable    limits the engine should be  by Increased Consumption of Engine Oil    If the engine oil comsumption has increased by about 50 more than    the  standard consumption    as 100    the  engine should   be     in  the engine taking the following  precautions  The orderof disassembling and reassembling may be different depending on thechange of  Carefully check for visible problems prior to disasembling or    cleaning because some faults may not be found after disassembling    or cleaning2 Drain all water oil and fuel before disassembling                                   833 Clean or wash the exterior of the engine4 Use proper tools and observe the order of disassembling      Keep    disassembled parts in proper order and protect as necessary Also    take special care to prevent the fuel system parts from being con    taminated by dirt or dust5 Do not disassemble or remove the parts that require no disassem    blyAssemble the engine taking the following precautions1 Prepare all necessary parts for reassembling2 Clean or wash the parts and apply oil as needed3 Check all gaskets washers and oil seals and replace them with new    ones4 Be sure to install in proper directions and positions see dowel    pins mating marks and specified directions    When tightening    torque is not specified tighten evenly to an ordinary torque    Apply a sealant where specified5 After completion of reassembly recheck for abnormality Prepare    for starting the engine   Run the engine at idle sufficiently for    test run                                  84                     SPECIFICATIONS AND SERVICE LIMITS                                           STANDARD             SERVICE                                             VALUE               LIMIT1   Compression pressure 320 RPM        32kgcm 2      Approx 26kgcm 22   Difference of compression     pressure between cylinders     max                                2Skgcm 23   Order of fuel injection                 1  24   Fuel injection timing    BTDC of compression stroke when started at     smoke set position                    255   Cylinder Head     a   Bottom surface distortion        OOSmmless     b   Valve guide ID                    66rnm     c   Valve seat angle                      45     d   Valve seat width                  15    18     e   Valve seat sinkage                                     1 rnrn6   Valve Clearance engine cold            02Smm7   Valve     a Stern OD                            66rnm     b Clearance between stern and        guide intake                                          OlOmm     c Clearance between stern and        guide exhaust                                         OlSrnm     d Seat face angle                        45     e Valve head thickness margin        width                                  Imm8   Valve Spring     a Free length                           44rnm     b Installed loadheight              1000Skg376rnm     15     c Squareness                            20                   39   Rocker Arm     a Clearance between rocker arm        and shaft                            004mm              02rnm10 Crankcase     a Cylinder ID                    6Smm                09Srnm     b Tolerance on oversize cylinder        bore                           o  003rnm for each oversize     c Taper of cylinder bore         within OOlrnm                                      85                                               STANDARD            SERVICE                                                 VALUE              LIMIT11 Piston    a Type                                 Solid type    b Material                             Aluminum Alloy    c OD skirt end                        6495mm    d Piston to cylinder wall       clearance                                                     03mm    e Oversize  available                  025 050 075mm12 Piston Pin    a Type                                 Semifloating    b Piston to pin clearance                                       008mm    c Pressin load with connecting       rod                                  500  l500kg13 Piston Ring    a No of rings  Compression           3 No 1 chromeplated                      Oil                   1 chromeplated    b Ring side clearance         Compression No 1                                         03mm                     No2                   003      008mm      02mm                     No 3                  003      008mm      02mm         Oil ring                           003      007mm      02mm    c Ring end gap                         020      050mm      15mm14 Connecting Rod    a Type                                 Forged Ibeam    b Bend and distortion                                      0l5mm or less    c Big end thrust clearance             01  035mm             05mm15 Connecting Rod Bearing    a Type                                 Kelmet metal with back metal    b Oil clearance                        0035  0050mm       015mm    c Undersize                            025 050 075mm16 Crankshaft    a   Type                               Fully     b   Bend                                               005 mm or less    c   End play                             01  03mm    d   Journal OD                            54mm           095mm    e   Pin 00                                42mm           095mm    f   Undersize finish dimensions           Journal US 025                standard value  025 0040                                                                    0055                   US 050                standard value  050 0040                                                                    0055                   US 075                standard value  075 0040                                                                    0055                                       86                                             STANDARD         SERVICE                                               VALUE           LIMIT     g Pin         us   025          standard  025 0035                                                           0050                    US 050            standard  050 0035                                                           0050                    US 075            standard  075 0035                                                           005017 Main Bearing     a Type                             Kelmet metal with back metal     b Oil clearance                    0029  0090mm       015mm     c Undersize                        025 050 07Smm18 Crankshaft Plate     a Thickness                           4  Olmm19 Camshaft     a Drive method                   Gear     b Clearance between journal and        cylinder block hole                                     015mm     c Cam lobe diameter both intake        and exhaust                      25S9mm              lOrnm     d Cam lobe diameter pump cam      4400mm              lOmm20 Tappet     a Clearance between tappet and        cylinder block hole                                     015mm21 Push Rod     a Bend                                                03mm or  SYSTEM1   Quantity of Engine Oil       28 liters upper limit     excluding                                  18 liters lower limit    3 liters in                                                              oil filter2   API Service SEec                   API spec CC or better3   Viscosity     a Summer 20C or higher           SAE 30 or 10W30     b Spring fall 5  20C          SAE 20 or 10W30     c Winter SC or lower             SAE 10W30                                    87                                               STANDARD          SERVICE                                                 VALUE            LIMIT4   Oil pump     a Type                               Trochoid type     b Check valve opening ressure          3Skgcm2     c Clearance between ou er rotor        and body                                                 030mm     d Clearance between outer rotor        and inner rotor                                          02Smm     e Clearance between rotor and        cover                                                    02SmmS   Oil Pressure Switch     a Generator normally open           18  23 PSI to close     b Propulsion normally closed        18  23 PSI to openFUEL SYSTEM1   Fuel                                  2 diesel fuel2   Fuel Filter TYEe                      Filter paper type cartridge3   Fuel PumE     a Type                                type     b Delivery rate                      200cc or more 15 sec 12V                                           free flow4   Fuel Injection Pump     a Model                              NDPFR2M     b Fuel injection rate          Smoke set SS                   1800 RPM 171mrn 3st          At start set MS                150 RPM 27Srnrn 3 st          Difference between cylinders     2mm 3 rev cyl or less standardS   Nozzle     a Type                               Throttle     b Model                              NDDN4SD24     c Injection start pressure           160 10 kgcm 2 lSOkgcm 2 or less                                               0GOVERNOR1   Type                                  Centrifugal weight type                                      88                                              STANDARD          SERVICE                                                VALUE           LIMITCOOLING SYSTEM1   Fresh Water Pump     a Type                              Centrifugal impeller type     b Water Temperature Switch        normally closed                 20SF S   to operate2   Sea Water Pump     a Type                              positive displacement                                          GPM at 3000 RPM                                          GPM at 1800 RPM at discharge                                                           from  SYSTEM1   Starter     a Type                               overrunning     b Outputvoltage                    09KW  l2VDC     c Direction of rotation             Clockwise as viewed from pinion                                          side     d   Noload terminal voltage        11SVDC     e   Noload current                 60A or less     f   Noload speed                   6S00 RPM or more     g   Pinion gap                      OS  20mm2   Alternator     a voltage                           l2VDC     b Current                           3S amp     c Regulator Internal IC type      l44VDC 03V     d Noload output          Terminal voltage                l3SVDC          Current                         7 amp          Speed                           1300 RPM or less     e Load output          Terminal voltage                l3SVDC          Current                         30 amp or greater          Speed                           2S00 RPM or less3   Glow Plug     a Type                              Sheathed quick heating type     b Rated current                     10SV     c Resistance                        016 ohms at normal                                                    temperature                                     89                        TABLE OF TIGHTENING TORQUES                                                      Kgm          IbftCylinder head bolt M8                           35       40    25     29Rocker cover nut MB                             05       07     4      5Connecting rod cap nut                            32       35    23     25Flywheel bolt MIO                               65       70    46     51Crankshaft pulley nut M24                      150  200       lOB  144Oil filter                                        11       13     8      9Nozzle holder                                     50       60    36     43Nozzle holder and retaining nut                   60       80    43     58Glowplug                                          15       20   11      15UNLESS OTHERWISE INDICATEDGrade 6T     6mm boltnut                                 07    10       5       7     8mm boltnut                                 16     23     12      17    10mm boltnut                                 32     47     23      24    12mm boltnut                                 56     B2     41      59    14mm boltnut                                 77    105     56      76Grade 8T and 88     6mm boltnut                                  B    12       6      9     8mm boltnut                                 18     27     13     20    10mm boltnut                                 37     55     27     40    12mm boltnut                                 64     95     46     69    14mm boltnut                                104    140     75    101Grade 5 capcrew    14 UNC                                       12 15          9      11    14 UNF                                       15  18        11      13    516 UNC                                      25   28       18      20    516 UNF                                      29   32       21      23    38 UNC                                       37   46       28      33    38 UNF                                       41   48       30      35    716 UNC                                      61   68       44      49    716 UNF                                      69   76       50      55    12 UNC                                       94  101       68      73    12 UNF                                      101  111       73      80                                     90          OTHER OVERHAUL           CONTENTS                               PAGEMARINE ENGINE ELECTRICAL SYSTEM Activation by Keyswitch 1980 onwards  92  Starter Motor  95 A1ternator  99COOLING SYSTEM EXTERNAL                             Type HBW Short Profile Sailing Gear  114  Type BW Transmission  122                          91                                                                    ACTIVATION BY KEYS WITCH                                                                                                                         SCHEMATIC   DIAGAM                                                                                                                 IZVOC eAiTIt      eATTA RTUJt                                                   WIRI NG     DIAGRAM                                              So NOlE e                                         w SENOEA           NIT                                                                    ON                    rUEL   SOL we wtJ2 w 70 WIOO                             WZj                                z6 OWIOO                                IF CQUI  t                                                                                                                                                                                                                                                                                                                                               0                                                                                                                                                                                                                                                                                      FREHEAT SOL           SCEtlTES      oP