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Westerbeke Diesel 12d Two Parts Manual



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     TECHNICAL MANUAL


                WESTERBEKE



                  20B TWO

                  30B THREE



              MARINE DIESEL

           PROPULSION ENGINE




                 Publication #037600

                     Edition One

                      April 1990




j   r~ 'WESTERBEKE
       J   WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
       I   150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
                                            SAFETY PRECAUTIONS

The following symbols appear in this manual to call attention          Be sure the unit and its surroundings are well-ventilated.
to and emphasize conditions potentially dangerous to the
operator.
                                                                   ·   Use Extreme Care When Handling Engine Fuel
                                                                       (A constant danger of explosion or fire exists)
                       IWARNINGI
                                                                       Do not fill fuel tank(s) while the engine is running.
The above symbol is used in the manual to warn of possible
                                                                       Do not smoke or use an open flame near the engine or the
serious personal injury or loss of life.                               fuel tank.


                         CAUTION
                                                                   ·   Do Not Alter or Modjfy the Fuel System
The above symbol is used in the manual to caution personnel            Be sure all fuel supplies have a positive shut-off valve.
of possible damage to equipment.
                                                                       Be certain fuel line fittings are adequately tightened and
Read the manual carefully and thoroughly before attempting             free of leaks.
to operate the equipment. Know when dangerous conditions
can exist and take necessary precautions to protect personnel          Make sure a fire extinguisher is installed nearby and is
and equipment.                                                         properly maintained. Be familiar with its proper use. Ex-
                                                                       tinguishers rated ABC by the NFPA are appropriate for all
Fuels, exhaust gases, batteries, electrical equipment, and             applications encountered in this environment.
moving and hot parts are potential hazards that could result in
serious personal injury or death. Follow recommended proce-
dures carefully.                                                   ·   Use Extreme Care When Servicing Batterjes

Always operate bilge blowers for at least five minutes before          Wear rubber gloves, a rubber apron, and eye protection
starting a gasoline-fueled engine; ensure no gasoline fumes are        when servicing batteries.
present before starting.
                                                                       Lead acid batteries emit hydrogen, a highly-explosive gas,
                                                                       which can be ignited by electrical arcing or by a lighted
 ·   Prevent Electric Shock                                            cigarette, cigar, or pipe. Do not smoke or allow an open
                                                                       flame near the battery being serviced. Shut off all electrical
     Shut off electric power before accessing electrical equip-        equipment in the vicinity to prevent electrical arcing
     ment.                                                             during servicing.

     Use insulated mats whenever working on electrical equip-
     ment.
                                                                   ·   Avoid Moving Parts
     Make sure your clothing is dry, not damp (particularly
     shoes), and keep your skin surfaces dry when handling             Do not service the unit while the unit is running; if a
     electrical equipment.                                             situation arises in which it is absolutely necessary to make
                                                                       operating adjustments, use extreme care to avoid moving
     Remove wristwatch and jewelry when working on electri-            parts and hot exhaust system components.
     cal equipment.
                                                                       Do not wear loose clothing or jewelry when servicing
     Do not connect utility shore power to vessel's AC circuits,       equipment; avoid wearing loose jackets, shirts or sleeves,
     except through a ship-to-shore double-throw transfer              rings, necklaces, or bracelets that might be caught in
     switch. Damage to vessel's AC generator may result if this        moving parts.
     is not done.
                                                                       Make sure all attaching hardware is properly tightened.
     Be extremely careful when working on electrical com-              Keep protective shields and guards in their respective
     ponents. High voltage can cause injury or death.                  place at all times.

                                                                       Do not check fluid levels or the drive-belt's tension while
                                                                       the unit is operating.
 ·   Exhaust Gases Are Toxjc
                                                                       Do not work on the equipment when mentally or physically
     Ensure that the exhaust system is adequate to expel gases         incapacitated by fatigue.
     discharged from the engine. Check exhaust system
     regularly for leaks and make sure the exhaust manifolds
     are securely attached and no warping exists.
                                                IMPORTANT

                                   PRODUCT SOFTWARE DISCLAIMER


Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, parts lists and parts price lists, and other information, instructions and specifications provided from
sources other than Westerbeke, is not within Westerbeke's control and; accordingly, is provided to
Westerbeke customers only as a courtesy and service. Westerbeke cannot be responsible for the content
of such software, makes no warranties or representations with respect thereto, including the accuracy,
timeliness or completeness thereof, and will in no event be liable for any type of damages or injury
incurred in connection with, or arising out of, the furnishing or use of such software.

For example, components and subassemblies incorporated in Westerbeke's products and supplied by
others (such as engine blocks, fuel systems and components, transmissions, electrical components, pumps
and other products) are generally supported by their manufacturers with their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software may
be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of which Wester-
beke rarely has notice in advance, are frequently not reflected in the supplier's software until after such
changes take place.

Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software and the unavoidable existence of earlier, non-current, Westerbeke software editions in the field.
Additionally, most Westerbeke products include customer-requested special features that frequently do not
include complete documentation.

In summation, product software provided with Westerbeke products, whether from Westerbeke or other
suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective
product. It not only makes good sense but is imperative that appropriate representatives of Westerbeke or
the supplier in question be consulted to determine the accuracy and currency of the product software being
consulted by the customer.




                                                       1                                 Westerbeke Engines
                                            TABLE OF CONTENTS


                     Section ......................................................................... Page

                     20B TWO GENERAL SPECIFICATIONS ............................9

                     20B TWO SYSTEM SPECIFICATIONS ............................10

                     30B THREE GENERAL SPECIFICATIONS ...................... 12

                     30B THREE SYSTEM SPECIFICATIONS ......................... 13

                     20BTWO AND 30B THREE
                     ENGINE SERVICE SPECIFICATIONS .............................15

                     ENGINE OVERHAUL ........................................................23

                     PREPARATIONS FOR OVERHAUL. .................................24

                     ENGINE DISASSEMBLY ...................................................25

                     CYLINDER HEAD CONSTRUCTION
                     AND SERViCiNG ...............................................................26

                     VALVES AND VALVE SPRINGS .......................................30

                     VALVE CLEARANCE ADJUSTMENT ...............................33

                     GEAR CASE AND OIL PUMP ...........................................34

                     TIMING GEARS .................................................................38

                     CAMSHAFTS (Valve and Pump) ......................................41

                     PISTON AND CONNECTING ROD ..................................45

                     CRANKSHAFT ...................................................................50

                     CYLINDER BLOCK ...........................................................54

                     FUEL INJECTION PUMP ..................................................56

                     INJECTION NOZZLE ........................................................59

                     GOVERNOR SYSTEM ......................................................62

                     GOVERNOR ......................................................................65

                     GLOW PLUG .....................................................................66

                     COOLING SYSTEM ..........................................................67




Westerbeke Engines                                            2
                        TABLE OF CONTENTS
                           (CONTINUED)


STARTER .......................................................................... 71

ALTERNATOR .................................................................. 78

ENGINE TROUBLESHOOTING ....................................... 85

MARINE TRANSMISSIONS ............................................. 88

TABLE OF STANDARD
HARDWARE TIGHTENING TORQUES ........................... 89

SPARE PARTS .................................................................. 91

INDEX ............................................................................... 93




                                          3                                                Westerbeke Engines
             ...
T9PEngine Oil




                                           45° Exhaust Elbow




                                                         G:ear Shift Lever


50 Amp DC
Alternator




                                                          Gea~ As~~mbly
Adjustable Engine
Isolator                            Battery Ground Connection




   Westerbeke Diesel Engines   ·4
                                     ,FreSh W_ Fill CaP~


                  !VI ll'ilake Silenger                 ~


           Zinc I'\mJUt:i~

                                                                      Fuellnjeciion~.
                                                                      Pump
                                                                         -   .   -

-Gear Dipstick
 and Oil Filler




_~~~~e Engine Isolator




                                                    5       Westerbeke Engines
                                                .           ..
                                           fresh Water Fill Cap




                                                                                Ge~r   Shift l:,ever

:50 Amp
~t~rnator




AdJU;;'LQU',\;;
:Engine
Isolator          Starter with Solenoid'
                          .      -                                DC .Battery Ground Connection




             Westerbeke Engines                     6
                                  .Air Intake Silel'!cer       Fuel Injection Pump          .~reh~t Solenord

                                                                                                 ThrotHe and
                                                                                     /           Shut-Off       .~
                                                                                                 Connections
20 Amp DC Circuit


    Zinc Anode




                                                                                                 Oil Pressure
                                                                                             /SW~l!

Gear Dipstick
and Oil Filler




                 ...

Adjustable Engine
Isolator
                                                                                               . Lube Oil
             Fresh Water Block Drain Plug                                                      . Drain Ho~~~




                                                           7                         Westerbeke Engines
                                            UNIT 1.0. PLATES




       ·       MODEL             SPEC         .      AVO .. MA USA             SER.NO..



                                       20B TWO UNIT 1.0. PLATE




       ·       MODEL             SPEC                AVO" MA USA                SER.NO..



                                       30B THREE UNIT 1.0. PLATE



The unit 1.0. plate is attached to the exhaust manifold of the engine. These illustrations are provided so
that the owner/operator may transcribe the specifications and serial number from the 1.0. plate on the
engine to one of the illustrations above. This will allow for easy reference when seeking parts, service or
technical needs.




Westerbeke Engines                                    8
                                 20B TWO MARINE DIESEL ENGINE
                                    GENERAL SPECIFICATIONS


Engine Type                                    Diesel, four-cycle, two-cylinder, fresh water-cooled.
                                               Vertical, in-line, overhead valve mechanism
                                               (18 hp at 3600 rpm maximum).

Governor                                       Mechanical, centrifugal weight type.

Combustion Chamber                             Swirl type.

Bore & Stroke                                  2.99 x 2.76 inches (76 x 70 mm)

Piston Displacement                            38.75 cubic inches (0.635 liters)

Firing Order                                   1-2

Direction of Rotation                          Clockwise, when viewed from the front.

Maximum Torque (at 2200 rpm)                   30 Ib-ft (4.15 kg-m)

Compression Ratio                              23:1

Compression Pressure                           398 psi (28 kg/cm2 ) at 280 rpm

Valve Timing                                   Intake Opens BTDC
                                               Intake Closes ABDC

                                                  Exhaust Opens BBDC
                                                  Exhaust Closes ATDC

Valve Seat Angle                                  Intake & Exhaust 45°

Valve Clearance                                   Intake 0.010 inches (0.25 mm)
(engine cold)                                     Exhaust 0.010 inches (0.25 mm)

Dimensions                                     Length: 25.87 inches (657.10 mm)
                                               Width: 16.00 inches (406.40 mm)
                                               Height: 19.75 inches (501.65 mm)

Inclination                                    Continuous 15°
                                               Temporary 25° (not to exceed 30 min.)

Weight                                            228 Ibs (103.4 kgs)

Fuel Consumption                               0.7 U.S. gph (2.65lph) running at 2500 rpm
(propeller allowing rated rpm)                 (approximate).

Idle Speed                                        1000 -1200 rpm

Cruise rpm                                        2500 - 3000 rpm




                                              9                                Westerbeke Engines
                       20B TWO MARINE DIESEL SYSTEM SPECIFICATIONS


FUEL SYSTEM

  General                                    Open flow - totally self-bleeding, manual priming.

  Fuel                                       No.2 Diesel (cetane # 45 or better).

   Injector Pump                             In-line plunger type (Bosch type).

   Engine Timing                             19° ±1° BTDC
   (spill timing)                            Static

   Injector Pressure                         1991 psi (140 kg/cm2)

   Nozzle                                    Throttle type.

   Lift Pump                                 12-volt DC; lift capacity 5 ft (1.5 m)
   PN 037818

   Air cleaner                               Plastic screen type - cleanable.

   Air Flow (engine combustion)              40.6 cfm (1.1 cmm)


COOLING SYSTEM

   General                                   Fresh water-cooled block,
                                             thermostatically-controlled
                                             with heat exchanger.

   Operating Temperature                     170 - 190° F (77 - 88° C)

   Fresh Water Pump                          Centrifugal type, metal impeller, belt-driven.
   PN 037015

   Raw Water Pump                            Positive displacement, rubber impeller,
   PN 033636                                 mechanically-driven.

   Raw Water Flow, at 3600 rpm               11.1 U.S. gpm (42 Ipm) approximate.
   (measured before discharging
   into exhaust elbow)

   System Capacity (fresh water)·            2.9 qts (2.7 liters)


LUBRICATION SYSTEM

   General                                   Pressure type by Trochoid pump,
                                             gear-driven, with external pressure relief valve.