SENDER                                                       12NOT USEO                                                                                                                                                                                                                                    Reo 1                                                                                                                  W04V                                                                                                                  c                                                                                             92                   MARINE ENGINE ELECTRICAL SYSTEM                       ACTIVATION BY  the ignition switch ON activates the instrument panel    Theoil and water temperature gauges will zero the voltmeter will indicate battery voltage and the hourmeter will start to record time Thealarm buzzer should sound     The e1ectr ic fuel pump will star t  the key will activate the preheat circuit     This closes asolenoid on the engine with an audible click and supplies 12 volts tothe engine glow plugs   Preheat as needed for weather conditions  Anoticeable voltage drop will indicate on the voltmeter when the preheat circuit is  to preheat turn the key to START     This energizes thestarter and turns the engine over Once the engine starts release thekeyswitch   It should spring back to the ON position and pop out ofthe preheat positionThe voltmeter shu1d indicate a charge from the alternator 135  145vol ts  The oil pressure and the alarm buzzer should shut off   Oilpressure opens the oil pressure switch in the alarm circuit shuttingoff the alarm   The water temperature switch operates the oppositeIt closes when an overheat condition exists and the operating temperature of the engine reaches 205 F and sounds the alarm       Thetachometer will reg ister eng ine speed as it takes impulses from thealternator as it charges       If the alternator does not produce acharge the tachometer will not operate The hourmeter will continueto record time The hourmeter is on a separate 12 volt circuitThe circuit is protected by a circuit breaker located on the engineAny time excessive current flows the circuit breaker will trip Thisis a manual reset breaker which must be reset before the engine willoperate electrically againCAUTION   The builderowner must ensure that the instrument panelwiring and engine are installed so that electrical devices cannot comein contact with sea waterThe latest information regarding your eng ine s electr ical system isincluded on the wiring diagram shipped with the engine     Be sure tostudy this wiring diagram and all notes thereonGLOW PLUG    A glow plug is provided in each combustion chamber    in order toensure smooth engine starting during the cold weather   The tip of the glow plug glows red hot when energized on preheat                                  93    When 12 volts positive is connected to the glow plug terminal andthe negative to the sheathing the glow plug tip should glow redhotTo check energize 2 to 4 times for about 30 seconds each     Do notenergize too long because it will damage the plug    If the glow plugs installed on the engine take too long to glowredhot one of the glow plugs is shor ted     Usually the glow plugtakes about 25 seconds or less to glow redhot    A glowplug can be checked for an open circuit fault by using acircuit tester and checking the continuity between the positive terminal on top of the glowplug and the cylinder head   I f there is nocontinuity the glowplug should be  voltmeter can be a useful instrument in determining the status ofyour electrical system and warn you when an abnormality occurs   Thevoltmeter will indicate differently depending when the readings aretakenFully charged batteries that are in a static state should read between123 and 126 volts on the dial   The term static means that the battery has not been charged or discharged for at least 2 hours   If thereading is between 11 and 115 volts then the battery is about halfdischarged and should be charged to insure its usefulness      If theengine is started and the needle does not go up this would indicatethat no charge is being delivered to the batteryWhen the battery is being charged the needle should be between 126and 13 volts   The needle may move up to about the 146 volt rangetoward the end of the charge cycle at which time the needle dropsback to the 126 to 13 volt range as voltage regulation controls thisfunction   If the battery voltage exceeds 15 volts this indicatesthat the battery is being overcharged and will damage the battery ifleft unchecked The voltage regulator is most likely at faultWhen the battery is being charged hav ing electr ical loads placedupon it and no charging current applied it is normal for the needleto indicate between 114 and 126 volts                                   tachometer is operated by pulses generated  from anyone of theal ternator phases   The pulse fr equency is determined by the rotational speed of the alternator rotor     The rotor speed is dependentupon the engine crankshaft speed and the RATIO of the  to the cr ankshaft pulley     The tachometer in an  is calibrated by Westerbeke for the standard alternator if anoptional alternator ie 90 amp is used to operate the tachometerthe calibration should be checked        Also when a tachometer isreplaced the new instrument must be calibrated                               CAUTION                    WHEN CALIBRATING THE TACHOM                    ETER USE A PHILLIPS SCREW                    DRIVER WITH AN INSULATED SHAFT1   Use a motor tester with an RPM indicator another tachometer or a     strobotach to determine the speed of the crankshaft turning2   Remove the plastic plug and flatwasher located on the rear of the     tachometer3   Insert an insulated Phillips screwdriver into the calibration     control slot and slowly turn  to increase the RPM     reading clockwise to decrease reading direction of screw as     viewed from the rear of the tachometer case        An accurate     calibration setting is more easily achieved at the higher side of     the dial scale4   Replace plastic plug and      The starter is a DC series motorwith a  pinion whichis smoothly moved by magnetic swi tchoperation into and out of mesh withthe flywheel ring gear      It is made up roughly of a motorwhich generates power an  which transmits the torque andprevents the overrunning after theeng ine star ts and a magnetic switchwhich moves the pinion into mesh with        I Magnetic switch        7 Yokethe ring gear and sends the load             2 Shift lever            8 Polecurrent to the motor                        3 Front bracket          9 Field coil                                             4 Over running clutch   10 Armature                                             5 Stop ring             II Brush                                             6 Center bracket        12 Rear bracket                                   95     The stationary par t consists of yoke pole piece f iel coilfront bracket center and rear brackets and magnetic switch and therotating part consists of armature and overrunning clutchThe magnetic switch is made up of an iron core plunger and connectorcoil and the plunger and clutch are connected with a    Turn    the   battery      swi tch off or remove      the ground terminal      from the battery2   Remove the wires from      B terminal and S ter      minal3   Remove the mounting      nut then the            CAUTION It is not necessarily a starter problem if the engine      does not start even when the starter swi tch is depressed    The      trouble may rest with the solenoid circuit breaker battery or      engine itself Therefore check the circuit for starting without      removing the starter and if no abnormality is found then remove      it from the engine and test it1   Checking of Starter Circuit      a   Battery state of charge      b   Battery connections clean and tight battery switch ON      c   Circuit breaker test      d   Proper size wire to starter      e   Good ground connection      f   Proper size battery 45 amp hour minimum2   Noload Test                                                            SWItch     If the starter and battery areconnected as illustrated and when theswitch is closed the starter willrotate  It is judged as normal if thestarter rotates smoothly at the speedstated below   I f any abnormali ty isfound in this test check in accordance with the following procedures                                    96a   Checking of brushes      Check the brushes and the insu      lated     condi tion   of   brush      holders on the pressure               side   of    the   brush  spr ingb   Checking of armature      1 Check for short cir      cuit    using  a    growler      tester      2 Check grounding There      should be no continuity      between the commutator and      the armature shaft      3 Check commutator      Check undercut depth and      roughness3   Checking of Field CoilCheck for grounding   These should be no continuity between one endbrush of the coil and yoke  In this case the shunt coil groundingwire will be  for disconnection       There must be continuity at both ends ofcoil between brushesCheck condi tion of installation   If the pole piece and coil areloosened or damaged replace them as yoke assembly  The pole pieceis caulked to the yokeCheck the solenoid   If the pinion fails to move out into mesh withthe ring gear check the solenoid in the following mannera   Continuity test      Continuity must exist between the terminals 5 and M and be      tween the terminal 5 and body   If the resistance is zero it      means  the   solenoid  is  defective   and  must   be  replaced                                      97b   Pullin Test      The pullin coil is judged as      normal   if   the    plunger   is      attracted and the pInIon comes      out when the battery is connected                                                          Removed Connector      between the solenoid terminals      S and M      CAUTION Do    not apply voltage      continuously    for  more   than      10 secondsc   Holding Test      Wi th the battery connected bet      ween the solenoid terminal S      and the body pullout the pinion      by hand as far as the pinion      stopper  If the pinion does not    I   Removed Connector      return when released the holding      coil is considered normal      CAUTION Do    not apply voltage      continuously    for  more   than      10 secondsd   Return Test      With the battery connected be      tween the solenoid terminal M      and the body pullout the pinion                                     by hand as far as the pinion                                                      Removed Connector      stopper   If the pinion returns      immediately when released both      coils are considered as normal      CAUTION Do    not apply voltage      continuously    for  more   that      10 seconds5   Checking of Pinion Gap     If the battery is connected between the solenoid terminal 5 andthe starter body the pinion will jumpout and stop    In such a state pushthe pinion lightly back toward thearmature and measure the gap between                                        Stop ringthe   pinion   and   the   stop  ring                                                                                           I                                                                IMeasured value of pinion gap should                            II                                                           be 05 20 mm                                                Ii                                                             Pinion gap                                   98     To adjust the clearance increase or decrease the number of fiberwashers on the solenoid mounting surface      Increasing the  the amount of clearance     CAUTION Avoid applying voltage continuously for over 20 seconds     to prevent overheating of the solenoid     In this test after reassembling if the pinion fails to jump out     or if the pinion gap is too big or too small faulty shift lever     improper installation of plunger spr ing or faulty solenoid is      reassembling reverse the order of disassembling     CAUTION In the installed position of the starter the starter     shaft must be exactly in parallel with the axis of center of the     engine   The starter must be securely installed so it will not     move when starting the engine If the tightening is insufficient     or if any foreign substance exists on the mounting surface the     bracket may be broken or cocking of the starter may occur     Insure the mounting surfaces are clean     The star ter per formance largely depends on the wir ing and bat     tery   Use proper size wire for the distance between the battery     and the starter and tighten the terminals     DO NOT USE A HIGHVOLTAGE TESTER SUCH AS A MEGGER OTHERWISE A    DAMAGED DIODE RESULTS   DURING HIGHSPEED OPERATION OF THE ENGINE DO NOT DISCONNECT THE   POSITIVE OR NEGATIVE TERMINAL OF THE BATTERY FROM THE A TERMINAL   OF THE REGULATOR    A VOLTAGE SURGE WILL OCCUR THAT WILL DAMAGE   ALTERNATOR DIODES SHOULD THESE CONNECTIONS BE OPENED    DO NOT RUN THE ENGINE WITH THE LEAD DISCONNECTED FROM THE    B TERMINAL OF THE ALTERNATOR THE INTERNAL REGULATOR VOLTAGE    COIL WILL BE DAMAGED   WHEN MAKING A RAPID CHARGE OF BATTERY USING A QUICK CHARGER BE   SURE   TO  DISCONNECT  THE   BATTERY CABLES OTHERWISE  DAMAGED   ALTERNATOR DIODES WILL RESULT   WHEN USING A STEAM CLEANER BE CAREFUL NOT TO ALLOW DIRECT CONTACT   OF STEAM WITH THE ALTERNATORThe charging system consists of an alternator with internal  engine mounted circuit breaker battery and    Because of the use of ICs integrated circuits the electronic voltage regulator is very compact and is builtin the rearbracket of the alternator                                  99Charging Voltage Test1 Turnkeyswitch     offon marine engines or disconnect    the   oil                        0 to Ltaipressure switchwire on generator sets2     frompositive      terminal ofbattery and                               Batteryconnect anammeter in               series betweenthe cable andpositive      terminal of thebattery3    Connect a voltmeter between terminal L of alternator andground    Check to ensure that the voltmeter reading is zero           Ifthe pointer of the voltmeter deflects a voltage present adefective alternator or wiring is suspected4   Turn keyswitch on or connect the oil pressure switch terminalto ground but do not start the engine         The voltmeter readingshould be considerably lower than the battery voltage               If thevoltmeter reading is much the same as the battery voltage adefective alternator is suspected5 With the ammeter terminals shortcircuited start the  SURE THAT WHEN THE ENGINE IS STARTED NO STARTING CURRENT ISAPPLIED TO THE AMMETER6    Remove the short circuit across the ammeter terminals andincrease the engine speed immediately to approximately 2000 to3000 rpm Take the ammeter reading7    If the ammeter reading is SA or less take the  without changing the engine speed 2000 to 3000 rpmThe reading is the charging voltageNOTE    Since the electronic voltage regulator is a  type the charging voltage varies with  the temperature around the rear bracket of the alternator must be measured and the charging voltage corrected to thetemperature       Description                      Standard value   Charging voltage                      144 03V at 20C 6SF   Temperature compensation                   OlVlOC sOF   gradient                                  1008 If the ammeter reading is more than SA continue to charge thebattery until the reading falls to less than SA or replace thebattery with a fully charged one     An alternative method is tolimit the charging current by connecting 14 ohm 25W resistor inseries with the batteryOutput Test1   Disconnectthe batteryground cable                         RelilJl2   Disconnect                                             Oi to Loadthe cable fromterminal B ofalternator andconnect anammeter      Band this cable3     Connect avoltmeter between    terminalB  andground 4      Set theengine    tachometerNote The RPM is that of the alternator             The pulley  vs crank pulley is 178 to 1        All readings are at135 VDC5      Connect battery ground cable to battery         The  indicate the battery voltage6   Start the engine7   Turn on the 12 volt accessories equaling the amperage outputof the alternator accelerate the engine to the specified speed2000 to 3000 RPM and measure the output current           The outputcurrent should be close to alternator maximum outputOutput current                        1300 RPM   2500 RPM     5000 RPMCold 20 C 68 F                      7 amp     30    After removing the three through bolts insert a  the front bracket and stator While prying it remove thefront bracket and rotorNOTE    If the screwdriver is inserted too deep the stator coilmight be damaged2    Hold the rotor in a vise and remove the pulley nut     Thenremove the pulley fan spacer and seal    Next remove the rotorfrom the front bracket and remove the seal3    Unsolder the rectifier from the stator coil lead wires andremove the stator assembly                                101NOTE Make sure that the solder is removed quickly in less thanfive seconds    If a diode is heated to more than lSOC 3l0Fit might be damaged4    Remove the condenser fromterminal B5   Unsolder the plates B andL from the rectifier assembly6    Remove the mounting screwand B terminal bolt and removethe electronic voltage regulatorand brush holder The regulatorand   brush   holder   cannot   beseparated7       Remove    the        Brush and brush spr ingreplacement When only a brush or brushspring is to be replaced it canbe replaced without removing thestator etc    wi th the brush holder assembly raised as shownunsolder the pigtail of the brushNOTE   If the terminals L and B of the rectifier assembly arebent damage might result to the rectifier molding     Thereforethe plates Band L should be gently bent at the  method for disassembling the stator winding  unit and the integrated circuitdiode  from the rear bracketOnce the front bracket and rotor assembly are separated from therear half of the alternator1       Insert   a    between the statorcore and the edge of the rearbracket on the same side as thebrushholder    Raise this sideof the stator core away from thebracket so as to open a gap ofabout 12 inch   BE CAREFUL NOTTO ALLOW THE SCREWDRIVER BLADETO ENTER FAR ENOUGH TO TOUCH THESTATOR WINDING2     Maintaining the 12 inchgap insert the screwdriver between the stator core and thebracket on the rectifier sideand move the stator  the brushholder for adistance of 12 to 34 of aninch without lifting it from thebracket                              1023   Insert a 2 Philips screwdriver through this opening andremove the two screws holdingthe rectifier4      Remove the nut anchor ingthe B terminal bolt and thecapaci tor   mounted   thereto  onthe    outside    rear    of   thebracket    Then remove the thirdPhilips     screw    holding   thebrushholder to the bracketS    Carefully withdraw  and rectifier fromthe rear bracket as one  uni tWith the bracket out of the way it is easy to unsolder the statorwinding leads from the rectifier quickly to avoid heat damage tothe diodes and IC chips      It is also easier to renew brushesbecause there is no need to bend the connecting plates between thebrushholder and the rectifier and possible damage the  reversing this procedure make sure that the stator windingleads are gently pushed back from possible contact with the rotorbody after seating the stator into the rear  Assembly1 Check the outside circumference of the slip ring for dirtinessand roughness  Clean or polish with fine sandpaper if requiredA badly roughened slip ring or a slip ring worn down beyond theservice limit should be replaced     Description           Standard value         Service limit                              mm in              rom inSlip ring OD              33 12992           322 12677Runout                      003 0012            02 008                            or less2    Check for continuity    between   thefield coil and slipring    If there is nocontinui ty the fieldcoil    is         the    rotorassembly                                103   3    Check for con   tinuity   between    the   slip ring and shaft   or core     If there   is    continui ty    it   means that the coil or   slip ring is grounded   Replace    the     rotor   assemblyStator Assembly   1 Check for continuity between   the leads of the stator coil   If there is no continui ty the   stator    coil   is   defective   Replace the stator assembly                                                                                 2   Check for an open circui t        between the stator coil leads   and the stator core  If there   is continuity  the stator is   grounded and must be replaced                                 104Rectifier Assembly     Heatsink Assembly Test   Check for con   tinuity between   the  heats ink   and stator coil   lead connection   terminal with an   ohm meter   there   is                  If               con                                 g ID  i                                                                                                                                                                                                                 tinui ty in both   directions the   diode is short                                                                           IfJ                                                                                          TERMINAL 8   circuited                                                  HEAT5NK   Replace the rec                                               A5SEMBLY   tifier assembly     Heatsink Assembly Test   Check for con   tinuity between   the  heatsink   and stator coil   lead connection   terminal     If   there   is  con   tinui ty in both   directions the   diode is short        U   circuited   Replace the rec   tifier assembly   Diode Trio Test   Using     an   ohm   meter check the   three diodes for   continuity      in   both directions   If     there    is   either con   tinui ty    or  an   open circuit in   both directions      rlICJC7tjtTJ   the     diode   is   defective   Replace the rec   tifier assembly                                 105    Brush and Brush Rig    1 Check the length of the brush     A brush worn down to the ser    vice limit line should be replaced     Description           Standard value           Service limitLength of brush           18 mm 709 in         8 mm 315 inLoad of brush spring      304 to 422 N           206 N 5 lbs                            7 to 1 lbs    2  Check the brush spring pressure to make sure the brush moves    smoothly in the brush holder    Reassembly    Reverse the disassembly procedure but pay special     attention   to    reassembly of the following    1   Install seals in front and    rear of the front bearing as    shown    2   To install the rotor assembly    in the rear bracket push the    brushes into the brush holder    insert a wire to hold them in    raised position and then install    the rotor    NOTE   After installation remove    the wireSERVICE  refer to the Service Bulletin Section at the rear of the manualas there are several that relate to the electrical system                                  106                         COOLING SYSTEM EXTERNAL1    marine diesel engines are equipped with fresh watercooling   Transfer of heat from engine fresh water to sea water isaccomplished by a heat exchanger similar in function to an    Sea water flows through the tubes of the heat exchangerwhile fresh water flows around the tubes     The sea water and freshwater never mix with the result that the cooling water passages in theengine stay clean2   FRESH WATER CIRCUITHeat rejected dur ing combustion as well as heat developed by fr iction is absorbed by the fresh water whose flow is created by a freshwater circulating pump The fresh water flows from the engine througha fresh water cooled exhaust manifold a heat exchanger in most casesan oil cooler and returns to the suction side of the fresh water circulating pump   The flow is not necessarily in this order in everymodel  When starting a cold engine most of the external flow to theheat exchanger is prevented by the closed thermostat   Some amount ofbypass is maintained to prevent overheating in the exhaust manifoldAs the engine warms up the thermostat begins to open up allowing fullflow of engine fresh water through the external cooling system3   SEA WATER CIRCUITThe sea water flow is created by a posi ti ve displacement  pump gear pump in certain special cases Normally the pumpdraws sea water directly from the ocean via the seacock and sea waterstrainer    Sometimes a transmission oil cooler or perhaps a Vdrivewill be piped on the suction side of the sea water pump     Generallyit is better to have as few devices on the suction side of the seawater pump as possible to preclude priming difficulties    Usually seawater flows directly from the discharge of the sea water pump to theheat exchanger sea water inlet     After passing through the tubes ofthe heat exchanger the sea water may enter a transmission oil coolerif present and if sea water cooled    Ultimately the sea water entersa water injected wet exhaust system the most popular type of exhaustsystem in use     In the case of larger engines the sea water flow isdi vided pr ior to enter ing the exhaust systems so that a portion isused to cool the exhaust system      Full sea water flow would  exhaust back pressure4   SEA WATER PUMPThe sea water pump is self priming and positive displacement It is arotary pump with a nonferrous housing and a neoprene impeller   Theimpeller has flexible vanes which wipe against a curved cam platewithin the impeller housing producing the pumping action      On noaccount should this pump be run dry   There should always be a spareimpeller and impeller cover gasket aboard                                     1075    SEA WATER PUMP 32617 IMPELLER REPLACEMENTThe following instructions are general and indicative only  where applicable may be packaged wi th your     Remove the four screws and washers that hold the front cover to       the pump body Remove the cover and gasketb    Grasp the   impeller   hub wi th a pair of pliers and withdraw the       impellerc    Apply a small amount of petroleum jelly to impeller blade ends of       new impeller Line up impeller hub screw with slot in pump shaft       and insert impeller into pump until flush with cover mounting       surfaced    Immerse the new gasket in water for a moment before installing       Install the gasket cover screws and washers       Note No sealant is needed on the cover gasket for proper       sealing   In you intend to reuse the cover gasket immerse it in       water until reassembly of the cover The gasket will shrink when       dried out                                                i                                   r                                                                                                      Y                                                  6    SEA WATER PUMP 32617  SEAL REPLACEMENTa   Remove the pump from the mounting bracket and remove the dr ive      pulleyb   Remove the front cover and impeller as above          Remove the cam and      inner wear platec   Remove the plastic bearing shield from the pulley shaft end of      the pump with the aid of a small screwdriver   Push through the      small recess in the outer circumference of the shield and pry it      out   With snap ring pliers remove the large outer snap ring      positioned in the pump body                                          108d   Support the pump and with a soft dowel that fits into the slot of      the shaft   Carefully press the shaft out of the pump     Press      away from the impeller bore    In most instances the bear ings      plastic spacer and Oring will come out with the shaft    If the      bearings remain in the pump when pressing out the shaft be sure      to support the bearings by the inner racee   Reach in from the impeller bore side and withdraw the seal with      needle nose pliers Clean the seal areaf   Apply a liberal amount of    petroleum jelly to the seal lip and      then dip the seal in water   and press the seal squarely into the      seal bore lip facing the     impeller bore  Use the inner wear      plate to position the seal     flush with the impeller bore inner      surfaceg   Apply lubricant to pump shaft and bearings outer surface      position plastic spacer and Oring on shaft Press bearings and      shaft assembly on outer race of bearings Take care to see that      the shaft passes through the seal without damaging it Press the      shaft assembly in until it bottoms in the pump body Rotate the      shaft to insure it is freeh   Replace the large outer snap ring and plastic bearing shieldi   Replace the inner wear plate and cam    Apply a small amount of      sealant to the cam inner surface and the screw holding screw      The inner wear plate if worn or grooved can be reversedj   Replace the impeller as described in 57    SEA WATER PUMP 32617  SHAFT AND BEARING REPLACEMENTIf shaft and bearing replacement become necessary it is  the pump be replaced8    FRESH WATER PUMPThe water pump is a  type and is installed atthe front top of the crankcase Thepump    shaft   is    supported    doublerow radialball bear ings which are greased andsealed                                      Drain the cooling water     The drain plug              is    located on      the      righthand side of the crankcaseb   Remove the water hosec   Remove the alternator and sea water pump beltsd   Remove the pulleye   Remove the water pump    Check the parts for      cracks    damage   and      water    leakage   and    if      defective replaceb   Check the rotating condition of the impeller and shaft If they      make noise or do not rotate smoothly replace them as an      assemblyc    Check the fan if equipped for cracks and damage and if defec      tive replaced   Check