Westerbeke Engines                          10
                       208 TWO MARINE DIESEL SYSTEM SPECIFICATIONS


  Oil Filter                                   Full flow, paper element, spin-on type.
  PN 036918

  Sump Capacity (including filter)             3.0 U.S. qts (2.9 liters)

  Operating Oil Pressure (engine hot)          15 - 45 psi (1.0 - 3.1 kg/cm2 )

  Oil Grade                                   API SPECIFICATION OF CF OR CG-4


ELECTRICAL SYSTEM

  Starting Battery                             12-volt, 26 A-H, (-) negative ground
                                               (recommended) (35 A-H in cold areas)

  Battery Capacity                             90 -125 (ampere-hours)

  Starter                                      12-volt, 1.2 t
               [SRE I)



      NOTE: API SPECIFICATION OF CF OR CG-4 IN ACCORDANCE WITH THE THERMAL
               ENVIRONMENT (SEE TABLE).




       Oil Pressure Relief Valve
       Spring/Plunger Type                       Oil Pump
                                                 Crankshaft Driven




                                           Oil Pump and Oil Filter




                                                         21                                           Westerbeke Engines
                     NOTES




Westerbeke Engines     22
                         ENGINE OVERHAUL


Section ..........................................................................Page

PREPARATIONS FOR OVERHAUL ................................. 24

ENGINE DISASSEMBLY .................................................. 25

CYUNDER HEAD CONSTRUCTION
AND SERVICING .............................................................. 26

VALVES AND VALVE SPRINGS ....................................... 30

VALVE CLEARANCE ADJUSTMENT ............................... 33

GEAR CASE AND OIL PUMP .......................................... 34

TIMING GEARS ................................................................ 38

CAMSHAFTS (Valve and Pump) ...................................... 41

PISTON AND CONNECTING ROD ................................. 45

CRANKSHAFT .................................................................. 50

CYUNDER BLOCK ........................................................... 54

FUEL INJECTION PUMP ................................................. 56

INJECTION NOZZLE ....................................................... 59

GOVERNOR SYSTEM ...................................................... 62

GOVERNOR ..................................................................... 65

GLOW PLUG .................................................................... 66

COOUNG SySTEM .......................................................... 67

STARTER .......................................................................... 71

ALTERNATOR .................................................................. 78




                                        23                                               Westerbeke Engines
                                                    PREPARATIONS FOR OVERHAUL


1. Shut off and disconnect all fuel lines, raw water and exhaust connections.

2. Unbolt the engine and carefully move it to the overhaul shop.

3. Once at the overhaul shop, drain all lubricating oil and coolant from the engine and exchanger system.

4. Clean the engine's exterior of all dirt and oil deposits.




    ~1\1\'\llllllllllIIIIIHl\iI!I"H'iH::~;H~r
     1\I,j' \' i'i 'i";',' "
                      I' .
                             l
     i,'     \111.1   :;"        '.         ..,,'
      .
           :.*'::
               I:
                                       .-
                                       .. "




                                 Oil Sump Drain                           Heat Exchanger Drains




Westerbeke Engines                                             24
                                          ENGINE DISASSEMBLY


This section describes the disassembly of the engine when performing a complete overhaul of the unit. The
procedures which follow include the disassembly of subassemblies, inspection of their components parts,
repair or replacement of these parts (if necessary), and the reassembly of the subassemblies.


Removal of External Parts and Subassemblies

1. Remove the exhaust manifold and related hoses as a unit. Disassemble and inspect these parts.

2. Remove the heat exchanger and its related hoses and mounts from the front of the engine. Have the heat
   exchanger cleaned and tested at a local automotive radiator repair shop or replace it if necessary.

3. Remove the starter motor and circuit breaker assembly. Examine the starter and have it repaired or
   replaced if necessary.

4. Remove the intake silencer, fuel lines, fuel pump and fuel filter with bracket assembly from its attachment
   on the bell housing.

5. Remove the high pressure injector lines from between the injection pump and injectors. Note the location
   of each line.

6. Remove the transmission bell housing assembly.

7. Remove the raw water pump from its mounting point on the engine.

8. Remove the alternator, the fresh water pump's drive belt, and the alternator's mounting bracket.

9. Remove the fresh water circulating pump's pulley and remove the fresh water pump.

10. Remove the engine's backplate.

11 Remove the water temperature switch and the water temperature sender.

12. Remove the oil pressure switch, the oil pressure sender, and the oil filter.

13. Remove the thermostat housing and the thermostat.

14. Remove the crankshaft pulley from the crankshaft.

The basic engine assembly is now ready for disassembly, cleaning, inspection, and repair if necessary.




                                                      25                               Westerbeke Engines
                      CYLINDER HEAD CONSTRUCTION AND SERVICING




                ~
           ~~~
            @
      .·   ~~
                                                                         ~--I'




                                                                        ·
                                                                        .F----J.
                                     -=---ej)




                Cylinder head a cross section




                               CYLINDER HEAD COMPONENT PARTS

             1. Cylinder head.                                6. Water outlet fitting.
             2. Valve guide.                                  7. Cylinder head gasket.
             3. Cylinder head bolt (main bolt).               8. Mouth piece.
             4. Cylinder head bolt (sub-bolt).                9. Thermostat.
             5. Seat ring (3600 rpm specification engine).   10. Thermostat fitting.




Westerbeke Engines                               26
Cylinder Head Removal

1. Remove the high pressure injection line assembly.

                                                 CAUTION

      When disconnecting each injection line from the injection pump side delivery valve holder,
      grasp the holder with a wrench to prevent it from loosening. After removing the pipe assembly,
      plug the nozzle holders and delivery valve holders to prevent intrusion of dust.

2. Disconnect the glow plug lead wire.

3. Disconnect the air breather hose.

4. Remove the rocker cover.

5. Remove the rocker shaft assembly.

6. Loosen the cylinder head mounting bolts in the
   numerical order as illustrated and remove the
   cylinder head assembly (including the intake and
   exhaust manifold).                                     Sequence for Loosening Cylinder Head Bolts    ·.·20B'

7. Remove the cylinder head gasket. Clean the
   cylinder head and the cylinder block surface from
   which the gasket has been removed.

8. Remove the injector assemblies and glow plugs
   from the cylinder head.

9. Remove the intake manifold from the cylinder head.

10. Remove the valve retainers, valve springs and
    valves from the cylinder head.
                                                          Sequence for Loosening Cylinder Head Bolts




                                                 CAUTION

      When removing each valve retainer, depress the retainer against the valve spring and remove
      the retainer lock. Identify each valve by putting a mark indicating the number of the cylinder
      from which the valve is removed.

11. Remove the valve stem seals.




                                                     27                                      Westerbeke Engines
Cylinder Head Inspection and Repair


                                                              Check cylinder head surface for warpage between
                 Check guide for ware and damage.             bolt holes: within O.05mm




             Check for valve contact,                                                     Check for cracks, damage,
             wear, damage, and sink of seat face.                                         water leak and remove oil, sludge,
                                                                                          sealant deposit, carbon deposit.




Valve Guide Replacement                                                                    (\625)
                                                                                          (\612)
If a valve guide is found defective. replace it.
                                                                                                            (\66.6

1. Remove the valve guide by pressing at its upper                                           i
   end and pull it out to the valve seat side.                                               I
                                                                                                        I

                                                                                                    -
2. Install the valve guide by press fitting the guide                            '--
                                                                                             I      -
   from the upper side ofthe cylinder head to a height
   of 14 ± 0.5 mm from the valve spring seat face.
                                                                             I
                                                                                             I



                                                                                             I
                                                                                                        (
                                                              Press·fitting Valve Guide




Westerbeke Engines                                       28
Valve Seat Repair
                                                                                                     Valve sinkage

If a valve seat is found defective, reface it or
replace the cylinder head.


                    Sinkage of valve                                                                           Interface
                                                                                                               and wear
         Standard                      Service limit

          0.5 mm                         1.5 mm


                                                                    Checking Valve Sinkage

                        CAUTION

      When checking valve sinkage, the valve guide
      must be in normal condition. Resurface the
      valve seat so that it contacts the mid-portion of
      the valve face.




                                                                    Resurfacing Valve Seat   (Common to intake and exhaust valves)

Valve Seat Installation

Installation of the cylinder head is in the reverse
order of removal. Pay attention to the following.

1. Renew the cylinder head gasket. No application
   of sealant is necessary. On the upper front of the
   gasket is engine model to which that gasket is
   applicable. Be careful not to confuse it with a
   gasket for another engine model.

2. Tighten the cylinder head bolts in the numerical                 Sequence for Tightening Cylinder Head Bolts
   order shown in the figure at right, going through
   that order two or three times. Tighten each bolt a
   little at a time until all are tightened to the specified
   torque.

3. When connecting the injector line assembly,
   loosen the pipe clamp. When tightening the nut
   at each end of the pipe, grip the nozzle holder or
   delivery valve holder with a wrench to prevent it
   from being turned together with the nut. Also, take
   care not to allow dust to enter the fuel line.

                                                                    Sequence for Tightening Cylinder Head Bolts




                                                               29                                     Westerbeke Engines
                                 VALVES AND VALVE SPRINGS




                                ~=---':~'
                                   ~--(2)




                                                              ..----@




                              VALVE SYSTEM COMPONENT PARTS

                     1. Valve stem cap.               4. Valve stem seal.
                     2. Retainer lock.                5. Valve spring.
                     3. Valve spring retainer.        6. Valve.




Westerbeke Engines                               30
Valve Removal

1. Dismount the cylinder head assembly.

2. Depress the valve retainer (to compress the valve spring) and remove the retainer lock.

3. Remove the valve.


Valve Inspection and Repair

If any parts are found defective, repair or replace them.



                                                                 Q------           Wear and damage
                                                                                   (Without for agricultural)

                                                                 ~~
                                                                 @



                                                                                    Dents and wear



                                                                  I - - - - - R i d g e and damage

                                          Margin




Inspection of Valve and Valve Spring




                      Valve fatigue and damage

   Inspection item           Standard            Service limit             valve spring te5ter
  Free length (Dim)            40.5                  -I

   Load (kg/ mm)             5.94/35.5             -15%
     Squareness                  2'                   3'
     Margin (mm)                1.0                  0.5




                                                                      31                                        Westerbeke Engines
1. If the valve face is found worn down, resurface it
    with a valve refacer. If the margin of the resur-
    faced valve exceeds the service limit, replace the
    valve.                                                                             I---
                                                                                       f--

2. If the valve stem end has been indented by wear,
  flatten it with an oil stone.
                                                                                  ./          "         ~Margin
                                                                       , - -- /~------"'..."            t-
                                                                      45" \ / /                         ·
                                                                         /                              I


                                                               Inspecting Valve




Valve and Valve Spring Installation

1. Install the valves and valve springs, referring to notes shown in the figure below.

2. Mount the cylinder head assembly.

3. Adjust the valve clearances.

                                                    CAUTION

      Be careful not to damage the spring and stem seal by excessively compressing the spring
      when installing the valve spring.



                                                                     With retainer
                                                                     depressed to compress
                                                                     spring. install
            Press this surface                                       retainer lock.




                       Driving in             Installing spring                        Installing spring retainer
                       stem seal

Installation of Valve Spring




Westerbeke Engines                                        32
                                    VALVE CLEARANCE ADJUSTMENT


Valve Clearance Adjustment

Cylinder head bolts lIl.USt. be retightened before adjust-
ing the valve clearance. When retightening the cylinder
head bolts, draw out coolant, loosen the bolts slightly,
and then retighten the bolts to the specified torque in the                                       4
numerical order illustrated at right.                                                         o
Tightening torque:    M10 bolt     54.2 - 61.5 Ib-ft
                                                                                      0   2           0    1

                                   (7.5 - 8.5 kg-m)

                      M8 bolt      10.8 - 15.9 Ib-ft          Cylinder Head Bolt Tightening Sequence                   208
                                   (2.0 - 3.0 kg-m)

The rocker assembly (the rocker arms, shaft, and stays)
is to be kept removed when the cylinder head bolts are
retightened.

Rocker stay tightening torque: M8 bolt 10.8 - 15.9 Ib-ft
                                       (1.5 - 2.2 kg-m)

1. Set the cylinder to be adjusted to the top dead center
   of the compression stroke.

    Valve clearance: 0.0098 in. (0.25 mm) (cold) for          Cylinder Head Bolt Tightening Sequence                   308
    both intake and exhaust valves.
                                                                      ADJUST EXH.\USl' V.UVES TO 0.012 INCH&'!
                                                                                                     (11.:111 ~ .. )
2. The top dead center of the compression stroke can
                                                                      ADJUST INTAKE VALVES TO 0.010 I:SCHES
   be obtained by aligning the T.O.C. (Top Oead Center)                                           (0.2~ MM)

   mark (notch) on the crankshaft pulley with the mark
   on the gear case.

3. First align the T.O.C. mark for the No. 1 cylinder.
   Confirm that the valves do not move up and down
   when the crankshaft is turned about 20° in the normal
   direction of rotation and in the reverse direction.

4. When setting the top dead center for the 3 cylinder
   engine, perform as follows:

  a. Two Cylinder Engine From T.O.C. for the NO.1
     cylinder, turn the crankshaft 180° clockwise and the
     NO.2 cylinder is set to T.O.C.

   b. Three Cylinder Engine From the T.O.C. for the No.
      1 cylinder, turn the crankshaft 240° clockwise to set
      the No.3 cylinder T.O.C. Further, turn the
      crankshaft 240° clockwise, and the No. 2 cylinder
      is set to T.O.C.
                                                              Injection Timing Mark




                                                       33                                         Westerbeke Engines
                                     GEAR CASE AND OIL PUMP




                                                                    (Ii)




                                                                                  '!})




                                    GEAR CASE COMPONENT PARTS

             1.   Bushings.           5.   Relief plunger.         9. Oil pump housing.
             2.   Plug.               6.   Relief spring.         10. Gear case gasket.
             3.   Gear case.          7.   Oil pump inner gear.   11. High-pressure pump gear housing.
             4.   Front oil seal.     8.   Oil pump outer gear.   12. Housing gasket.




Westerbeke Engines                                   34
Gear Case and Oil Pump Removal and Inspection

1. Remove the crankshaft pulley.

2. Remove the fan and fan belt.

3. Remove the tie-rod cover from the side face of the injection pump.

4. Remove the tie rod and tie rod spring. Be careful not to let the spring fall into the case.

5. Remove the governor cover assembly.

6. Remove the water pump assembly.

7. Remove the alternator.

8. Remove the pump housing.

9. Remove the gear case assembly.


Check the removed parts. If any parts are found defective, repair or replace them.




                                    Cracks and damage




                  Wear and damage




                  0~
                   ~\      @


        © r[J)
                  /
                    [(({W f7lr\                                               Wear, damage, and clearance




        S,rio,   f",~
       Smooth movement
                        I ~

                                        I
                                         @
                                  Seal surface interference
                                                                                   Thoroughly clean oil line.



Inspection of Gear Case and Oil Pump




                                                              35                           Westerbeke Engines
Front Oil Seal Replacement

1. Remove the front oil seal.

2. Press-fit the new front oil seal.

                                                   CAUTION

                  Apply a thin coat of engine oil to the circumference and lip of the oil seal.


Governor Shaft Bushings' Replacement

1. Remove the expansion plug and draw the bush-
   ings out.

2. Press-fit the new bushings into positions shown in
   the figure at right.


                                                                 To be flush with                        To be in contact
                                                                 this plane                              with bottom

                                                            Press· fitting Governor Shaft Bushing




Governor System Inspection
                                                                                            Check springs
                                                                                            for fatigue.
Check the governor system parts. If any parts are
found defective, repair or replace them.




                                                                                     Check shaft
                                                                                     for flaws.

                                                                                             Check sliding sleeve
                                                                                             joint for wear and damage.




                                                            Check weight for wear and damage.




Westerbeke Engines                                     36
Governor Levers' Disassembly and Reassembly
                                                                           Expansion plug     Grooved pin    Projection
1. Removal of the shaft.                                                                                     approx.2mm


  a. Remove the expansion plug, taking care not to
     scratch the gear case.

  b. Pull out the grooved pin.
                                                                                                            Section A-A
2. Installation of the shaft.                                                 Gear case

  a. Install the shaft in the reverse order of removal.           Installing Governor Shaft

  b. After installing the shaft, press-fit the expansion plug
     into the shaft hole in the gear case.


Gear Case Installation


                                         Tightening torque
                                            O.8-1.0kg.m



                                                 ~


 Tightening torque:
 4-5kg.m




                                Taper plug tightening
                                torque: 1.5-2.2kg.m



   Sealant: HERMESEA
   H1 or THREE-BOND 1344



Gear Case Assembly




                                                             37                                Westerbeke Engines
                                    TIMING GEARS




            "'4




                                            Cj)




                          TIMING GEAR COMPONENT PARTS

                     1. Crankshaft gear.    3. Camshaft gear.
                     2. Idle gear.          4. Injection pump camshaft gear.




Westerbeke Engines                         38
Timing Gears' Removal

1. Pry the snap ring out and remove the idle gear.

2. Remove the valve camshaft and injection pump cam-
   shaft on which the respective gears are press-fitted.
   Remove the gears from the shafts.

3. Remove the crankshaft. Remove the gear from the
   crankshaft.




Timing Gears' Inspection

                                                                                                            Injection pump
Check the removed gears. If any gear is found defective,                                                    camshaft gear
replace it.                                                                                    -r....-,,,.: _ /      Check tooth faces
                                                                                                                     and end surfaces
                                                                                                                     for wear and damage.

                                   Idle gear bushing

              Description            Standard value    Service limit

         Clearance between bush·
         ing and shaft              0.03 - 0.07            0.2




                       Backlash between gears in mesh

              Description            Standard value    Service limit

           Crankshaft-Idle

            Idle-Camshaft           0.01 - 0.14            0.3
         Idle-Fuel pump Gear


                                                                                                                       /
                                                                                                                   Valve camshaft gear
                                                                                              Crankshaft gear

                                                                            Inspecting Timing Gears




                                                                       39                                    Westerbeke Engines
Timing Gears' Installation

1. Press-fit the crankshaft gear onto the shaft.

2. Press-fit the valve camshaft gear and injection
   pump camshaft gear onto the respective shafts.

3. Install the gears in the following sequence.

  a. Turn the crankshaft to set the No. 1 cylinder to
     top dead center on compression stroke.
                                                                         Idler Gear
  b. Install the valve camshaft and injection pump               (Note timing marks1&2)
     camshaft.

  c. Install the idle gear so that timing marks on it are
     in alignment with marks on the other gears.

  d. Confirm that timing gears are in alignment with
     each other.




Westerbeke Engines                                          40
              CAMSHAFTS (Valve and Pump)



                                     @

                                 @   I

@
                   @
                           ~~                                             rID




                           (1)




              CAMSHAFT COMPONENT PARTS

    1. Camshaft (valve).                  8. Tappet.
    2. Camshaft gear.                     9. Push rod.
    3. Ball bearing.                     10. camshaft (injection pump).
    4. Woodruff key.                     11. camshaft gear.
    5. Sunk key.                         12. Ball bearing (rear).
    6. Camshaft stopper.                 13. Snap ring.




                           41                             Westerbeke Engines
Valve Camshaft Removal

1. When it is necessary to remove only the valve camshaft, use the following procedure.

  a. Dismount the cylinder head assembly.

  b. Pull out the push rods.

  c. Pull out the tappets.

  d. Remove the gear case assembly.

  e. Remove the camshaft stopper bolt.

  f. Draw the camshaft assembly out.


2. Removal of the injection pump camshaft.

  a. Disconnect the injector lines.

  b. Remove the injection pump assembly.

  c. Remove the gear case assembly.

  d. Remove the shaft rear cover.

  e. Remove the stopper bolt.

  f. Remove the shaft from the front of the engine.




Westerbeke Engines                                    42
Camshafts' Inspection




                                     Cam lobe-Wear
                                     and damage


                                                                                                        End
                                                                                      Bend---
                                                                                                        face-Wear
                                                                                                        and damage




                                                              Journal bearing-Wear
                                                              and damage



                Each ball
                bearing-Wear
                and noise
                                                                                              Cam contact
                                                                                              surface-Wear
                                                                                              and damage




                                                              Cam lobe-Wear
                                                              and damage


                                    Oldham's coupling-Wear


Inspection of Camshafts



         Major diameter of injection pump cam                                 Major diameter of valve cam

      Standard value                   30                            Standard value                   27.37
       Service limit                  -0.7                            Service limit                    -1.0




                                                             43                                   Westerbeke Engines
Camshafts' Installation

When installing the camshafts, give care to the fol-
lowing.

1. Coat the bearings and cam lobes with oil.

2. Install the camshafts in the reverse order of
   removal.

3. Position the timing marks on the gears in alignment
   with the marks on the idler gear.

4. After installation, check and adjust fuel injection        Timing Gears in Alignment with Each Other
   timing and valve clearances.




Westerbeke Engines                                       44
                       PISTON AND CONNECTING ROD




                                     Os-=-- :   ---(J)




                                     3         1_'!l1



                  (~)~

                             !---I




                                      ~"    (8)--IQ'



            PISTON AND CONNECTING ROD COMPONENT PARTS

1. Piston ring No.1.   5. Piston pin.                8. Connecting rod cap.
2. Piston ring No.2.   6. Connecting rod.            9. Connecting rod bolt.
3. Oil ring.           7. Connecting rod bearing.   10. Connecting rod nut.
4. Piston.




                                      45                             Westerbeke Engines
Piston and Connecting Rod Removal

1. Remove the cylinder head assembly.

2. Remove the oil pan.

3. Remove the oil screen.

4. Chalk the cylinder number on the side face of the big end of each connecting rod to prevent confusion
   of connecting rods.

5. Remove the connecting rod cap from each piston
                                                                                      Pressing
   and rod assembly and draw the assembly upward
   from the cylinder. Take care not to allow the con-
   necting rod to scratch the crankshaft pin and
   cylinder. Keep the removed parts (connecting rod,
   rod cap, piston etc.) classified by cylinders.              FRONT
                                                               mark (arrow)

6. Remove the rings from each piston with the piston
                                                                  Piston
   ring pliers.

7. Using the piston setting tool, pull out the piston pin
   from each piston.                                        Removing Piston Pin



Piston and Connecting Rod Inspection

Inspect the removed parts. If any parts are found defective, replace or repair them.




                                                                      · Bend and twist
                                                                - - - · Big end play

                                    08----::                            Standard: 0.1 -O.35mm




                                    8
           Damage, wear, _ _ {
           and ring gap              ~



                                     ~~
 · Wear, seIzure, and streaks
 · Clearance between piston and cylinder tf~. ~
                                                                                  · Contact and seizure
   Standard:O.07-0.115mm         ----- ~
                                                                     }     -      · Flaking and fusion
 · Wear of p,ston ring grooves           ~$                                       · Oil clearance
                                                                                    Standard: O.022-0.052mm


   Damage and wear   -------V
                                                                ® ___- - Damage

Inspection of Piston and Connecting Rod




Westerbeke Engines                                     46
Inspection of piston ring gaps. Put each piston ring
into the cylinder bore and push the ring with the piston
to position the ring on square with the cylinder wall.
Measure the ring gap with a feeler gauge. If the meas-
urement exceeds the service limit, replace that piston                                             Piston
ring.
                                                                                     o              Cylinder
                          CAUTION
                                                                                                   Ring
      When only the replacement of rings is to be                                  Ring gaps
      made, without reboring (honing) of the cylinder,
      position the ring to be measured at the least worn    Measuring Ring Gap
      place of the cylinder skirt. Install the new rings
      having the same size as the piston. Piston rings
                                                                       Ring               Standard             Service limit
      available for servicing are sized into three clas-
      ses: STD, 0.25 OS, and 0.50 OS.                               All rings            0.15-0.40                  1.5




Inspection of ring groove in piston. Measure the side
clearance for each piston ring set in the ring groove in
the piston. If the service limit is exceeded, replace the
ring with a new one.