the belts for elongation and cracks due to deterioration      and if defective  reassembling rever se the order of disassembly                  The alternatorbelt adjustment can be made in the following mannera   Adjustment of Alternator Belt      The     al ternator    bel t    should      deflect 10 to 12 rom deep when      pressed at the center point bet      ween the water pump pulley and      the    alternator     or    alternator      pulley      Adjust the alternator      belt tension by moving the alter      nator          After    adjustment      securely tighten the pivot bolt          Crankshaft                                                  pulley      and adjusting arm bolt9    ENGINE FRESH WATERIt is preferable to fill your engine with a 50  mixture This precludes the necessity of draining coolant in the winterSince most antifreezes contain preservative agents of one kind oranother rusting within the engine is minimized Also the  boils at a higher temperature than water giving coolingsystem head room                                         110When draining the engine open the pressure cap first to relieve thevacuum created by draining10   FILLING THE FRESH WATER SYSTEMIt is very important to completely fill the fresh water system beforestarting the engine     It is normal for air to become trapped invar ious passages so all high points must be opened to atmosphere tobleed entrapped air    When an engine is started after filling wi thcoolant the system may look deceptively full until the    At this time when water flows through the external coolingcircuit for the first time pockets of air can be exposed and rise tothe fill point Be sure to add coolant at this timeAfter a number of seasons use of the engine water scale and rust mayoccur in the block water jacket and exchanger resulting in considerable reduction of cooling efficiency Therefore it is necessaryto flush the cooling system once every two or three years      CAUTION Adhere to the manufacturers instructions when using      the additive Do not mix different brand products      Be sure to put the proper amount of antifreeze in water and agi      tate well before adding it to the cooling system  Du not use a      concentrated antifreeze solution11  thermostats are of two types      One is simply a chokingdevice which opens and closes as the engine temperature rises andfalls   The second type has a bypass mechanism    Usually this is adisc on the bottom of the thermostat which moves downward to close offan internal bypass passage wi thin the head     Both types of thermostats from 1980 onwards have a hole punched through them to serveas a bypass while the engine is warming up            This    in   the  exhaust   manifold   during   engine   thermostats must be equal in this design  replacing a thermostat be sure that it is rotated so as to notstrike the thermostat housing projections inside the head temperature senders or temperature switches which may be installed closeto the thermostat Also insure the bypass hole is not blocked by anypart of the housingA thermostat can be checked for proper operation by placing it in apan of cold water and then raising the temperature of the water to aboil The thermostat should open noticeably with travel on the orderof 14 n  12 n  and be fully opened when the water is boiling12 WATER TEMPERATURE SWITCHThe water temperature switch is located in the thermostat housing atthe front of the cylinder head    This switch will close on a propulsion at 205 F to activate an alarm buzzer and on a  it will open to deenergize the fuel run solenoid to shut theengine off                                  III13 WATER TEMPERATURE SENDERThe water temperature sender is located in the thermostat housing atthe front of the cylinder head     It senses the temperature of thewater flowing through the thermostat and electr ically transmits thisreading to a water temperature gauge in the engine instrument panel14 TRANSMISSION OIL COOLERCertain transmissions require oil cooling       In these         cases     oil cooler is usually cooled by sea waterNormally sea water enters     this    cooler   after   exiting    the     heatexchanger but not always                                       113                    HBW SHORT PROFILE SAILING    BRIEF DESCRIPTIONThe Type HBW Short Profile Sailing Gears are equipped with a positively driven mechanically operated helical gearing system    The servooperated multipledisc clutch requires only minimum effort for gearchanging making the transmission suitable for singlelever remotecontrol via a rod linkage Morse or Bowden cableThe torque transmission capacity of the clutch is exactly rated preventing shock loads from exceeding a predetermined value and thusensuring maximum protection of the engineThe transmission units are characterized by low weight and smalloverall dimensions The gearbox castings are made of a  aluminum alloy chromized for improved sea  and optimum adhesion of paintThe transmissions are    Maintenance is restrictedto oil level checks see Maintenance2   GEAR CAS INGThe rotating parts of the HBW transmission are accomodated in an oiltight casing divided into two halves in the plane of the verticalaxis Amply dimensioned cooling ribs ensure good heat dissipation andmechanical rigidityAn oil filler screw wi th dipstick and an oil drain plug are screwedinto the gear casing   The filler screw is provided wi th a  shaft for actuating the multipledisc clutch extends     through   acover on the side of the gear casing3   GEAR SETSThe transmission is equipped with shaved casehardened helical gearsmade of forged lowcarbon alloy steel The mUltispline driving  the transmission with the engine is hardened as wellThe driven shaft propeller side of the transmission is fitted with aforged coupling flange except on the Vdrive model                                  1144   MULTIPLEDISC CLUTCH INCLUDING OPERATION  POWER TRAINThe engine torque is applied to the input shaft 36 in the  of rotation and IN SHIFTING POSITION A forward viagear 44 the frictionally engaged clutch discs 51 and 52 to theexternal disc carrier 57 and from there via the guide sleeve 59to the output shaft 66IN SHIFTING POSITION B reverse the torque is transmitted from theinput  shaft 36   via  intermediate gear 26  gear 65   clutchdiscs 51 and 52    to the external disc carrier 57 the guidesleeve 59 and the output shaft 66 FUNCTIONThe transmission uses a positively driven mechanically        clutch system mounted on the output shaftThe thrust force required for obtaining positive frictional  the clutch discs is provided by a servo system    This essentially compr ises a number of balls which by the rotary movement ofthe external disc carrier are urged against inclined surfaces provided in pockets between the guide sleeve and the external disccarrier and in this manner exert axial pressure      The thrust forceand as a result the transmittable friction torque are thus proportional to the input torque applied   Due to the cup springs 48 supporting the clutch disc stack and a limitation of the range of axialtravel of the external disc carrier 57 the thrust force cannotexceed a predetermined value                                   115The actuating sleeve 60 is held in the middle position by springloaded pins     To initiate the shifting operation the  60 need merely be displaced axially by a shifting fork untilthe arresting force has been overcome Then the actuating sleeve 60is moved automatically by the springloaded pins while the externaldisc carr ier which follows this movement is rotated by the fr ictional forces exerted by the clutch discs and the shifting operationis completed as described above                                                     Power flow in lever position                                                              A                                                  85   SHAFT BEARINGSBoth the input and the output shafts are carried in amply  roll bearingsThe intermediate gear and    the   movable   gears     are     carried       in     sturdyneedle roller bearings6   SHAFT SEALSExternal sealing of the input and output shafts is provided by radialsealing rings The running surface on the shafts is casehardened7   LUBRICATIONThe  transmissions   are                 The     bear ings  aregenerously    supplied     with   splash     oil              and      oil      mist                                       DELIVERY CONDITIONFor safety reasons the gearbox is NOT filled with oil for shipmentThe actuating lever is mounted on the actuating shaftBefore leaving the factory each transmission is subjected to a testrun with the prescribed ATF oil    The residual oil remaining in  after draining acts as a preservative and  protection against corrosion for at least 1 year if the unitsare properly stored2   PAINTING THE GEARBOXALWAYS COVER THE RUNNING SURFACES AND SEALING LIPS OF THE RADIALSEALING RINGS ON BOTH SHAFTS BEFORE PAINTING    Make certain that thebreather hole on the oil f iller screw is not closed by the  plates should remain clearly legible3   CONNECTION OF GEARBOX WITH ENGINEA torsioelastic damping plate between the engine and the transmissionis to compensate for minor alignment errors and to protect the inputshaft from external forces and loads   Radial play should be at least05 mm4   SUSPENSION OF ENGINEGEARBOX ASSEMBLY IN THE BOATTo protect the gearbox from detrimental stresses and loads  be made for elastic suspension of the enginegearbox assemblyin the boat or craftThe oil drain plug of the gearbox should be conveniently accessible5   POSITION OF GEARBOX IN THE BOATThe inclination of the gearboxunit in the direction of theshafts should not  an angle of 20 degrees15 degrees for    the Vdrivemodel  See  gearbox can also be mountedwith the output shaft in theUPWARD position    Interchangethe oil dipstick and the oildrain plug in this case                                   1176   OPERATION OF GEARBOXThe adjustment of the shift lever on the transmissjon when attachingthe shift control cable to it is of prime importance to ensure properclutch engagement and long service life for the  control cable when attached to the transmission shift arm balljoint connector should be attached so as to be at a 90 angle wi ththe   lever  and  transmission  in  the  neutral posi tion     The transmission shift arm can be rotated on the transmission sidecover shifting shaft by loosening the securing bolt 13mm androtating the shift arm to produce the 90 angle between the arm andthe shift cable when the transmission is in neutral    Insure thatthere is at least 020 inch clearance between the shift arm and theshift cover before retightening the securing boltThe shift cable and pedestal control must allow the transmission shiftarm to move from the neutral posi tion into the forward or  a MINIMUM of 1 37 inches 35mm when the outermost balljoint attachment hole is used on the shift arm or 118 inches 30mmwhen the inner is used      Use of the inner attachment hole is preferred   Ref Illustration                                                     Minimum Travel inner hole used                                                                          118                                                                                       I                                                                         30mm I                                1J                                                                                                               1                                                                                                                                                                                                                                                                                                                                                                                      I                  Shift Cable Attachment from Rear                                                                                                                                                                                  o                  Shift Arm Securing BoltFailure to properly adjust the shift arm and cable to produce theMINIMUM shift arm travel required for clutch engagement will result inclutch slippage and eventual  the shift arm and shift cable to produce shift lever movement greater than the minimum is recommended                                             118Movement at the shift arm preferably should be 1S to 2 inches of armmovement into the forward and reverse position Cockpit controls mustbe of a design that will allow for this desired cable travelThis shift lever travel should be verified at initial  periodically thereafter at least once a yearWhen shifting the transmission from the controls in the vessels cockpit it should be done smoothly and without hesitation dump it intogear The position of the shift cover plate underneath the actuating leveris factory adjusted to ensure proper operation of the transmission andis sealed with LocTite orange     Therefore do not loosen the 4capscrews Removal or disturbing of this cover will void all  by WesterbekeWhen installing the gearbox make certain that shifting is not impededeg by restricted movability of the cable or rod linkage byunsuitably positioned guide sheaves too small bending radius etc7   ENGINEGEARBOX  should be taken that the enginegearbox compartment is    INITIAL OPERATIONFill the gearbox with automatic transmission fluid    The fluid levelshould be the index mark on the dipstick see illustration                                                 To check luld level              Transmission on Operation            Vent 4Ii            Hole      Seang Washer                                                                        TransmisSion Casing                                                                        Surface                                                                            Vent                                         I   I                    I                                                                                  Full Mark                                                      Do not screw In lor                                                      luld level checks                                               119To check the fluid level just insert the dipstick DO NOT SCREW INRetighten the hex screw with the dipstick after the fluid level checkDo not omit the oring seal2   OPERATING TEMPERATUREThe maximum permissible temperature of the transmission fluid is130C  If this temperature is to be exceeded an optional oil cooleris available3   OPERATION OF GEARBOXThe zero position of the operating lever on the control console mustcoincide with the zero position of the ctuating lever on  Shifting is initiated by a cable or rod linkage via theactuating lever and an actuating cam     The completion of the gearchanging operation is  controlledGear changing should be smooth not too slow and continuous     Direct changes from forward to reverse are permissible since the multipledisc clutch permits gear changing at highRPM including sudden reversing at top