                                                              Measuring Ring Side Clearance



                                                                      Ring                Standard             Service limit

                                                                     No. I                     -                   0.3

Piston and Connecting Rod Installation                               No.2               0.05-0.09                  0.2

                                                                       Oil              0.03-0.07                  0.2
When reassembling the piston and connecting rod and
                                                            Note : No. I ring is of the semi·key stone type.
installing the piston and rod assemblies in the cylinder
block, pay attention to the following.
                                                                                        Pressing
1. Reassemble the piston and connecting rod, using
   the Piston Pin Setting Tool, by pressing the piston
   pin in to the set position.
                                                               FRONT
                                                               mark (arrow)


           Description               Standard                      Piston

      Pin press·fitting force
                                    1000±500kg
    (at a normal temperature)

                                                            Installation of Piston and Connecting Rod




                                                      47                                       Westerbeke Engines
                                                      Pressing




                                                           Push rod


                                                       Connecting rod




                       FRONT mark (arrow)




                                                            ', .....~~-- Tool body




2. Installation of piston rings.



              FRONT mark - - -.....
                                                        Ring set positions:
                                                        No.1 ring.
                                                        No.2 ring.
                                                        oil ring
                                                                              d           ~     "r mark and
                                                                                                OS size mark




                                                                                               "r mark and
                                                                                               OS size mark
                Rod front --.------~
                mark



                                                                                             OS size
                                                                                             identification
                                                                                             paint



              Align notches -
              accurately with
              each other.
                                                                        Color of discrimination STO =Without color
                                                                                                O.25=White
                                                                                                O.50=Blue


               Tightening torque: ____{O"\
               3.2-3.5kg.m            \01

Installation of Piston Rings and Connecting Rod Cap




Westerbeke Engines                                    48
3. Set the piston ring gaps to the proper positions as
   shown in the figure at right. Coat the rings and
   cylinder wall with oil.
                                                                     Ol'ri"if               ~


                                                                                               ~
                                                                                                No.1 ring gap




                                                                Front ~



                                                                            ~
                                                                    No.2 ring   gap~        ,J!."     0' 0011
                                                                                                 expander of oil
                                                                                                 ring


                                                          Proper Arrangement of Ring Gaps



4. Using a piston ring compressor to compress the rings into the grooves, push the piston and rod assembly
   down into the cylinder. Be careful not to break the rings by excessively knocking the head of the piston.
   Note that the front marks on the piston and connecting rod are toward the engine front.


5. Coat the bearing surface of the connecting rod caps
  with engine oil. Fit each cap to the connecting rod
  using match marks put before removal as a guide.
  In the case of a new rod which does not have a mark,                                      Connecting
  position the notches (provided for preventing the                                         Rod
  bearing from rotating) on the same side.


                                                                            I
                                                                            I

                                                                                     :
                                                                            ~
                                                                            :
                                                                            I        I
                                                                                     I




                                                                            ~
                                                                            I
                                                                            I
                                                                                     I
                                                                                     I


                                                                           ~cap

                                                                                   ®




                                                    49                                      Westerbeke Engines
                                        CRANKSHAFT




                                                      ®



                              CRANKSHAFT COMPONENT PARTS

                1. Key.                  6. Washer.        11. Rear oil seal case.
                2. Crankshaft.           7. Spring washer. 12. Gasket.
                3. Crankshaft gear.      8. Flywheel.      13. Flywheel bolt.
                4. Crankshaft pulley.    9. Ring gear.
                5. Nut.                 10. Rear oil seal.




Westerbeke Engines                            50
Crankshaft Removal

1. Loosen the flywheel bolts and remove the flywheel.

2. Loosen the crankshaft pulley nut and remove the
   pulley.

3. Remove the rear oil seal case assembly.

4. Remove the main bearing caps.

5. Take out the crankshaft.


Crankshaft Inspection

Inspect the removed parts. If any parts are found defective, repair or replace them.




                   · Journals and pins- Damage and uneven wear
                   · Cracks. clogging of oil hole, and bend
                   · Wear of journal contact surface




                                                                                             Wobble



                                                                                Damaged to
                                                                                tooth face




                                                                      Wear and damage




Inspection of Crankshaft and Flywheel




                                                                 51                               Westerbeke Engines
Checking the crankshaft for wear. To check the
crankpins and main journals for tapering wear and
out-of-round wear, the diameter of each crankpin or
main journal should be measured at two places along
the crankpin or main journal, in two directions "A" and
"B" each place, as shown in the figure at right. If
necessary, regrind the crankpins and main journals to
the next under size. If any crankpin or main journal
has been worn out beyond the service limit, replace
the crankshaft.

                                                                      Checking Crankshaft for Wear



        Diameter of crankpin and main journal         (mm)               Under·size diameters       (mm)


        Description                  Standard     Service limit          Description          Main journal        Crankpin

        Main       journal
                                       43            -0.70               0.25 US         42.715""'42.730 39. 715""'39. 730
        dia.

        Crankpin dia.                   40           -0.70               0.50 US         42.465""'42.480 39.465""'39.480



Inspection of the crankshaft oil clearance.          Oil
clearance is calculated by subtracting the diameter of
main journal or crankpin from the inside diameter of
the main bearing or rod bearing. To check the main
bearings and rod bearings for tapering wear and out-
of-round wear, the inside diameter of each main bear-
ing or rod bearing should be measured, after its                                                                  2
bearing cap is fastened to the specified torque, at two
places along the bearing, and in two directions "A" and
"B", each place as shown in the figure at right. If
necessary, replace the worn bearing with a new one.
If the oil clearance still exceeds the service limit,
                                                                          Measuring Main Bearing 1.0.
regrind the crankshaft to the next under size and
replace the bearing with one of the corresponding
under sizes.

                                                            CAUTION

                   A crankshaft which has been sized cannot be reground to any under size.


     Tightening torque       (kgm)                                    Oil clearance    (mm)

     Description                                Standard              Description                            Service limit

     Main bearing cap bolt                      5.0""'5.5             Main bearing                               0.10
     Rod bearing cap nut                        3.2""'3.5             Rod bearing                                O. 15




Westerbeke Engines                                            52
Crankshaft Rear Oil Seal Replacement

1. Pry the oil seal out with a screwdriver.

2. Drive in a new oil seal to the oil seal case.


When installing the crankshaft, pay attention to the notes given in the figure below.


                                  Cap tightening          Thrust bearing only
                                  torque: 5.0- 5.5kg.m    for No.2 cap




            Direction of
            installation of cap
                                                                                J       Side seals coated


                                                                                , 7-'ONO "'"
                                                                                        with sealant




                                                                                -\ 9
                                                                                 .-J~ Round end down
              Front




                                                                                        Make cap flush with
                                                                                        cylinder block end face
                                                                                        (common to front and
                                                                                         rear end faces)



        Crankshaft end
        play: 0.05-0.175




Installation of Crankshaft




                                                         53                               Westerbeke Engines
                                     CYLINDER BLOCK




                           CYUNDER BLOCK COMPONENT PARTS

                1. Cylinder block.     5. Main bearing.       9. Idler gear shaft.
                2. Front plate.        6. Starter bracket.   10. Oil filter shaft.
                3. Bearing cap.        7. Rear oil seal.     11. Oil level gauge guide.
                4. Cover.              8. Oil seal case.




Westerbeke Engines                           54
Cylinder Block Inspection

Inspect the cylinder block. If it is found defective, repair or replace the block.

Cylinder Bore (mm):

        Mgdel             Standard                                                        A pprox.10mm
                                                                                          from upper end
        20B               76 + 0.03 -0.0
        30B               76 + 0.03 -0.0                                                                Front   ~
                                                                            ,                Center
                                                                                                        ~\J7
Wear Umit Before Rebore:     + 0.02 mm                                                       Lower
                                                                 -                '--                           Direction of
                                                                                                                measuing

                                                                     Measuring position



                                                              Cylinder Bore Measuring Positions


Cylinder Reboring

When reboring a cylinder, use the following procedure.

1. Select a piston size: 0.25 as or 0.50 as.

2. Measure the piston diameter.                                                         I~
                                                                                         0
3. Reboring finish dimension = [piston 00]
   [clearance] - [honing allowance (0.2 mm)]
                                                       +         Measure
                                                                 diameter
                                                                 here ----L.-~r
                                                                                     l
                                                                                   55 mm




    Clearance (between piston and cylinder)
    Standard: 0.071 - 0.084 mm (A-D)
                                                                Measuring Piston Diameter



                                                   CAUTION

      When it is necessary for a cylinder to be rebored to the next over size, the remainders must
      also be rebored to the same over size.




                                                       55                                             Westerbeke Engines
                                   FUEL INJECTION PUMP




                            INJECTION PUMP COMPONENT PARTS

                1. Union collar.           8. Delivery valve.   15. Plunger.
                                           9. Gasket.           16. Lower seat.
                3. Delivery valve holder. 10. Seat valve.       17. Adjusting shim.
                4. Valve spring.          11. Plunger barrel.   18. Tappet roller.
                5. Holder stopper.        12. Sleeve.           19. Pin.
                6. Housing.               13. Upper seat.       20. Control rack.
                7. O-ring.                14. Plunger spring.   21. Stop wire bracket.




Westerbeke Engines                              56
Injection Pump Inspection while on the Engine                  Inspection           Inspection procedure                        Criterial

                                                               Idling speed       Measure engine speed.            900+ sgrpm
Never attempt to disassemble the pump unless it is
necessary. If the pump is assumed defective, it is                                I) Quickly accelerate
                                                                                                                   No remarkably black·
recommended to replace the pump assembly.                   Exhaust smoke color         engine without load.
                                                                                                                   smoke exhaust permitted.
                                                                                  2) Apply load to engine

                                                            Fuel cut ·off         Turn ignition switch to OFF      A solenoid acting
Injection Pump Removal
                                                            solenoid              from ON.                         sound.

1. Disconnect the fuel injection pipes.

2. Remove the tie-rod clip cover.
                                                                                                         '~fn1:lction
3. Remove the tie-rod clip and tie-rod.                                                                  ---- IJ                      Pipes

                                                                                                   I I                          I
Injection Pump Disassembly                                                        M,~,e
1. Remove the stopper plate.                                                  ,~'~
2. Unscrew the delivery holder. Take out the delivery
   valve and valve spring.

3. Remove the tappet roller and stopper pin.

4. Remove the tappet, plunger spring, etc.

                       CAUTION

      When replacing the plunger barrel, delivery
      valve, etc., do not loosen the adjusting screw and
      plate for each cylinder. When those parts have
      been replaced, it is necessary to measure fuel                                                        0 - O-ring-Cracks
      injection quantity by utilizing a pump tester and                                                        ~          and deterioration

      cam box. All parts removed from the pump                                                                 ©
      should be kept classified by cylinders and im-                                                        fj--                Wear and
                                                                                                                                scratch
      mersed in clean fuel.
                                                             Control rack--
                                                             movement
                                                             (Catching)
                                                                                                            ~t~
                                                                                                            11"
                                                                                                               -       Plunger-Interference
                                                                                                                       wear, scratch,
Injection Pump Inspection                                                                                   ~          rust, seizure

                                                                                                            I8J
                                                                                                            I
                                                                                                            ®

                                                                                                          e-
                                                                                                          o
                                                                                                                , ri?Jc:::::,
                                                                                                                                Interference,
                                                                                                                                wear




                                                           Inspection of Injection Pump




                                                     57                                                Westerbeke Engines
Injection Pump Assembly

1. Insert the plunger barrel into the housing.

2. Install the delivery valve and valve spring. Temporarily tighten the holder.

3. Insert the control rack.

4. Insert the control pinion. Align the matchmark on the rack with that on the pinion.

5. Install the spring upper seat.

6. Insert the plunger spring.

7. Fit the lower seat to the plunger. Insert the plunger into the barrel side.

8. Depress the tappet roller assembly and install the stopper pin.

9. Tighten the delivery holder.
             Tightening torque: 3.5 - 3.9 kgm


Injection Pump Installation

Install the injection pump assembly in the reverse order
of removal.
                                                                       Stamp
                       CAUTION

      When installing the plunger barrel, engage the
      dowel pin on the housing side with the groove in
      the barrel. Position the plunger so that the part
      number stamp on its flange faces the direction
      opposite to the rack side. (Engage the feed hole               Rack side
      with the plunger lead.) After installation, check
      for proper injection timing.                             Direction of Installation of Plunger




Westerbeke Engines                                     58
               INJECTION NOZZLE




                       @:_--




                       I
                       ::g



                       <9         @



                       @          @




 NOZZLE HOLDER ASSEMBLY COMPONENT PARTS

1. Body subassembly.                  5. Distance piece.
2. Shim washer.                       6. Nozzle assembly.
3. Pressure spring.                   7. Retaining nut.
4. Pin.




                             59                             Westerbeke Engines
Injection Nozzle Removal

1. Disconnect the injection pipe and fuel return pipe.

2. Remove the injection nozzle assembly from the cylinder head.

                                                   CAUTION

      Attach an identification number tag to the removed injection nozzle. Plug the openings from
      which the pipes are disconnected and the nozzle is removed to prevent intrusion of dust,
      water, and other foreign particles into the pipes and combustion chamber.

Injection Nozzle Disassembly

If the removed nozzle assembly is assumed defective, disassemble the assembly and repair or replace the
faulty parts.

1. Grip the nozzle holder body in a vise. Loosen the retaining nut. Never vise the retaining nut to prevent
   deformation.

2. Take out the shim washer, pressure spring, distance piece, and nozzle assembly.

                                                   CAUTION

      Scrape off carbon deposits with a wooden spatula. Keep the removed parts immersed in
      washing oil (kerosene). Take special care not to scratch the needle valve in the nozzle
      assembly.


Injection Nozzle Inspection

Inspect the removed parts. If any part is found defec-
tive, replace it.


Injection Nozzle Assembly
                                                                                 ~   . Fatigue and
1. Insert the nozzle assembly into the retaining nut so                          !gl/  break




                                                                                                     ~T
    that the nozzle is perfectly seated in the nut.

2. Place the distance piece, retaining pin, pressure                             ©
   spring, and shim washer on the nozzle assembly.
                                                                                @
3. Tighten the nozzle holder body fully by hand.              Poor contact   ~                              Deformation
                                                                                                            and break


                                                                                 ~
                                                                                                     While immersed
4. Grip the nozzle holder in a vise. Tighten the retain-                                             in kerosene.
                                                                                                     check for smooth
   ing nut to the specified torque.                                                                  sliding.


                 Tightening torque: 3.5 - 4.0 kgm



                                                            Inspecting Nozzle
                                                                                9
Westerbeke Engines                                     60
Injection Nozzle Adjustment

Adjust injection start pressure by increasing or
decreasing the thickness of the shim washer to be                                        Tightening torque:
                                                              Tightening torque:
                                                                                         3.5-4.0kg.m
inserted. Varying shim thickness by 0.1 mm causes             2.5-3.0kg.m

injection start pressure to change 10 kg/cm.

10 kinds of shims available from 1.25 mm to 1.7 mm in
thickness, 0.05 mm step.


                Injection start pressure
                                                                           Return pipe
       Standard
                                                           Assembling the Nozzle
     Allowable limit            130 kg/ an' or less




Injection Nozzle Installation

1. Clean the nozzle holder fitting surface of the cylinder head. Install the nozzle holder with a gasket
   interposed.

        Tightening torque: 5.0 - 6.0 kgm

2. Connect the fuel return pipe and injection pipe.

        Tightening torque:
            Injection pipe             2.5 -3.5 kgm
            Fuel return pipe           2.5 -3.0 kgm




                                                      61                                  Westerbeke Engines
                                   GOVERNOR SYSTEM




                                                                I---@




                                                            ®



                          GOVERNOR SYSTEM COMPONENT PARTS

       1. Sealing metal.        11. Tie-rod clip.                   21. Stop lever assembly.
       2. Sealing wire.         12. Tie-rod cover.                  22. O-ring.
       3. Low and high speed.   13. Tie-rod cover gasket.           23. Snap ring.
       4. Governor spring.      14. Tension lever                   24. Stop lever.
       5. Sliding shaft.        15. Start spring.                   25. Grooved pin (3 x 20).
       6. Stopper               16. Governor spring lever.          26. Grooved pin (3 x 14).
       7. Governor spring.      17. Speed control lever assembly.   27. Torque spring test.
       8. Governor shaft.       18. Cover assembly.                 28. Sealing cap.
       9. Governor lever.       19. Governor cover gasket.
      10. Tie-rod.              20. Return spring.




Westerbeke Engines                            62
Torque Spring Set Installation                                                          Torque spring set


Install and adjust the torque spring set using the follow-
ing procedure:

1. Set the speed control lever to the high idling speed
   position by adjusting the high speed set bolt.                     Turn in this torque spring
                                                                      set until engine speed
2. Turn in the torque spring set until engine speed drops             drops about 50rpm from
                                                                      high-idling speed.
    about 50 rpm from high idling speed.
                                                                                                        Adjust to specified
3. From this position, turn back the torque spring set                                                  number of loosening
                                                                                                        turns -N"
   by the specified number of turns (N). Lock the                     Sealing cap
                                                                      (Stake after setting)                  Number of loosening
   torque spring set at that position with the special nut.

4. Install the torque spring set sealing cap and stake
   the cap to prevent loosening.

                               Number of loosening
    ~                          turns (N)
    20B Two & 30B Three          2.2


                                                              Torque spring set




Torque Spring Set Assembly
                                                                                                   2. Spring 1. Spring
When the torque spring set has been disassembled or            . tr   identification                                     Projection
its component parts have been replaced, reassemble                             mark
and adjust the torque spring set using the following
procedure:

1. Assemble the torque spring set as shown in the
   figure. Using the adjusting screw (5), adjust the
   projection (8) of the torque spring stopper (1) from                                                        6. Torque spring
   the spring case (2) to get the specified projection.
                                                              Assembling torque spring set
2. To measure the projection (8), keep the torque
   spring set in vertical position as illustrated. Put the
   dial gauge probe against the spring stopper (1) at            A : Height of spring stopper               B : Height of case
   the center of its end face using a small dial gauge
   (having the sensitive probe which does not com-
   press the torque spring when pushed against the
   spring stopper end).




                                                              Measuring spring stopper projection (0)




                                                         63                                          Westerbeke Engines
3. Leaving the dial gauge set condition unvaried, depress the spring stopper (1) and slide the torque spring
   set support spring case (2). Read the deflection of dial gauge which corresponds to the projection of the
   spring stopper from the spring case. (Measurement should be made two or three times repeatedly to
   make sure of accurate measure.) For the models which do not require any torque spring action, set the
   projection (8) to a value in the range of 0 to -0.4.

4. After adjustment, tighten nut (4) to a torque of 0.8 to 1.2 kgm.

5. Check to see that the spring stopper (1) can be depressed smoothly and that the end face of the stopper
   (1) can become flush with the end face of the spring case (2).

6. For the purpose of identification of projection (8), apply paint of the color specified to the surface shown
   in the figure at the right of paragraph (1).

                 MQd.eL                         projection 8 mm       Identification color
                 206 Two & 306 Three           o '"  -0.4             Red

Replace the gear case and inspect the governor. When removing the gear case, be sure to remove the
tie-rod cover by the side of the fuel pump and disconnect the tie-rod from the rack. If any parts are found
defective, replace them.

                                                  CAUTION

      If the governor is assumed to be malfunctioning, check the bearing on the gear case side,
      too.




Westerbeke Engines                                    64
                                                           GOVERNOR




                                           Check springs               ~GJ                         Check levers for
                                                                   ~~\d)./
                                                                                                   smooth movements.
                                           for fatigue.




                                 ~\,i)
                                             7
                                 Check springs
                                 for fatigue.




                  ~~                                                   Check weight for
                                                                       wear and damage.
                   Check shaft
                   for flaws.                              Check sliding sleeve
                                                           for wear, damage
                         Check sliding sleeve              and smooth movement.
                         joint for wear and damage.


   Inspection Governor System Parts


Governor Removal and Installation

To remove the levers, pull out the grooved pins which have been driven into the governor lever, stop lever,
and speed control lever. Loosen the bolts fastening the levers and shafts.

Install the levers and shafts, one after another, checking for proper functioning.

After press-fitting each grooved pin, check the shaft for smooth rotation. Coat the O-rings with oil before
installing them. No deflection exceeding 20 mm is permitted for the governor spring installed. Install the
governor spring lever and speed control lever so that the play of angle between levers (standard: 5°) is
minimized.




                                                                               5' (Standard)
                                                                               No play exceeding
                                                                               5' permitted




                                  Instaling Speed Control Lever



                                                                  65                               Westerbeke Engines
                                                 GLOW PLUG


Glow Plug Inspection

Check for conduction between the glow plug terminal and body. Ifthe plug is not conductive at all or shows
a large resistance, replace the plug.

Glow plug tightening torque: 1.5 - 2.0 kgm.




                            Checking Glow Plug




Westerbeke Engines                                  66
                                            COOLING SYSTEM


Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw waterflow through
their independent cooling circuits. Refer to your generator's Parts List for part numbers and part descriptions
if you need to order cooling system parts for your engine.




                  INJECTED   E~- _ _ _ _ _ PRESSURE               CAP


                                                                         EXHAUST MANIFOLD




                                                                                            WATER
                                                                      ~'r---=~-_ TEMPERATURE
                                                                 .~~"'1'                    SWITCH


        {7'




                   INCOMING
                   RAW WATER




              FRESH WATER ~
                                                                                    FRESH WATER DRAIN
               RAW WATER . . .
                                                                                  RAW WATER DRAIN




                                           Typical Cooling System




                                                      67                                Westerbeke Engines
Fresh Water Pump Drive BeH Tension

Generator models come equipped with belt guards that cover over the belt(s) on the front of the engine.
("Out of sight-out of mind." The belt guard is not installed for that purpose.) Operators are advised that
the inspection, service, and maintenance spoken of below should be followed.

                                                IWARNINGI

      Never attempt to adjust the drive belt's tension while the engine is in operation.

                                                 CAUTION

      Excessive water pump drive belt tension can cause rapid wear of the belt and reduce the
      service life of the fresh water pump's bearings. Excessive slack or the presence of oil on the
      belt can cause belt slipping, resulting in high operating temperatures.

The water pump drive belt is properly adjusted if the belt can be deflected no less than 3/8 inch and no more
than 1/2 inch (10 mm, 12 mm) as the belt is depressed with the thumb at the midpoint between the two
pulleys on the longest span of the belt. A spare drive belt should be carried on board.


Raw Water Pump

The raw water pump is a self-priming, gear-driven, rotary pump with a non-ferrous housing and a neoprene
impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing,
producing the pumping action. On no account should this pump be run dry. There should always be a
spare impeller and impeller cover gasket aboard (an impeller kit). Impeller failures occur when lubricant
(raw water) is not present. Such failures are not warrantable and the operator's are cautioned to make sure
raw water flow is present at start-up. Know your pump, know its location on the engine and know how to
change the impeller in it.




                                               CURVED CAM PLATE




                                   RAW WATER PUMP




Remove the impeller with the aid of two small screwdrivers, as illustrated, and carefully pry the impeller
out of the pump. Install the impeller by positioning the hub pin to align with the slot in the drive shaft.
Move the blades to conform to the curved cam plate and push the impeller into the pump's housing.



Westerbeke Engines                                    68
Raw Water Pump Overhaul

Raw water pump #033636 repair instructions are as follows:

Disassembly
The pump, as removed from the engine, will have hose attachment nipples threaded into the its inlet and
outlet port. They may be left in place or removed if they interfere with the pump disassembly. Note the
port location and positioning if removed.




a. Remove the six cover plate screws (ref 13), cover plate (ref 12) and the cover plate gasket (ref 11).

      NOTE: Screw material should be stainless steel part number 034463. Also, replacement of
      the cover plate gasket is recommended; however, if you are going to reuse it, keep the gasket
      submerged in water until the pump is reassembled. If it's allowed to dry, the gasket will shrink
      and not be reusable

b. Remove the impeller (ref 9) with its drive screw (ref 10) from the pump housing.

c. Remove the screw (ref 4) and sealing washer (ref 5) and draw the cam (ref 6) from the pump housing.

d. Remove the circlip (ref 3).

e. Support the pump housing, at the mounting flange end, on an arbor press and, with a drift, press out the
   shaft (ref 8) and bearings (ref 2) from the pump housing from the impeller end.

f. With the pump housing supported, push the seals (ref 7) out of the pump housing. Push the impeller side
    seal out that side and then lift the spacer (ref 14) out. Then, push the bearing side seal out that side.

g. Supporting the bearings inner face (ref 2), push the shaft (ref 8) out of the bearings.

      NOTE: Inspect all parts and replace those showing wear or corrosion.




                                                      69                                Westerbeke Engines
Assembly
a. Install the seals (ref 7) and spacer (ref 14) in the pump housing. Push the impeller side seal into the
   housing. Rotate the pump and install the spacer (ref 14) against the seal face. Push the bearing side
   seal into the housing from the bearing side.

          NOTE: The seal's flat surfaces, having printing and numbers, face towards each other.

b. Install shaft (ref 8) into bearings. Support bearings (ref 2) at their center race. Push the shaft into the
   bearings, pushing at the impeller drive slot end using the base of the drive slot. Push the shaft through
   both of the bearings, flush against each other so the flat sided end of the shaft extends beyond the second
   bearing center race 15 mm (19/32 in.) ±.5 mm (1132 in.).

c. Support the pump housing at the impeller side. Apply a small amount of petroleum jelly to the seal's (ref
   7) inner lips and to impeller shaft (ref 8). Carefully, install the shaft rotating it through the seals till the
   bearings contact the housing from the bearing end. Use a pushing tool that will push this shaft and
   bearing assembly into the pump housing by applying pressure against the outer bearing race. Push the
   assembly into the housing until the bearings seat fully in the housing. Install the circlip (ref 3).

d. Position the cam (ref 6) in the housing and secure it in place with the screw (ref 4) and sealing washer
   (ref 5).