speeds in the event of danger4   OPERATION WITHOUT LOADRotation of the propeller without load freewheeling eg while theboat is sailing being towed or anchored in a river as well asidling of the engine with the propeller stopped will have no detrimental effects on the gearboxLocking of the propeller shaft by an additional brake is not requiredsince locking is possible by engaging the reverse gear   DO NOT sailwhile engaged in forward5   LAYUP PERIODSIf the transmission is not used for periods of more than 1 year itshould be COMPLETELY filled with fluid of the same grade to   Protect the input shaft and the output flange by means ofan anticorrosive coating if required6   PREPARATION FOR REUSEDrain the transmission of all fluid and refill to the proper levelwith the prescribed    TRANSMISSION FLUIDTo ensure troublefree operation of    the clutch   use only  fluid ATFUnder no circumstances should the fluid contain any additives such asmolybdenum sulphite                                 120We recommend commercial Automatic Transmission Fluid ATF  Type A orDexron II2    FLUID QUANTITYHBW   5 approximately 04 literHBW   10 approximately 06 literHBW   20 approximately 08 literHBW   50 approximately 03 literHBW   100 approximately 035 literHBW   150 approximately 055 literHBW   150V approximately 10 literHBW   220 approximately 075 literHBW   250 approximately 075 literHBW   360 approximately 140 literHBW   360A approximately 150 literHBW   400 approximately 200 literHBW   450 approximately 180 literUse the index mark on the dipstick as a reference3    FLUID LEVEL CHECKSCheck the fluid level in the transmission daily Correct fluid levelis the index mark on the dipstick see item 1 under OPERATION  Always use the same fluid type when topping up4    FLUID CHANGEChange the fluid for the first time after about 25 hours of operationthen at intervals of at least once per year5    CHECKING THE CABLE OR ROD LINKAGEThe cable or rod linkage should be checked at shorter time intervalsCheck the zero position of the operating lever on the controlconsole and of the actuating lever on the gearbox on this occasionThe minimum lever travel from the neutral posi tion to the  OA  OB should be 35 mm for the outer and 30 rnrn for theinner pivot point Make certain that these minimum values are safelyreached   Check the cable or rod linkage for easy movabili ty seeitem 6 under INSTALLATION6     of the transmission in the field is not recommended    Ifan overhaul or repair is needed the work should be done by Westerbekeor an authorized Westerbeke service center                                      121                           BW  manual transmissions rotate opposite to the engine when in forward gear   Shifting effort is very low   The input power on the BW3is transmitted to the output shaft by helical spur gears when in forward In reverse this task is taken over by a high performance rollerchain The unit also incorporates a servi conetype clutch The BW7and BW12 transmit their power with casehardened helical gears and inreverse there is an intermediate gear The reversing process on theseis carried out by a servo double disc    Fill the transmission with 20 to 40 SAE weight engine oil the     same as is used in the engine2   Oil capacity     BW3 approximately 035 liter     BW7 approximately 10 liter     BW12 approximately 10 liter3   Check the oil level daily with the engine stopped The level must     be between the upper and lower dipstick marks when the dipstick is     completely  into the housing4   Change the oil initially after the first 30 hours thereafter     every 250 hours once per year minimum   The BW7 and BW12 have a     dr ain plug for oil removal   Oil may also be removed by suction     through the dipstick tube where oil is added5   Operating oil temperature must not exceed l20C 250FOPERATION1   Normal shifting should be done below 1500 RPM2   The BW3 may be locked in reverse when sailing or freewheeled in     neutral3   The BW7 and BW12 may be locked in either forward or reverse when     sailing or freewheeled in    Never loosen the shift lever cover screws except in the course of     qualified servicing as this upsets a critical adjustment2   Disassembly of the transmission in the field is not recommended     If an overhaul or repair is needed the work should be done by     Westerbeke or an authorized Westerbeke service center                                   122            GENERATOR SETSCONTENTS                                        PAGEManual Starter Disconnect Toggle Switches  124Generator  3KW 60 Hz and 24KW 50 Hz  130                        123                                                       MANUAL STARTER DISCONNECT TOGGLE SWITCHES                                                                                                                          SCHEMATIC DIAGRAM                                WIRING DIAGFIAM                                      Sit lIIOIe                                                                                                I                                       wTNOCR                                                 I                                                                                                I                                                                AlTRNATOA                                                                                                 I                                                                                                 I                                                                                                 I                                                                                                 I                                                                                                 I                                                                                                 L                                                                                                            I                    e               futl   L                                                                                                           I                                                                                                           I                                                                                   1                                                                                                                  I          Itv1                                                                                                                                                                             LFI                                                                                     8A                                                                                                                                                              PMHAT SOL                                                                                                       OIL SSURESWITCH                                                                                                                     aLIIO                         SIItIESo IS ALTEIINATOJI                           IZVOlT IoO                                                                                                                                                         I                                                                                                                                                         I                                                                                                                                                                                                                                                                                                         4mttl                                                                                                     124               MANUAL STARTER DISCONNECT TOGGLE  manually controlled series of Westerbeke marine diesel generatorsis equipped wi th toggle swi tches on the eng ine control panel andoptionally at remote panels   The following instructions and methodsof correcting minor problems apply only to such toggle  three switches are momentary contact type and serve the     1     Preheat  The PREHEATDEFEAT toggle switch is a double pole           single throw swi tch    The swi tch serves two purposes pre           heating the engine for easy starting and defeating or           bypassing the engine protective oil pressure switch       The           defeat function acti va tes the fuel run solenoid instrumen           tation  alternator   excitation    electric  fuel  pump and           supplies DC voltage to the start switch    2     Start   The START toggle switch is a double pole single           throw swi tch  The swi tch when depressed supplies 12 volt           DC power to the starter solenoid energizing the starter to           start the engine    3     Stop The STOP toggle switch is a single pole single throw           normally closed swi tch  This swi tch provides power to the           fuel run solenoid instrument cluster and alternator excita           tion after the oil pressure switch has closed upon starting           Opening of this swi tch opens the power circui t to the fuel           run solenoid thus stopping the flow of fuel to the engine           and stopping the engineENGINE OPERATION    1     Preheat Depress the PREHEAT switch This will activate the           instrument panel gauges and lights    The fuel run solenoid           will be activated drawing the throttle arm into the run           position The preheat solenoid will close and supply voltage           to the glow plugs The electric fuel pump will be activated           Hold the preheat switch depressed 15 to 60 seconds depending           on ambient temperature    2     Start    Continuing to hold the PREHEAT switch depressed           depress the START switch    This will energize the starter           solenoid engag ing the star t   Once the eng ine f ires and           star ts to run release the START swi tch only   Continue to           hold the PREHEAT switch depressed until the engine oil           pressure reaches 25 PSI then release it    3     Stop  Depress the STOP switch and hold it until the engine           stops completely  Remove any load from the generator before                                    125         stopping it  The STOP switch opens the circuit to the fuel         run solenoid deenergizing it moving the throttle arm into         the shut off position stopping the engineREMOTE ENGINE OPERATIONFor remote operation of the generator system the same three switchesare used    The PREHEAT and START swi tches are connected in parallelwith the local panel switches and serve the same functions as in thelocal panel   The STOP switch is in series with the local panel STOPswi tch and serves the same functions as in the local panel Thegener ator may be stopped from local or remote posi tions   The greenindicator light in the remote panel signals that the engine hasstarted and to release the START swi tch only       Hold the  for a few more seconds to allow oil pressure to riseAC GENERATORSOnce the diesel generator sets have been placed in operation there islittle or no control adjustment required by the AC Generator   Whenstarting the generator it is always a good plan to switch off allAC loads especially large motors until the engine has come up tospeed and in cold climates starts to warm up     These  prevent damage by unanticipated operation of AC machinery andprevent a cold engine from being stalled                                  126                                         MANUAL STARTER DISCONNECT TOGGLE  PROTECTIONThe engine control system is protected by a 20 amp manual reset circuit breaker located on the engine as close as possible to the  Control toggle switch                  Probable Cause           depressed      Battery switch or       Check switch andor batno panel indications   power not on            tery   fuel pump      20 amp circuit          Reset breaker if opensand preheat solenoid    breaker tripped         again check preheatnot energized                                  solenoid circuit and                                                run circuit for shorts                                                to groundStart switch            Connection to           Check  no           solenoid faultystarter engagement                        Faulty switch           Check switch with ohm                                                meter                        Faulty solenoid         Check that 12 volts                                                present at solenoid                                                connection                        Loose battery           Check battery                        connection              connection                        Low batteries           Check battery charge                                                stateStart depressed        Poor connections to     1 Check  indications OK   fuel solenoid          positioning of fuelStart solenoid OK      Defective fuel run      solenoid for plungerFuel solenoid not       solenoid PN 23041                                       2 Manually check                                                movement of fuel run                                                solenoid plunger and                                                throttle armNo ignition cranks    Faulty fueling system   1 Check for fuel todoes not start Fuel                            generator systemsolenoid energized                             2 Check for air in                                                fuel system Allow                                                system to selfbleed                                                3 Fuel lift pump                                                failure                                   127No ignition cranks   Faulty fueling system   4 Filters cloggeddoes not start Fuel                            Replace filters andsolenoid energized                            allow system to self                                               bleed by depressing                                               PREHEAT switch onlyFailure to stop       Fuel solenoid           Stop engine by manually                       PiN 23041 return      moving the throttle                       spring                  lever to shut off That                                               failing shut off fuel                                               and air Check fuel                                               solenoid linkage and                                               repair for free move                                               ment                       Stop switch failure     Stop engine by depres                                               sing emergency stop                                               switch on engine or                                               manually moving throttle                                               to shut off