      NOTE: Use a small amount of Permatex #1 on the inner cam surface and screw threads.
      Remove any excess from the impeller housing.

e. Apply a light film of silicone or petroleum jelly to the inner surface of the housing for the impeller.

      NOTE: Just coat the surface, do not over apply. Install the impeller with the drive screw (ref
      9 and 10). Push the assembly into the housing with the drive screw mating in the slot of the
      drive shaft.

f. Install the cover gasket (ref 11), cover (ref 12), and secure them with the six cover screws (ref 13).




Westerbeke Engines                                      70
                               STARTER




       (,!l)



         I})    lID




               .~~


                       STARTER COMPONENT PARTS

1. Front bracket assembly.     6. Through bolt.            11. Gear.
2. Lever assembly.             7. Armature.                12. Yoke assembly.
3. Spring set.                 8. Rear bearing.            13. Brush holder assembly.
4. Center bracket assembly.    9. Pinion.                  14. Rear bracket.
5. Switch assembly.           10. Pinion shaft assembly.




                                    71                                Westerbeke Engines
Starter Adjustment and Repair

If any abnormality is assumed by the following tests,
adjust the starter or disassemble and repair it.
                                                             Push back
                                                             Lightly
1. Pinion gap inspection.

  a. Interpose a battery (12 V) between the starter
     terminallS" and the starter body, and the pinion
     will protrude and stop.

                                                              O.5-2.0mm
                      CAUTION

      Never apply battery voltage for over 10 seconds       Inspecting Pinion Gap
      continuously.

  b. Lightly push the pinion back and measure the return stroke (called pinion gap).

  c. If the pinion gap is not within the standard range, (0.5 to 2.0 mm), adjust it by increasing or decreasing
     the number of packings on the magnetic switch. The gap is decreased as the number of packings
     increases.

2. No-load test.

  a. Connect the ammeter, voltmeter, and battery to
     the starter as illustrated.

  b. When the switch is closed, the pinion must
     protrude and the starter must run smoothly (at
    3000 rpm or more). Ifthe current or starter speed
     is out of specification, disassemble the starter
     and repair it.

                                                            No·load Test



                                                  CAUTION

      Use thick wires as much as possible and tighten every terminal securely. This is a solenoid
      shift type starter which makes a rotating sound larger than that of a direct-drive type starter.
      When detecting starter rotation at the pinion tip, take care of protrusion of the pinion.




Westerbeke Engines                                    72
3. Magnetic switch.

  Perform the following tests. If any test result is not
  satisfactory, replace the magnetic switch assembly.

  a. Disconnect the wire from terminal "M."

  b. Attraction test.

     Connect a battery to the magnetic switch terminals
     Sand M. The pinion must protrude.
                                                                                   Starter
                        CAUTION
                                                            Attraction Test
      Do not apply battery current for more than 10
      seconds.

  c. Holding test.

     With a battery connected to the magnetic switch
     terminal "S" and to the starter body, manually pull
     out the pinion fully. The pinion must remain at that
     position even when released from holding by hand.

                                                                                      Starter

                        CAUTION
                                                            Holding Test

      Do not apply battery current for more than 10
      seconds.

  d. Return test.

     With a battery connected to the magnetic switch
     terminal "M" and to the starter body, manually pull
     out the pinion fully. The pinion must return to its
     original position when released from holding by
                                                                                    Starter
     hand.

                        CAUTION
                                                            Return Test

      Do not apply battery current for more than 10
      seconds.




                                                      73                      Westerbeke Engines
Starter Disassembly

1. Disconnect the wire from the magnetic switch terminaI M."
                                                           I




2. Loosen the two screws fastening the magnetic switch. Remove the magnetic switch assembly.

3. Remove the two through bolts and two screws fastening the brush holder. Remove the rear bracket.

4. With two brushes brought in a floating state, remove the yoke and brush holder assembly. Then, pull the
   armature out.

5. Remove the cover, pry the snap ring out, and remove the washer.

6. Unscrew the bolts and remove the center bracket. At the same time, washers for pinion shaft end play
   adjustment will come off.

7. Pull out the reduction gear lever and lever spring from the front bracket.

8. On the pinion side, pry the snap ring out, and pull out the pinion and pinion shaft.

9. At each end of the armature, remove the ball bearing with a bearing puller. It is impossible to replace the
   ball bearing press-fitted in the front bracket. If that bearing has worn off, replace the front bracket
   assembly.




Westerbeke Engines                                    74
Starter Inspection



                                                                                                          Break and short circuit




                        Wear and
                        chipping




                Bearing: Play. noise.
                and rough rotation




                                                                             Insulation



                           Bearing: Play. noise.   Break and short circuit
                           and rough rotation


        Inspect about the following:

            Description                 Standard    Service limit                     Description           Standard            Service limit

          Depth of under cut            0.5 mm         0.2 mm                       Height of brush           17 mm                 6 mm

         Commutator O. D.               38.7 mm      -1.0 mm                         Spring pressure           3 kg




1. Inspect the magnetic switch for conduction
between terminals S and M and between terminals S
and body. There should be a low resistance found 1 -
2 ohms. If no resistance is found the circuit is open.
The solenoid should be replaced.




                                                                               Checking Magnetic Switch




                                                                    75                                           Westerbeke Engines
2. Inspecting the armature.

  a. Check the armature with a growler tester. If it's
     short circuited, replace the armature. Also, check
     for insulation between the commutator and its
     shaft. If poorly insulated, replace the armature.

  b. Measure the commutator 0.0. and the depth of
     undercut. Repair or replace it if the service limit
     is exceeded. Also, check the commutator out-
     side surface for dirtiness and roughness. If
     rough, polish the commutator with fine-grain
                                                            Checking Armature Coil
     sandpaper.

3. Brush holder inspection.

  a. Check the brushes. If worn out beyond the ser-
     vice limit, replace the brushes.

  b. Check the brush spring tension. If decreased
     beyond the service limit, replace the springs.

  c. Check for insulation between the positive brush
     holder and holder base. If poorly insulated,
     replace the holder assembly. Also, check the
     brush holders for proper staking.

4. Field coil inspection.

  a. Check for insulation between one end (brush) of
     coil and yoke.

  b. Check for conduction between both ends
    (brushes) of coil.

  c. Check the poles and coil for tightness.
                                                            Checking Field Coil

Starter Adjustment and Assembly
                                                                 Adjusting      Gear
Reassembly the starter assembly in the reverse order             washer

of disassembly, giving care to the following:

1. Pinion shaft end play adjustment. Set the end play
   (thrust gap) to 0.5 mm or less by inserting an adjust-
   ing washer between the center bracket and reduc-
   tion gear.
                                                                             O.5mm maximum
                                                                 - - f l..- -
  a. Fit the pinion shaft, reduction gear washer and
     snap ring to the center bracket.
                                                            Adjusting Pinion Shaft End Play




Westerbeke Engines                                     76
  b. Measure end play by moving the pinion shaft in the axial direction. If the end play exceeds 0.5 mm,
     increase the number of adjusting washers inserted.

2. Greasing.

  Whenever the starter has been overhauled, apply grease to the following parts:

  1. Armature shaft gear and reduction gear.

  2. All bearings.

  3. Bearing shaft washers and snap rings.

  4. Bearing sleeves.

  5. Pinion.

  6. Sliding portion of lever.

                                                CAUTION

      Never smear the starter fitting surface, terminals, brushes, or commutator with grease.




                                                    77                               Westerbeke Engines
                                       ALTERNATOR




                                                                                @


                     CD                                                          I
                                                                               @




                                            @



                                                                     @




               @



                             ALTERNATOR COMPONENT PARTS

         1. Pulley.                 5. Rear bearing.        9. Rectifier assembly.
         2. Front bracket assembly. 6. Stator.             10. Rear bracket assembly.
         3. Front bearing.          7. Terminal set.       11. Condenser assembly.
         4. Rotor assembly.         8. Regulator assembly.




Westerbeke Engines                              78
Alternator On-Engine Inspection

1. Erroneous handling can cause damage to the charging circuit and other troubles so avoid the following:

  a. Never connect the battery in reverse.

  b. Do not use a megger and other high-voltage testers.

  c. When recharging the battery, disconnect the battery cable from the alternator.

  d. Never disconnect the lead wire from the alternator terminal B while the engine is running.

  e. Never ground the alternator terminal B to which battery voltage is always applied.

  f. Never short circuit or ground terminal L

  g. When using a steam cleaner, be careful not to direct steam directly to the alternator.

2. Checking for regulated Voltage.

  a. Interpose an ammeter between the positive ter-
     minal of the battery and terminal B or the alter-                                       Ammeter

     nator.

  b. Ground the alternator terminal "L" through a
                                                             L
    voltmeter.
                                                             R

  c. Note that the voltmeter indicates zero volts when
     the key switch is in the OFF position. The
     voltmeter will indiCate a voltage considerably
     lower than battery voltage when the key switch
     is in the ON position (while the engine is             Checking for Regulated Voltage
     stopped).

  d. Short-circuit the ammeter and start the engine.

  e. Read the voltmeter indication (regulated voltage) under the following test conditions: Ammeter
     indication is below 5 A; engine speed is at 1800 rpm and 2500 rpm; and lamps are switched off.
     Regulated voltage shows a tendency to decrease as alternator temperature increases.

3. Output inspection.

  a. Disconnect the grounding cable from the battery.

  b. Interpose an ammeter between the battery and alternator terminal "B." Ground the terminal"B" through
     a voltmeter.

  c. Connect the battery grounding cable.

  d. Start the engine.




                                                       79                                    Westerbeke Engines
  e. Apply all load Including the lamps.
                                                                                      Ammeter
  f. Increase engine speed until normal alternator speed                   r-----~+~Ar-----~~
      is attained. Read the maximum indication of the
      ammeter at 13.5 V of voltmeter indication. Output
      current must conform to the specification.




                                                              Checking for Output

AHernator Removal
                                                                  Characteristic    Terminal      Current   I    Speed
                                                                                    voltage (V)    (A)    I      (rpm)
1. Disconnect the battery cable.                                                                            I 1,300
                                                                            15A         14           0      I maximum
                                                                                                            I
2. Disconnect the lead wire from terminal "S" on the back        No-load I 35A
                                                                                                            :
                                                                                                              1,300
   of the alternator.                                            output 1
                                                                                        14           8      I
                                                                                                            I maximum

                                                                            50A         13.5        24          1,300
                                                                                                                maximum
3. Disconnect the alternator connector.
                                                                            15A         14        15            2,500
                                                                                                  maximum       maximum
4. Loosen the alternator brace bolt and support bolt.
                                                                  Loaded                          30            2,500
   Push the alternator toward the engine and remove the           output    35A         14
                                                                                                  maximum       maximum
   fan belt.
                                                                            50A         13.5      50            2,500
                                                                                                  maximum       maximum
5. Dismount the alternator.


Alternator Disassembly

1. Remove the three through bolts.

2. Heat the rear bracket around the rear bearing up to
   50 - 60° C (with a solder iron) and separate the bracket
   from the stator coil.




                                                   CAUTION

      Pry open the alternator with a screwdriver blade inserted into the clearance between the stator
      core and front bracket. Se careful not to insert the blade too deep.

3. Grip the rotor in a vise, remove the pulley nut, and pull out the pulley, fan, and spacer.

4. Pull out the rotor assembly from the front bracket.




Westerbeke Engines                                     80
5. Unsolder the stator coil lead wires. Remove the stator assembly.

                                                       CAUTION

                             Never heat the lead wires long to prevent damage to diodes.

6. Disconnect the capacitor from terminal liB.    II




7. Loosen the screws fixing the rectifier and remove the rectifier.


Alternator Inspection

Inspect the disassembled parts, if any part is found defective, replace it.

                             Deformation                                                 Break and
                             and damage                                                  short circuit


                                 I                                                            t

                                                                                    ~
                                                                                    , I  Wear and roughness
                  Wear

             Break and
             short circuit




                                                  Wear to limit line



   Inspection of Alternator


1. Inspecting the diodes.

  a. Connect a circuit tester (ohmmeter) across the lead wire and case of the diode to be tested. The diode
     is considered normal if its resistance is large in either direction and small in the reverse direction.

   b. If there is equal resistance in both directions, the diode is suspected to be defective. Replace the rectifier
      assembly.

   c. Check every diode for conduction.




                                                             81                             Westerbeke Engines
2. Inspecting the field coil.

  a. Check for conduction between slip rings. If there
     is no conduction, the field coil is suspected to be
     broken. Replace the field coil.




                                                              Checking Field Coil for Conduction



   b. Check for conduction between a slip ring and
      shaft (or core). If any conduction is found, the
      field coil is suspected to be poor in insulation.
      Replace the field coil.




                                                              Checking Field Coil for Insulation

3. Inspecting the stator coil.

   a. Check for conduction between lead wires of the
      stator coil. If there is no conduction, the stator
      coil is suspected to be broken. Replace the
      stator coil.




                                                              Checking Stator Coil for Conduction




   b. Check for conduction between each lead wire
      and stator core. If any conduction is found, the
      stator coil is suspected to be poor in insulation.
      Replace the stator coil.




                                                              Checking Stator Coil for Insulation




Westerbeke Engines                                       82

                                                     \
AHernator Assembly

Reassemble the alternator assembly in the reverse order of disassembly giving care to the following:

1. The rear bearing has an eccentric groove. Install the snap ring so that its projection fits in with the deepest
   part of the groove.

2. When installing a new rear bearing, press-fit the bearing with its groove facing the slip ring side.

3. When press fitting the rear bearing into the rear
   bracket, heat the bracket.

                       CAUTION

      Pass a wire through the small hole in the rear
      bracket to lift the brushes before installing the
      rotor to the rear bracket. Remove the wire after
      the rotor is installed.


AHernator Installation
                                                               lifting Brushes

Install the alternator in the reverse order of removal.

1. When Installing the support bolts, Insert the
spacer In place using the following procedure:

  a. Push In the support bolts to the normal position.
     (Leave the nuts removed from the bolts.)

  b. Push the alternator backward. Measure the
    clearance between the alternator rear bracket
    and gear case bracket to determine the number
     of spacers to be inserted into the clearance (0.2
     mm maximum).




                                                          83                              Westerbeke Engines
                     NOTES




Westerbeke Engines     84
                                 ENGINE TROUBLESHOOTING


                                    possjble Cause             Verifjcatjon/Correctjon

Preheat is depressed:               1. Connection or           1. Check for 12 volts at the
no preheat.                            switch.                    PREHEAT switch and at the
                                                                  S terminal on the preheat
                                                                  solenoid.

                                    2. Preheat solenoid.       2. No activation with 12 volts
                                                                  at the S terminal. Tap solenoid
                                                                  with a mallet to determine if it
                                                                  is stuck internally. Solenoid
                                                                  should produce a click when
                                                                  activated and deactivated.

                                    3. Glow plugs are          3. Twelve volts is present at
                                       faulty.                    the glow plugs. Remove each
                                                                  plug and check the resistance
                                                                  of the plugs with an ohmmeter.
                                                                  (1.5 - 2.2 ohm.)


Preheat is depressed:               1. Faulty connections      1. Check for 12 volts at the
fuel pump does not                     or bad pump.               fuel pump connections.
operate.                                                          If 12 volts are present, the
                                                                  pump is possibly faulty.
                                                                  Tap pump with a mallet.
                                                                  Pump's plunger may be stuck.
                                                                  Check for contamination
                                                                  which will affect the pump.


Start is depressed:                 1. Fuel solenoid or        1. Check for 12 volts at lead
no fuel delivery to injectors.         connections to it are      positive terminal at the back
                                       faulty.                    of the fuel solenoid when the
                                                                  PREHEAT button is depressed.
                                                                  Twelve volts with no activation
                                                                  indicates a faulty solenoid.

                                    2. Voltage problem.        2. Less than 10 volts found at the
                                                                  lead terminal on the solenoid
                                                                  will not properly activate the
                                                                  solenoid and will cause a failure.
                                                                  Check for low batteries or voltage
                                                                  loss in small electrical wiring or
                                                                  corroded connections.

                                    3. Shut off lever.         3. Check that shut off lever is
                                                                  returned to the run position.




                                               85                      Westerbeke Engines

                                    ..
.E.auI1               Possjble Cause                 Yerifjcatjon/Correctjon

START switch is de-   1. Connection to starter       1. Check connection S at the
pressed: no starter      solenoid faulty.               starter solenoid for 12 volts
engagement.                                             with the switch depressed.
Engine does not
crank.                2. Faulty start switch.        2. Check switch with an
                                                        ohmmeter.

                      3. Faulty preheat solenoid.    3. Twelve volts is present
                                                        at the S terminal of the
                                                        starter solenoid.

                      4. Loose battery               4. Check battery connections
                         connection.                    at both the + and - ground.

                      5. Low batteries.              5. Check battery charge state.
                                                        Low voltage at the solenoid's
                                                        S terminal with no activation.

                      6. Sea water in                6. Remove exhaust hose at exhaust
                         cylinders.                     elbow and drain water. Correct
                                                        the cause of sea water intrusion.


Engine cranks,        1. Shut-off valve at           1. Return shut-off valve to
but does not start.      fuel tank.                     its on position. Now bleed
                                                        the fuel system.

                      2. Faulty fueling system.      2. Check for fuel
                                                        to engine.

                      3. Air is in the fuel          3. Bleed the fuel system.
                         system.                        Locate the leak and correct
                                                        it. Check return fuel for no
                                                        air present.

                      4. Fuel pump is not            4. Check pump operation.
                         operating.                     Check for 12 volts at pump.

                      5. Fuel filters are clogged.   5. Oean/replace filters.

                      6. Fuel solenoid not working   6. Check 12 volts present at
                         (optional).                    solenoid.


Failure to stop.      1. Fuel solenoid faulty        1. Stop engine by man-
                         (optional).                    ually shutting off
                                                        fuel and air.

                      2. Shut off cable.             2. Cable not operating shut
                                                        off lever.




Westerbeke Engines                86
                       possjble Cause                 Yerifjcatjon/Correctjon

Engine Stops.          1. Fuel starvation.            1. Check to see that the
                          Fuel shut-off is turned        shut-off valve at the
                          off.                           fuel tank is on.


                       2. Fuel pump is                2. Inspect the fuel pump for
                          inoperative.                   12 volts and see if it is
                                                         pumping.


                       3. Water is in the             3. Pump water out of the
                          fuel.                          bottom of the fuel tank(s) and
                                                         change the fuel filters and
                                                         bleed the fuel system.

                       4. Exhaust system is           4. Check exhaust system for
                          restricted.                    some type of blockage
                                                         such as carbon buildup at
                                                         the exhaust elbow. Check
                                                         for a fault in the muffler.
                                                         Check for a collapsed
                                                         exhaust hose.



Battery runs down.     1. DC charge circuit faulty.   1. Perform DC voltage check
                                                         of charge circuit.

                       2. Bad battery                 2. Connections are corroded
                          connections.                   or loose at the battery and/or
                                                         at the engine.



Black exhaust smoke.   1. Engine is                   1. Check generator data plate
                          overloaded.                    for rating and monitor the load
                                                         that is producing the black
                                                         exhaust smoke.

                       2. Poor fuel quality or        2. Check fuel filters. Make sure
                          incorrect fuel.                you are using #2 diesel fuel.

                       3. Faulty injector(s).         3. Remove and test injectors.

                       4. Lack of air.                4. Check air intake for
                                                         restrictions. Make sure
                                                         adequate combustion air is
                                                         present.




                                  87                          Westerbeke Engines
                                    MARINE TRANSMISSIONS


JSGear
The standard transmission on the 20B Two and 30B Three is the JS Gear. Contact Westerbeke Corpora-
tion factory for overhaul information.


HURTH MARINE GEAR
ZF INDUSTRIES MARINE US HEADQUARTERS
3131 SW 42ND STREET
FORT LAUDERDALE, FL 33312

TEL. 954-581-4040
FAX 954-581-4077

BORG WARNER MARINE & INDUSTRIAL TRANSMISSIONS
200 THEODORE RICE BLVD
NEW BEDFORD, MA 02745

TEL. 508-979-4881
FAX 508-979-4826




 Westerbeke Engines                              88
                     TABLE OFSTANDARD HARDWARE TIGHTENING TORQUES

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard
hardware.
                                      Pitch                     Ib-ft                    kg-m
~rad~4T
     6mni bolt head/nut               1                     2.9 - 5.1                0.4 - 0.7
     8mm bolt head/nut                1.25                 7.2 - 11.6                1.0 - 1.6
    10mm bolt head/nut                1.25                13.7 - 22.4                1.9 - 3.1
    10mm bolt head/nut                1.5                 13.0 - 21.7                1.8 - 3.0
    12mm bolt head/nut                1.25 (ISO)          25.3 - 39.8                3.5 - 5.5
    12mm bolt head/nut                1.5                 25.3 - 39.8                3.5 - 5.5
    12mm bolt head/nut                1.75                21.7 - 36.2                3.0 - 5.0
    13mm bolt head/nut                1.5                 32.5 - 50.6                4.5 - 7.0
    14mm bolt head/nut                1.5                 36.2 - 57.9                5.0 - 8.0
    14mm bolt head/nut                2                   34.0 - 55.7                4.7 - 7.7
    16mm bolt head/nut                1.5                 54.2 - 79.6                7.5 -11.0
    16mm bolt head/nut                2                   51.4 - 76.7                7.1 -10.6

~rad~6T
     6mm bolt head/nut                1                    4.3 -        6.5          0.6 -   0.9
     8mm bolt head/nut                1.25                10.8-        15.9          1.5 -   2.2
     10mm bolt head/nut               1.25                21.7 -       32.5          3.0 -   4.5
    10mm bolt head/nut                1.5                 19.5 -       30.4          2.7 -   4.2
    12mm bolt head/nut                1.25 (ISO)          36.2 -       57.9          5.0 -   8.0
    12mm bolt head/nut                1.5                 36.2 -       50.6          5.0 -   7.0
    12mm bolt head/nut                1.75                34.7 -       49.2          4.8 -   6.8

~rad~ 7T, aT and a.a
     6mm bolt head/nut                1                     5.8 - 8.7                0.8 - 1.2
     8mm bolt head/nut                1.25                14.5 - 21.7                2.0 - 3.0
    10mm bolt head/nut                1.25                28.9 - 39.8                4.0 - 5.5
    10mm bolt head/nut                1.5                 26.8 - 37.6                3.7 - 5.2
    12mm bolt head/nut                1.25 (ISO)          54.2 - 75.9                7.5 -10.5
    12mm bolt head/nut                1.5                 50.6 - 65.1                7.0 - 9.0
    12mm bolt head/nut                1.75                43.4 - 61.5                6.0 - 8.5
    13mm bolt head/nut                1.5                57.9 - 86.8                 8.0 -12.0
    14mm bolt head/nut                1.5                72.3 -108.5                10.0 -15.0
    14mm bolt head/nut                2                   68.7 -101.3               9.5 - 14.0
    16mm bolt head/nut                1.5               108.5 - 166.4              15.0 - 23.0
    16mm bolt head/nut                2                 101.3-159.1                14.0 - 22.0

~rad~ ~ cac~~r~w
          1/4 UNC                                            9     -    11           1.2 - 1.5
          1/4 UNF                                           11     -    13           1.5 - 1.8
          5/16 UNC                                          18     -    20           2.5 - 2.8
          5/16 UNF                                          21     -    23           2.9 - 3.2
          3/8 UNC                                           28     -    33           3.7 - 4.6
          3/8 UNF                                           30     -    35           4.1 - 4.8
          7/16 UNC                                          44-         49           6.1 - 6.8
          7/16 UNF                                          50 -        55           6.9 - 7.6
          1/2 UNC                                           68 -        73           9.4 -10.1
          1/2 UNF                                           73 -        80          10.1 -11.1




                                                   89                              Westerbeke Engines
                                        Socket Size                      .Lb:ft.                  &l:m
Cylinder head bolt                      M 10 (14 mm)                    54 - 61                  7.5 - 8.5

                                        M 8 (12 mm)                     14 -22                   2.0 - 3.0

Rocker shaft hold down bolts            M 8 (12 mm)                     11 - 16                  1.5 '" 2.2

                                  (See the "Cylinder Head" section of this manual.)