Test                                               switch with ohmmeter                       Fuel injection pump     Depress emergency shut                       failure                 off switch on engine                                               Stop engine by opening                                               the high pressure injec                                               tor lines at the injec                                               tors  stop air intakeEngine stops          Low oil pressure or     Check oil fresh water                       overheated              and sea water cooling                       Low oil pressure        Check for satisfactory                       switch fails to close   operation with switch                                               bypassed Check with                                               ohmmeter                       High water tempera     Same as above                       temperature switch                       opens at too low a                       temperature                       20 amp circuit breaker Same as above                       tripping                       High exhaust tempera   Same as above                       ture switch open at                       too low a temperature                       Emergency stop switch   Check operation of                       or stop switch in       switch with an ohmmeter                       panel defective and                       opening fuel run                       solenoid circuit                                  128Engine stops           Switch and wiring      Inspect all wiring for                                               loose connections and                                               short circuitsNot charging battery   Alternator drive       Check drive belt and its                                               tension Be sure alter                                               nator turns freely                                               Check for loose connec                                               tions Check output with                                               voltmeter Insure 12 V                                               present at regulator                                                runs down       Oil pressure switch    Observe if gauges and                                               panel lights are acti                                               vated when engine is not                                               running Test the oil                                               pressure switchBattery runs down       High resistance leak   Check wiring Insert                        to ground              sensitive O2S amp                                               meter in battery lines                                               Do not start engine                                               Remove connections and                                               replace after short is                                               located                        Low resistance leak    Check all wires for tem                        to ground              perature rise to locate                                               fault                        Alternator             Disconnect alternator at                                               output after a good                                               battery charging If                                               leakage stops Remove                                               alternator and bench                                               test Repair or                                               replace                                     129                             TECHNICAL DATA30 KW                    115 VAC                     250 AMP at 115 VAC44 KW                    115 VAC                     347 AMP at 115 VAC60 KW                    115 or 115230 VAC          257 AMP at 230 VAC65 KW                    115 or 115230 VAC          270 AMP at 230 VAC77 KW                    115 or 115230 VAC          335 AMP at 230 VAC80 KW                    115 or 115230 VAC          340 AMP at 230 VAC110KW                    115 or 115230 VAC          460 AMP at 230 VAC125KW                    115 or 115230 VAC          520 AMP at 230 VACFrequency                           60 Hertz Standard                                    50 Hertz available at reduced                                    ratingRPM                                 1800  60 Hertz                                    1500  50 HertzVoltage    Normal                          115 VAC           230 VAC    Maximum  No load               132 VAC           264 VAC    Minimum  Full load             108 VAC           216 VACExcitation Voltage        115 VAC output voltage                                    130    r   230V                1                      Internal Wiring Diagram                                     Internal Wiring Diagram                        3 and 44 KW 3 Wire                                         3 and 44 KW 2 Wire                            115230 Volt                                                   115 Volt                                AC                                                         AC                                           Field                                                  Field                                        Excitation                                              Excitation                                         Rectifier                                                                                                                                 Rectifier     Armature                                                         Armature                           AC                                                         AC230v                                     Internal Wiring Diagrams                                          6  125 KW                                        115v and 11523Ov                                                                  r       l15V                                                                                 1    115V115V4                2                                              AC       Field                                                     Excitation                                                     Rectifier           Armature                                         AC                                                                                            Field Excitation                                                                                            Rectifier Wiring                                                                                           Same as for 230v                                                        131                           GENERAL                    MODELS 3 KW  l25KW                         60 Hertz                         24 KW        94KW                   50 HertzNo Electrical Output1   Remove load from generator and verify                        no      output         directly            at     generator output leads with voltmeter2   Check for proper electrical connections                    Refer to Internal Wiring     diagrams     NOTE Gener ator armature slip rings and brush rigs are numbered     from inboard at the windings or flywheel end outward toward the     rear support bearing2A Residual Voltage Check     Disconnect field leads from                5VoitsAC                  25 Volts AC    25 Volts AC     bridge rectifier          Note     posi tion of leads on rec     t i fie r   to   and        to            Operate   the     generator and check AC out     put no load on generator                                    Hot                                  H     Measure       voltage   between     neutral       lead    and    hot     leads                              Hot        Neutral                        Neutral                                                 2 Wire                                                  Unit                          3  4 Wire Units                                          132          2wire unit         5 Volts AC Hot lead to neutral          3 and 4 wire unit   25 volts AC each hot lead to neutral                                                approximte     Residual Voltage checks OK You can assume the rotating armature     and brush rig are OK     The generator problem lies in the rec     tifier andor field coils     Residual voltage not present  Check brush rig and static capaci     tors   Check rotating armature resistance values and continuity     check found elsewhere in this manual3   Test operation of generator by bypassing bridge rectifier Apply     12 volts DC to field leads on bridge rectifier  to  and      to     Run generator no load     Measure voltage output at     generator leads  Generator output with 12 volts DC excitation to     the field coils should be 50 to 70 Volts AC If 50 to 70 volts AC     is produced this should indicate that the generator is OK and     that the bridge rectifier is defective4   If no voltage is produced check the static capacitors that it     is not shorted to ground If found faulty remove connection from     output terminal at brush rig and repeat Step 35   Flash Field Coils     units may lose their     residual    magnetism    1423Ov 11     from extended stor     age rough handling     during installation     or disassembly and                                        Internal Wiring Diagram     assembly for instal                                            Basic 4 Wire     lation   etc    re     quiring   the    field     coils to be excited     wi th 6 to 12 volts     DC to restore the                                                          612 Volt     magnetism    to    the                                                    DC Battery     generator    This is     done in the follow     ing manner     Stop the engine and     remove the generator     end bell cover This     will    expose    the     cooling fan brush                                     Armature     rig   assembly    and                                                         AC     rectifier      Check     internal wiring     refer    to   figure     The   positive         lead from the field     coils is connected                                      133     to the positive marked terminal on the rectifier and the negative      lead from the field coils is connected to the opposite     UNMARKED terminal on the rectifier Using jumpe leads with insu     lated alligator clips connect 6 to 12 volts DC battery positive     to the positive of the rectifier and negative to the UNMARKED ter     minal of the rectifier for approximately 10 seconds This should     restore magnetism to the stationary field coils   Be careful not     to connect DC voltage to the AC terminals on the rectifier as     this will damage the rectifier     Remove the alligator clip connections replace the end bell cover     and operate the generator and check AC output voltage6   Check for a short or open in the rotating armature or in the sta     tionary field coils                 ROTATING ARMATURE RESISTANCE VALUES     30  44KW 2wire      1 ohm or less slip ring to slip ring     30  44KW 3wire      1 ohm or less between slip rings 1 and 3     NOTE No continuity should be found between slip rings 1  2     and 2  3 on the 3wire unit  If so an internal short in the     armature winding exists Replace the armature     65 77 80 110       1 ohm or less between slip rings 1  3     and l25KW                and 2  4     NOTE  3 and 4wire units There should be no continuity found     between slip rings 1  2 2  3 and 3  4 If continuity is     found an internal short exists between these windings and the     armature should be replaced     NOTE All units There should be no continuity found between any     of the slip rings and the armatures central steel shaft If con     tinui ty is found the windings are shorted to the shaft and the     armature should be replaced     Rotating armature slip rings are numbered from inboard of the     generator flywheel end outward to the rear support bearing     When referring to 2 3 and 4wire units these are the number of     generator output leads being connected to the load You will find     on the 110 and 12 5KW units that there are 8 leads corning from     the brush rig and are combined for a total of 4 output leads The     number of wires can also be related to the number of slip rings on     the rotating armature                    FIELD COIL RESISTANCE    TOTAL          30  44KW            325 ohms               5          65 77  80KW       222 ohms               5          110  l25KW          142 ohms               5                                   134     NOTE There should be no continuity found between the field coils     and the generator body7   Replacement of Field Coils     Field coils are connected in series and the reisitance   value given     above in this text is the total of the four field        coils   To     determine the resistance value of one divide by four    Each field     coil has a mounting position on the generator housing     and cannot     be interchanged with another field coil     When installing a replacement field coil s the installer must     insure that the coil is correct for the mounting position in the     housing and will have the correct polarity when excited with 9      12 volts DC     The field coil shoes that hold the coil securely to the generator     housing are held in palce by bolts that must be properly tightened     when the coil and shoe are installed to the generator housing     When connecting the coils in series insure the butt connections     are good and secure and positioned away from rotating parts     To insure the field coils have been posi tioned properly in the     generator housing and will have the correct polarity           the     following test must be made before reassembly of the generator     1   Connect a 9  12 volt DC battery           to the leads off the coils that           would normally be connected to           the  and  connectors of           the bridge rectifier       These           leads   are    unmarked and   the           polarity in their connection to           the DC battery is not important           NOTE When removing the leads           from   the battery and recon           necting them to the bridge rec           tifier you should maintain the           same polar i ty as used in this           test plus lead to  on rec           tifier and negative to unmarked            connection on rectifier     2   Wi th a 3 inch iron bolt or its           equivalent place this bolt bet           ween each adjoining field coil                    912           shoe    It should be held in               Volt Battery DC           place by the magnetic attraction           set up between the coilshoes by           the 9  12 volts excitation of the field coils Should this           fail to happen between any of the four adjoining coilsshoes           then an incorrect coil