Crankshaft pulley nut
·5.0~BCD                                M 16 (24 mm)                  72.3 - 86.7                 10 -12

Oil pan drain plug                          M 18                      36.2 - 43.4                5.0 - 6.0·
(All Models)

Oil filter                                                               8.0 - 9.4                1.1 - 1.3
(All Models)                                                   (or tighten firmly by hand)

Delivery valve holder                   M 16 (17 mm)                   25.3 - 28.2                3.5 - 3.9
(injection pump) (All Models)

InjeCtor nozzle mounting             . M 20 (21 mm)                    36.2 -43.4                 5.0 - 6.0
(All Models) (fo Engine)

Fuel Solenoid Locknut                   M 30 (36 mm)                   28.9 -36.2                 4.0 - 5.0

Glow plug                               M 10 (12 mm)                   10.8 -14.5                 1.5 - 2.0
(All Models)

Injector spray Pressure                                   140 ±.10/0 kg/cm2 (1990 psi ± 140/0)

Cylinder Compression                                         28 kg/m 2 at 280 rPm (398 psi)
Pressure
                                         M10(17 MM)                      60 -65                   8~3:-   8.9'
     FLYWHEEL BOLTS

                                   Tightening Torque for Common Bolts and Nuts

                                                                        Head mark
    Designation of screw thread     -
                                                4                            7                        10
                M6                         0.3---0.5                  " 0.8-- 1.0                 1.0- 1.3
                M8                         1.0-1.3                      1.5-- 2.2                 2.5- 3.5
               MIO                         1.8-2.5                      3.0--- 4.2                5.0 ...... 7.0
               MI2                         3.0,,:,",4.2                 5.5- 7.5                 '9.5--12.0
               MI4                         5.0--7.0                    8. O- 11.0                16.0-19.0


        * NOTE: M8 indicates Metric. 8 mm thread diameter




 Westerbeke Engines                                             90
                                                SPARE PARTS


Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than
your home port, certain spare parts should be kept on board to help minimize delays in your voyage. Please
refer to your engine's Parts List for part numbers when ordering spare parts. Listed below are those spare
parts that should be carried on board at all times.

  1. An impeller kit.

  2. A fuel system hardware kit.

  3. A secondary fuel filter element.

  4. A water pump belt.

  5. Hose clamps.

  6. A spare oil filter with a spare quart of diesel service engine oil along with a gallon of premixed antifreeze.

  7. A few zinc anodes and heat exchanger end plate gaskets.

  8. An oil pressure switch.

Other parts (listed below), whose life expectancy cannot be accurately predetermined, should be carried
on board (in addition to those listed above) especially if the vessel is to be taken on long ocean voyages.

   1. Fuel injectors.

  2. Glow plugs.

  3. Cooling system hoses.

  4. A starter.

   5. A 20 amp DC circuit breaker.

   6. An electric fuel pump.

   7. A raw water pump.

   8. Battery terminal connectors.

   9. A fuel run solenoid (optional).

The spare parts listed directly above are those we recommend be carried on board during long ocean
voyages. You may wish to ask other boat owners who have similar crafts and who have completed long
ocean voyages as to what spare parts they carried on board and what parts were needed at specific times
on the voyage. From the list provided directly above and from these inquiries, you can determine what spare
parts may be needed. In addition, if you are planning a long ocean voyage, consult your local Westerbeke
dealer for a listing of the Westerbeke dealers located on your route.




                                                        91                                 Westerbeke Engines
                     NOTES




Westerbeke Engines     92
                                                                            INDEX


         A

ALTERNATOR ............................................................................................................................................. 78
Alternator Assembly .....................................................................................,.............................................. 83
Alternator Disassembly ............................................................................................................................... 80
Alternator Inspection ................................................................................................................................... 81
Alternator Installation ................................................,................................................................................. 83
Alternator On-Engine Inspection ................................................................................................................ 79
Alternator Removal ...................................................................................................................................... 80


         C

                                                                          CAUTION

A SIZED CRANKSHAFT CANNOT BE REGROUND TO ANY UNDERSiZE ...................................... 52
APPLY THIN COAT OF ENGINE OIL TO OIL SEAL CIRCUMFERENCE AND LIP ........................... 95
BEFORE INSTALLING ROTOR TO REAR BRACKET·.····.·..·..·..............·..·.......·.·....·.....·..........·..·..· 83
CHECKING VALVE SiNKAGE .··.·..·....··.·....··..·.·····.··.··..····.··...·.·..·.....·..·..·..........·..·....................··.. 29
DISCONNECTING INJECTOR LINES ·.····.··.··.··.·····.··.....·.......·.....·.···.·..···.···.··............·.··.......···..·.. 27
DO NOT APPLY BATTERY VOLTAGE OVER 10 SECONDS CONTINUOUSLy .......·.............·. 72 & 73
EXCESSIVE FRESH WATER PUMP DRIVE BELT TENSION ...·...........·..·.·..·..·....·..·.··.·.··.·.··..·........ 95
IF GOVERNOR ASSUMED MALFUNCTIONING, CHECK BEARING OR GEAR CASE SIDE ....·.·..·. 64
INSTALLING THE PLUNGER BARREL ........................................................................................... 58
NEVER HEAT LEAD WIRES LONG ·.·..·.···...·..·.··....··.··.·..··.·..··..·.·········.·.··..·.·...............·.·.··.··.··.·.... 81
REMOVING VALVE RETAINERS ···.........·....··.····..·.·..··....·........·......·....·........·......·.....·....·......··.·.... 27
REPLACEMENT OF RINGS WITHOUT REBORING (HONING) ....................................................... 47
REPLACING THE PLUNGER BARREL·.·····.·.··.··.··.·······..··.·.··.···.·.····.···.·...·.··.·.........·..··.·.......·....... 57
SCRAPE OFF CARBON DEPOSiTS ··.·.....·.....··..··.·.··...·.....··...·..................·...·..·..·..··.....................· 60
SMEARING GREASE AFTER STARTER OVERHAUL ·.·..·..··.··....··.............·............·.........·..··...·..... 77
TAG INJECTION NOZZLE AND PLUG OPENINGS ·..·.···.····......···.·..............·..........·.·..·..···.......·..... 60
USE THICK WIRES ...·..·.·..........·......·...····..·..·..·..·.··..·.··.·..·.··..·..·..··.·....·............··..·.··.·................·.. 72
WHEN INSTALLING VALVE SPRING, DO NOT OVERCOMPRESS ·.·.·.....··.....·.................·....·.··..·. 32
WHEN PRYING OPEN ALTERNATOR, DO NOT INSERT SCREW DRIVER TOO DEEP ....·....·.....·.. 80
WHEN REBORING A CYLINDER TO OVERSIZE, REMAINDER MUST ALSO BE REBORED ..·..·..·. 55

Camshaft ............................................................,........................................................................................ 20
CAMSHAFTS (Valve and Pump) ................................................................................................................. 41
Camshafts' Inspection ................................................................................................................................ 43
Camshafts' Installation ................................................................................................................................. 44
Connecting Rod .......................................................................................................................................... 19
Connecting Rod Bearing ............................................................................................................................ 19
COOLING SySTEM ..................................................................................................................................... 67
CRANKSHAFT .....................................................................................................................................19 & 50
Crankshaft Inspection ................................................................................................................................. 51
Crankshaft Rear Oil Seal Replacement ...................................................................................................... 53
Crankshaft Removal .............................................................................................................................:...... 51
CYLINDER BLOCK..............................................................................................................................17 & 54
Cylinder Block Inspection ........................................................................................................................... 55




                                                                                93                                                 Westerbeke Engines
Cylinder Bore ............................................................................................................................................... 17
Cylinder Compression Pressure .................................................................................................................15
Cylinder Head ..............................................................................................................................................15
CYLINDER HEAD CONSTRUCTION AND SERVICING .............................................................................26
Cylinder Head Inspection and Repair .........................................................................................................28
Cylinder Head Removal ...............................................................................................................................27
Cylinder Reboring ........................................................................................................................................55


         o
Difference Between Cylinders (maximum) ....................................................................... '" ...................... .15


         E

ENGINE DISASSEMBLY ..............................................................................................................................25
ENGINE OVERHAUL ...................................................................................................................................23
ENGINE SERVICE SPECIFICATIONS, 20B TWO & 30B THREE ............................................................... 15
ENGINE TROUBLESHOOTING ..................................................................................................................85


          F

Fresh Water Pump Drive Belt Tension ........................................................................................................68
Front Oil Seal Replacement. ........................................................................................................................36
Fuel Injection Order .....................................................................................................................................15
FUEL INJECTION PUMP .............................................................................................................................56


          G

GEAR CASE AND OIL PUMP ......................................................................................................................34
Gear Case and Oil Pump Removal and Inspection ....................................................................................35
Gear Case Installation.....................................................·............................................................................37
GENERAL SPECIFICATIONS, 20B TWO ......................................................................................................9
GENERAL SPECIFICATIONS, 30B THREE ................................................................................................12
GLOW PLUG ................................................................................................................................................66
Glow Plug Inspection ...................................................................................................................................66
GOVERNOR .............................:....: ..............................................................................................................65
Governor Levers' Disassembly and Reassembly .......................................................................................37
Governor Removal and Installation .............................................................................................................65
Governor Shaft Bushings' Replacement. ....................................................................................................36
GOVERNOR SYSTEM .................................................................................................................................62
Governor System Inspection .......................................................................................................................36




 Westerbeke Engines                                                              94
INJECTION NOZZLE .................................................................................................................................. 59
Injection Nozzle Adjustment ....................................................................................................................... 61
Injection Nozzle Assembly.......................................................................................................................... 60
Injection Nozzle Disassembly ..................................................................................................................... 60
Injection Nozzle Inspection ........................................................................................................................ 60
Injection Nozzle Installation ........................................................................................................................ 61
Injection Nozzle Removal ........................................................................................................................... 60
Injection Pump Assembly ........................................................................................................................... 58
Injection Pump Camshaft ...........: ............................................................................................................... 20
Injection Pump Disassembly ...................................................................................................................... 57
Injection Pump Inspection .......................................................................................................................... 57
Injection Pump Inspection while on Engine ............................................................................................... 57
Injection Pump Installation ..............................................................................~ ... :....................................... 58
Injection Pump Removal ............................................................................................................................. 57
 Injection Timing at BTDC on Compression Stroke .................................................................................... 15



         M

MARINE TRANSMISSIONS ........................................................................................................................ 88
Main Bearing ...............................................:............................................................................................... 20


         o
Oil Specification .......................................................................................................................................... 21


          p

PRODUCT SOFTWARE DISCLAIMER .......................................................................................................... 1
Piston ........................................................................................................................................................... 17
PISTON AND CONNECTING ROD ............................................................................................................ 45
Piston and Connecting Rod Inspection ..................................................................................................... 46
Piston and Connecting Rod Installation ..................................................................................................... 47
Piston and Connecting Rod Removal ........................................................................................................ 46
Piston Pin ..................................................................................................................................................... 18
Piston Rings ................................................................................................................................................. 18
PREPARATIONS FOR OVERHAUL ............................................................................................................ 24
Push Rod ..................................................................................................................................................... 20


          R

Raw Water Pump ......................................................................................................................................... 68
Raw Water Pump OverhauL ............................................................ '" ........................................................ 69
Removal of External Parts and Subassemblies ......................................................................................... 25
Rocker Arm ........................................................................................................................,......................... 17




                                                                                  95                                                  Westerbeke Engines
             S

    SPARE PARTS .............................................................................................................................................91
    STARTER ......................................................................................................................................................71
    Starter Adjustment and Assembly................·..............................................................................................76
    Starter Adjustment and Repair ....................................................................................................................72
    Starter Disassembly .....................................................................................................................................74
    Starter Inspection.........................................................................................................................................75
    SYSTEM SPECIFICATIONS, 20B TWO ......................................................................................................10
    SYSTEM SPECIFICATIONS, 30B THREE ...................................................................................................13

,
\
             T

    TABLE OF CONTENTS ..................................................................................................................................2
    TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ................................................................89
    Tappet ..............·.·.........................................................................................................................................20
    TIMING GEARS .................................................................................................................................,.......... 38
    Timing Gears' Inspection .... ~ ........................................................................................................................39
    Timing Gears' Installation ............................................................................................................................40 .
    Timing Gears' Removal ...............................................................................................................................39
    Torque Spring Set Assembly .......................................................................................................................63
    Torque Spring Set Installation .....................................................................................................................63


              u
    UNIT 1.0. PLATES ..........................................................................................................................................8


              v
    Valve and Valve Spring Installation .............................................................................................................32
    Valve Camshaft Removal .....................................................................................................;....................... 42
    Valve Clearance (IN and EX) ........................·..............................................................................................15
    VALVE GLEARANCE ADJUSTMENT ..........................................................................................................33
    Valve Guide Replacement ...........................................................................................................................28
    Valve Inspection and Repair ........................................................................................................................31
    Valve Removal. .................................................................................................-............................................ 31
    Valve Seat Installation ..........-       ....:.................·.................................................................................................29
    Valve Seat Repair .........................................................................................................................................29
    Valve Spring ................................................................_    ................................................................................16
    Valves ...........................................................................................................................................................1"6
    VALVES AND VALVE SPRINGS ................... _                      ..............................................................................................30


              W

                                                                               IWARNINGI

     DO NOT ADJUST DRIVE BELT TENSION WITH ENGINE'ON ........................................................ 68




     Westerbeke Engines                                                                96
NOTES




  97    Westerbeke Engines


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