is installed and must be removed and           the correct one installed otherwise the generator when           assembled will not produce proper voltage                                    135Low Voltage Output1   Verify voltage output at generator output leadswith load applied     to generator check no load condition also   Check voltage at the     load   Check rating for generator and verify load with amp probe     at output leads   Check all connections to insure they are clean     and secure Insure that the wire size carrying the voltage to the     load is of sufficient size so as not to produce a voltage drop     NOTE Beware of motor starting loads and the amperage draw placed     on the generator from these types of loads       Generally the     amperage draw of a motor at start up will be 3  5 times the     amperage needed when running2   Check generator with Hertz meter           No Load Hertz         61  615 51  515           No Load Voltage       131  135 Volts Generator Cold           No Load Voltage       126  130 Volts Generator Hot3   Test Bridge Rectifier     Bridge rectifier may be faulty and should be checked as follows     1   Set ohmmeter           scale   on      Rxl           DC  zero     the           meter                                                                    Point 5     2   Connect the                                  Rectifier Mounting Hole           lead    from    the           meter    to   Point           i4    with     the                                          Point 3            lead from the           meter momentarily           contact      points           iI 2 3 and           5    No deflec           tion      of    the           needle should           occur showing           infinite           resistance     3   Remove   the             lead from Point           4 and connect the       lead to Point 4 and with the            lead momentarily touch    Points iI i2 and 3   Points 1 and           3 should show an aohm    resistance 2 ohms   Point 2 shoudl           show a 40ohm resistance   5 ohms     4   Touch Point 5 with the  lead no deflection of the needle           should occur  IF THE RECTIFIER FAILS ANY OF THE ABOVE TESTS           IT IS DEFECTIVE AND SHOULD BE REPLACED                                      1364   Check field coil resistance as per specification given in A65   Insufficient cooling of the generator    Ambient air enter ing the     generator should not exceed 104F 40C     Operating efficeincy of the generator decreases as the ambient air     temperature entering the generator end bell increases above 104F     Generators in confined areas may require the ducting of cool     outside air into the compartment and directed toward the inlet at     the generator end bell6   Check condition of brushes for wear and contact with slip rings on     armature Insure brushes are not sticking in holdersHigh Voltage Output1   Verify voltage at generator output leads     No load voltage   126  130 volts Generator Hot                       61  616 Hertz                       51  515 Hertz2   Check internal wiring of generator leads attached to brush rig and     leads from brush rig feeding AC to br idge rectifier     Refer to     Internal wiring schematics    These internal wiring diagrams are     applicable to related 50 Hertz units as well                                     137YOUR NOTES    138         SERVICE BULLETINSThe following Bulletins contain supplementary andupdated information about various components andservice procedures which are important to theproper functioning of your eng ine and its suppor tsystemsYou should familiar ize yourself wi th the subjectsand make sure that you consult the  s whenever your engine requires serviceor overhaul                        139              SERVICE BULLETINDATE     61579                                                BULLETIN NUMBER 20MODEL    All enginesSUBJEC   Connecting Pressure Sensing Devices to Oil Galleries     Oil pressure sensing devices such as senders and switches mustnever be connected directly to any oil gallery of an eng ine      Thereason is simply that continued engine vibration causes fatigue of thefittings used to make such a connection   If these fittings fail theengine loses its oil pressure and very quickly seizes    Such pressure sensing devices must be bulkhead mounted and connected to the oil gallery using an appropr iate grade of lubr icatingoil hose  Any fittings used to connect the hose to the gallery mustbe of steel or malleable iron  Brass must not be used for this purpose                              J H WESTERBEKE CORP                               AVON INDUSTRIAL PARK AVON MASS 02322 617 5887700                                          CA8LE WESTCORP AVON TELEX 924444PIN             SERVICE BULLETINDATE    5674                                                   BULLETIN NUMBER 69MODEL   All Marine Generators and Marine EnginesSUBJECT Exhaust System Failures    When engine sea water is fed into an exhaust system so that thefull stream strikes a surface erosion may cause premature failures    Proper design of either a water jacketed or a water injectednwetn exhaust system to prevent this problem requires that the seawater inlet be positioned so that the enter ing stream of water doesnot strike a surface directly Also the velocity of the entering seawater stream should be as low as possible which is achieved by havinginlet fittings as big in diameter as possibleIn addition to the above design considerations it is usually advantageous to divide the sea water flow at the point of entry to theexhaust system so that only a portion of it enters the exhaust systemThe remainder is normally piped directly over the side     The  of the sea water flow to pass through the exhaust systemcan only be determined by tr ial and error    The goal is to  exhaust temperatures with the least amount of sea water                             J H WESTERBEKE CORP                              AIION INDUSTRIAL PARK AIION MASS 02322 617 5887700                                          CA8LE WESTCORP AIIONTELEX 924444PIN                  SERVICE BULLETINDATE       4483                                                BULLETIN NUMBER 82MODEL      AllSUBJECT Battery                       BATTERY AMPERE HOURS                                            VOLTAGEW7 WPD4                             6090                                                12 VDCWI0Two 3KW                          90125                                               12 VDCW13 4KW                             90125                                               12 VDCW21 77KW                           90125                                               12 VDCW27 llKW                            90125                                               12 VDCW33 125KW                          90125                                               12 VDCW30                                125150                                                12 VDCW40 WPDI015                      125150                                                12 VDCW50                                125150                                                12 VDCW52 15KW                          125150                                                12 VDCW58 20KW                          125150                                                12 VDCW60 WBO20KW                      150170                                                12 VDCW70 25KW                          170200                                                12 VDCW80 30KW                          170200                                                12 VDCWI00 32KW                         200 minimum                                            12 VDCW120 45KW                         200 minimum                                            12 VDCThe ampere hour range shown is minimum           There is no real maximum                              J H WESTERBEKE CORP                              AVON INDUSTRIAL PARI AVON MASS 02322 tSfT 5887700                                         CABLE WESTCORP AVON TELEX 124444PIN                 SERVICE BULLETINDATE       September 18 1975                                       BULLETIN NUMBER 87MODEL      All Mar ine EnginesSUBJECT Alternator Output Spli tterGENERAL DESCRIPTION    The spli tter is a solid state device whichallows two batteries to be recharged and brought to the same  from a single alternator as large as 120 amp and at the sametime isolates each battery so that discharg ing one will have noeffect on the other    Charging rates are in proportion to the batteries voltage state of discharge      This method precludes thenecessity and even the desirability of a rotary switch for selectingwhich battery is to be charged    It also assures that ships servicescannot drain the engine starting      Mount splitter on a metal surface other than the engine pre       ferably in an air stream if available Do not install near engine       exhaust system Install with cooling fins aligned vertically2     Be sure to use a wire size appropriate to the output of the asso       ciated alternator   In full power systems number 4 wire is recom       mended from the alternator to the spli tter and from the spli t ter       to the batteries3     Connect the alternator output terminal to the center splitter ter       minal4     Connect one splitter side terminal to one battery s5     Connect the other splitter side terminal to the other battery s6     When the splitter is installed both batteries will see a charging       voltage 810 volts less than usual This voltage can be regained       if desired by connecting the regulator wire directly to the       alternator output terminal instead of the regulator terminalTEST INFORMATION  When the engine is not running the side  should read the vol tage of the respective battery    Thecenter splitter should read zero voltageWith the engine running and alternator charging the side  should read the same voltage which should be the voltage ofthe regulator or somewhat less   The center splitter terminal shouldread 82 volts higher than the readings of the side terminals                                                                      Continued                                   J H WESTERBEKE CORP                                  AVON INDUSTRIAL PARK AVON MASS 02322 617 5887700                                             CA8LE WESTCORP AVON TELEX 1124444PIN                     SERVICE BULLETIN 87 Continued                       Alternator Output SplitterThis unit is sealed for maximum life and is not  SPLITTER In the event of failure batteries may be  from alternator by connecting either splitter terminal 1 or2 to terminal A bypassing the splitter itself   This should not bedone simultaneously for both batteries unless they are and willremain at the same voltage state of charge                        sPLITTER                          sTARTER                                        POWER DISC SW REGULATOR        Ntti                               IoB                                         STARTING                                         BATTERYS                                           POWER DISCONNECT                                     SWITCH                        PN206S4                              SHI P5                                                              SERVICE                          20           a                    LOtOS                               OsERVI CE                             BAiTERYSSEE NOTE        LTERNATOR DRVJG ti 2070 INOTE On Alternators which have an isolation diode between their output and regulator terminals such as the Motorola units used with mostWESTERBEKE engines the regulator wire should be removed from the REGterminal and reconnected to the OUTPUT terminal as shown    The diodein the splitter will provide an equivalent voltage drop                  SERVICE BULLETINDATE       April 28 1976                                        BULLETIN NUMBER 92MODEL      AllSUBJECT  Water Temperature and Oil Pressure GaugesGiven a presumably faulty gauge indication with the instrument panelenergized the first step is to check for 12 VDC between the ign Band neg B terminals of the gaugeAssuming there are 12 volts as required                leave the instrument panelenergized and perform the following steps       1   Disconnect the sender wire at the gauge and see if            the gauge reads zero the normal reading for this            situation       2   Connect the sender terminal at the gauge to ground            and see if the gauge reads full scale the normal            reading for this situationIf both of the above gauge tests are positive the gauge is undoubtedly OK and the problem lies either with the conductor from the senderto the gauge or with the senderIf either of the above gauge tests is negative the gauge is  and should be  the gauge is OK proceed as follows    Check the conductorfrom the sender to the sender terminal at the gauge for  that the engine block is connected to ground     Some startershave isolated ground terminals and if the battery is connected to thestarter both plus and minus the ground side will not necessarily beconnected to the blockIf the sender to gauge conductor is OK and the engine block                             isgrounded the sender is probably defective and should be replaced                                J H WESTERBEKE CORP                                AVON INDUSTRIAL PARK AVDN MASS 02322 617j 5887700                                           CABLE WESTCORP AVON TELEX 924444PIN                SERVICE BULLETINDATE     May 20 1980                                               BULLETIN NUMBER 110MODEL    AllSUBJECT Ammeter Wire SizesAmmeters may be installed in conjunction wi th any Westerbeke mar inediesel engine or diesel generator set   The range of the ammeter mustbe appropriate for the maximum output of the   the wire size for      the alternator output  the ammeter var ies wi th the total length of that circui tThe table below shows the maximum current that can be carried varioustotal distances by various wire sizes to and from source to load                              WIRE SIZE TABLE         Total Length                             MAXIMUM CURRENTSystem    of wire in Volts       feet        35       40            55           60            70           85    120  12        1 to   5     12       12            12             8             8            8     6  12        5 to 10      10       10              8            6             6            6     4  12       10 to 20       6         6             6            6             3            3     1  12       20 to 30       6         4             4            2             1            1     1  12       30 to 40       4         2             2            1             1            o     o   24       1 to   5     14       14            12           12            10           10      8  24        5 to 10      12       12            10           10              8            8     6  24       10 to 20      10         8             8           6              6            4     4  24       20 to 30       8         6             6            4             4            4     2  24       30 to 40       6         6             4            4             2            2     o  32        1 to   5     14       14            12           12            10           10      8  32       5 to 10       12       12            10           10              8            8     6  32      10 to 20       10         8             8            6             6            4     4  32       20 to 30       8         6             6            4             4            4     2  32       30 to 40       6         6             4            4             2            2     o                                J H WESTERBEKE CORP                                AIION INOUSTRIAL PARK A liON  MASS 02322 617 5887700                                            CABLE WESTCORP AVON TELEX 92 4444PIN                 SERVICE BULLETINDATE        May 6 1982                                             BULLETIN NUMBER 114MODEL       All Mar ine EnginesSUBJECT     Domestic Water Heater Installation             Using Westerbeke  There are two 78 hose connections at the end of the manifoldwhich provide a parallel flow of engine cooling water to and from theheater   These connections are part of the FLOWCONTROLLER which assures aflow of hot water through the heater at all times and yet  restriction of engine cooling water flow caused by the heater all simply and   Remove the returnbend which normally connects the 78 hosespuds on engines as shipped from the factory    Connect these spuds to theheater with 78 ID wire inserted hose    The spud marked out indicatesthe flow from the engine and the spud marked in indicates the flow returning to the engineHoses should rise continuously from their low point at the heater and tothe engine so that trapped air will rise naturally from the heater to theengine   If trapped air can rise to the heater then an air bleed petcockust be installed at the higher fitting at the heater for bleeding the airNhile filling the system Avoid loops in hose runs which will trap airIf any portion of the engine cooling water circuit to or from the heaterrises above the engines own pressure cap then the pressurized  tank must be installed in the circui t to be the highest pointThe tank kit Part Number is 24177  Install the remote expansion tank in aconvenient location such as a sail locker for ease of checking fresh watercoolant levelThe cap on the engine mounted expansion tankmanifold should not be openedonce the system is installed and filledThe hose connection from the heater to the remote expansion tank should berouted and supported so as to rise continuously from the heater to the tankenabling any air in the system to  kits are available for retrofit to late 1980 1981 and 1982Westerbeke mar ine eng ines which employ the twopass exhaust mani foldThe kit numbers are       Kit 32276 for engines whose exhaust manifold is on the left side of       the cylinder head W21 RD60 W27 RD80 W33       Kit 32274 for W13 and Kit 32275 for W52 and W58 engines                             whose       exhaust manifold is on the right side of the cylinder head                                   J H WESTERBEKE CORP                                   AVON INDUSTRIAL PARK AVON MASS 02322 67 5887700                                              CABLE WESTCORP AVON TELEX 112 4444PIN                              I                               I                                I                                 I                                  I                                   I                                    I                                     I                                      I                                      I                                          I                                          I                                              I                                              I                                                  I                                                   I                                                    I                                                     I                                                      I                                                       I                                                        I                                         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                       I                                                                                           IEMOVe flE1URN SEP                                                                                            ISJppLEO rn ellGl                SERVICE BULLETINDATE       August 14 1983                                        BULLETIN NUMBER 125MODEL      All Propulsion   Oil Pressure Switches When removing and installing oil pressure switches of the type illustrated below care should be taken to use the correct type socket specifically designed to correctly fit the metal circumference of these switches The correct socket can be acquired through wellknown tool manufac turers such as SnapOn New Britain Cromwell Proto and others The use of channel lock pliers visegrips or pipe wrenches is not advised in that they may cause damage to the seal between the metal body and the plastic center insert resulting in a leak andor switch failure       DUAL PRONG                                                          SINGLE PRONG                                J H WESTERBEKE CORP                                AVON INDUSTRIAL PARK AVON MASS 02322 tSf7J 5887700                                           CABLE WESTCORP AVON TELEX 112 PIN                                 SERVICE BULLETIN DATE                    August 25 1983                                                        BULLETIN NUMBER 127 MODEL                   30 44 77 110                    l25KW Generators SUBJECT                 Fuel ShutOff solenoid 23041  Adjustment   Should it be necessary to disturb the mounting of a fuel shutoff   solenoid for unit maintenance or repair or to replace a failed sole   noid the following procedure must be observed when replacing the   solenoid on the generator  with the solenoid deenergized and attached to its mounting bracket  44  Mounting Clamp the solenoid plunger should be manually bot  tomed in the solenoid and the throttle arm manually moved to the run  position so as to be within 010  020 inches of contacting the  throttle stop screw    The linkage connecting the throttle arm and  solenoid plunger should then be connected and adjusted to maintain  these positions when the solenoid is electr ically energ ized with the  preheat switch on the instrument panel                          NOTE On 44KW generators the solenoids position                          may have to be changed by moving it fore or aft                          under the mounting clamp that holds it against the                          air intake silencer to properly install and adjust                          the connecting linkage to the throttle arm   Figure                A                                                               MANUAL CHECK                                     Terina    Check the operation and bottoming of the fuel                                                         solenoid    plunger  manually  by   doing theTeal                                     Llli                         Aux                                                         following 1         SYNCHRO                    Terrlin1      1 Connect an ohmmeter across the  terminal                 STARr                                      and vacant auxiliary terminal on the back                                                           of the fuel solenoid   Figure A                                                                             2 Wi th the fuel solenoid in the stop posi        r                                             tion 01 ohms resistance should be found                                                            across these two terminals        I     I NTfRNL                                        I                                                         3 Manually moving the throttle arm into the        I     CC5wITcN                                  run position and bottoming the fuel sole        I                        I                                         Ohm                noid plunger a resistance of about 15 to        I                        I     Meter                30 ohms should them register on the meter                                                             indicating that the plunger has bottomed                                                            against the internal swi tch deenerg izing                                                             the pull in windings  Failure to insure manually that the fuel solenoid operates as  described above will result in the failure of the solenoid when  operated electrically The fuel solenoid may fail within 30 seconds  if  the plunger   does not bot tom when electr ically energ i zed                                                               J H WESTERBEKE CORP                                                              AVON INDUSTRIAL PARK AVON MASS 02322 5171 S887700                                                                         CABLE WESTCORP AVON TELEX 824444 PINWhen operated electrically by use of the preheat switch on theinstrument panel the fuel solenoid plunger should move smoothly andrapidly into the solenoid with no binding or hesitation drawing thethrottle arm into the run position 010  020 inches off the throttlestop screw as the plunger bottoms in the fuel solenoidNOTE The throttle arm stop screw is adj usted and wiredsealed atthe factory to allow the throttle arm to move to the proper no loadspeed and voltage for the generator Further adjustment should not beneeded    Tampering with this stop screw without proper  may affect the generators warranty              SERVICE BULLETINDATE     December 6 1983                                          BULLETIN NUMBER 133MODEL   W10Two W13 W2l W27 W30 W33 W40 W50                             W52 W58 W70         W80 W100 W120 All Related  Z inc Pencil  11885 A zinc pencil PN 11885 is located in the sea water cooling circuit of all primary heat echangers on the above models      The purpose of the zinc pencil is to sacrifice itself to electrolysis action taking place in the salt water cooling circuit         This zinc pencil should be per iodically checked by unscrewing it from its mounting boss on the exchanger   For the lcoation of the zinc on your model refer to the cooling system section of your parts manual    Replace the zinc pencil as inspection dictates   Refer to Illustration A Should material be flaking off the zinc it should be scraped clean or be replaced by a good solid zinc pencil If it appears that a lot of material has been flaking off the zinc then it is advised that the end cap of the exchanger be removed and the flaked material be cleaned from that area of the exchanger A new end cap gasket should be on hand in case it is needed when replacing the end cap Refer to Service Bulleting 84 when removing end caps made of rubber                             ILLUSTRATION A           ZINC 11885             REPLACE                         CLEANREPLACE                               J H WESTERBEKE CORP                               AIION INDUSTRIAL PARK AIION MASS 02321 8171 5887700                                           CABLE WESTCORP AIION TELEX 824444PIN              SERVICE BULLETINDATE     December 28 1983                                       BULLETIN NUMBER 134MODEL    3KW 44KW 77KW llKW  l2sKW Related to 50 Hertz UnitsSUBJECT Fuel Solenoid  PN 23041 Fuel solenoid adjustment and operation as outlined in Service Bulletin 127 should be verified as part of the prestartup inspection commissioning of the generator During installation the adjustment of the fuel solenoid may be affected due to handling and positioning of the unit in the vessels hull Periodic inspection of the solenoids operation is also recommended at the initial 50hour servicing and every 200 hours thereafter              NOTE The flexible rubber boot cover ing                    the solenoid must not be removed                    as this helps protect the plunger                    from   contaminants  and  aids  in                    withdrawal of the plunger when the                    solenoid is deenergized                    periodically examine the plunger to                    ensure that it is clean Generally                    no lubrication is needed on this                    plunger                    Per iodic lubr ication is needed on                    the ball joint connection between                    the plunger and the throttle arm                              J H WESTERBEKE CORP                              AIION INDUSTRIAL PARK AIION MASS 02322 571 5887700                                          CABLE WESTCORP AIIONTELEX 92    PIN              SERVICE BULLETINDATE      April 3 1984                                           BULLETIN NUMBER 137MODEL     3KW 4 4KW 7 7KW 8KW llKW 12 5KW Also related 50 Her tz           UnitsSUBJECT   Cooling Fan Secur ing Nut Generator units must have proper air circulation while running to pro vide for combustion air for use by the engine and for cooling the generator unit minimum 250 CFM all units through l25KW for gener ator end cooling The fan on the back end of the above model generators plays an impor tant part in moving air through the generator for cooling In instal lations where surrounding air is limited outside air should be ducted to the area of the screened end bell inlet to provide this needed air for cooling and combustion as well The secur i ty of the generator fan hold down nut should be checked at installation commissioning at the initial 50hour servicing of the generator unit and periodically thereafter 200300 hours FIGURE A                 FLAT                 WASHER                    Cooling Fan                    Securing Nut                    FIGURE A                        Securing Nut Torque  25 lbft                                     over                                 J H WESTERBEKE CORP                                AIION INDUSTRIAL PARK AIION MASS 02322 6171 5887700                                            CABLE WESTCORP AIIONTELEX 1124444PINThe cooling fan securing nut should be tight enough so that when forceis applied to rotate the fan by pushing on the outer edge and bladeswith the palm of your hand protect the hand with a cloth or gloveyou should be able to turn the generator and engine without the fanslipping on the shaft     If properly torqued and fan still slipsreplace the  of generator cooling air through the generator must beavoided  The generator compartment ventilation must be sufficient toprevent generator air  that the screened endbell inlet and the screened dischargeslots at the flywheel are not obstructed preventing good air circulation through the generator while it is running

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