Westerbeke Diesel 30c Three Parts Manual

NOTES 97 Westerbeke Engines S SPARE PARTS 91 STARTER 71 Starter Adjustment and Assembly 225 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 225225 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 10 PLATES 8 v Valve and Valve Spring Installation 32 Valve Camshaft Removal 42 Valve Clearance IN and EX225 15 VALVE GLEARANCE ADJUSTMENT 33 Valve Guide Replacement 28 Valve Inspection and Repair 31 Valve Removal 31 Valve Seat Installation 225 29 Valve Seat Repair 29 Valve Spring 16 Valves 16 VALVES AND VALVE SPRINGS 30 W IWARNINGI DO NOT ADJUST DRIVE BELT TENSION WITH ENGINEON 68 Westerbeke Engines 96 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 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 DISASSEMBL Y 25 ENGINE OVERHAUL 23 ENGINE SERVICE SPECIFICATIONS 20B TWO 30B THREE 15 ENGINE 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 225 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 INDEX A ALTERNATOR 78 Alternator Assembly 83 Alternator Disassembly 80 Alternator Inspection 81 Alternator Installation 83 Alternator OnEngine 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 225225 72 73 EXCESSIVE FRESH WATER PUMP DRIVE BELT TENSION 95 IF GOVERNOR ASSUMED MALFUNCTIONING CHECK BEARING OR GEAR CASE SIDE 225225225 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 225225225 80 WHEN REBORING A CYLINDER TO OVERSIZE REMAINDER MUST ALSO BE REBORED 225225225 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 NOTES Westerbeke Engines 92 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 engines 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 belowwhose life expectancy cannot be accurately predetermined should be carried on board in addition to those listed 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 optionalThe 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 M 8 M 8 AdobeUCS9 AdobeUCSMARINE TRANSMISSIONS JSGear The standard transmission on the 20B Two and 30B Three is the JS Gear Contact Westerbeke Corpora255tion factory for overhaul information HURTH MARINE GEAR ZF INDUSTRIES MARINE US HEADQUARTERS 3131 SW 42ND STREET FORT LAUDERDALE FL 33312 TEL 9545814040 FAX 9545814077 BORG WARNER MARINE INDUSTRIAL TRANSMISSIONS 200 THEODORE RICE BLVD NEW BEDFORD MA 02745 TEL 5089794881 FAX 5089794826 Westerbeke Engines 88 if it EauI1 Possjble Cause START switch is de1 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 solenoids 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 Shutoff valve at 1 Return shutoff 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 Oeanreplace filters 6 Fuel solenoid not working 6 Check 12 volts present at Failure to stop 1 Fuel solenoid faulty 1 Stop engine by shutting off fuel and air 2 Shut off cable 2 Cable not operating shut off lever Westerbeke Engines 86 Preheat is depressed no preheat Preheat is depressed fuel pump does not operate Start is depressed no fuel delivery to injectors ENGINE possjble Cause 1 Connection or switch 2 Preheat solenoid 3 Glow plugs are faulty 1 Faulty connections or bad pump 1 Fuel solenoid or connections to it are faulty 2 Voltage problem 3 Shut off lever 85 1 Check for 12 volts at the PREHEAT switch and at the S terminal on the 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 Twelve volts is present at the glow plugs Remove each plug and check the resistance of the plugs with an ohmmeter 15 22 ohm1 Check for 12 volts at the fuel pump connections If 12 volts are present the pump is possibly faulty Tap pump with a mallet Pumps plunger may be stuck Check for contamination which will affect the pump 1 Check for 12 volts at lead positive terminal at the back of the fuel solenoid when the PREHEAT button is depressed Twelve volts with no activation indicates a faulty solenoid 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 Check that shut off lever is returned to the run position Westerbeke Engines NOTES Westerbeke Engines 84 facing the 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 b Check for conduction between a slip ring and shaft or coreIf any conduction is found the field coil is suspected to be poor in insulation Replace the field coil 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 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 Westerbeke Engines 82 Checking Field Coil for Conduction Checking Field Coil for Insulation Checking Stator Coil for Conduction Checking Stator Coil for Insulation 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 Wear Break and short circuit Deformation and damage I Inspection of Alternator 1 Inspecting the diodes Wear to limit line Break and short circuit t I Wear and roughness a Connect a circuit tester ohmmeteracross 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 AdobeUCSe Apply all load Including the lamps f Increase engine speed until normal alternator speed is attained Read the maximum indication of the ammeter at 135 V of voltmeter indication Output current must conform to the specification AHernator Removal 1 Disconnect the battery cable 2 Disconnect the lead wire from terminal S on the back of the alternator 3 Disconnect the alternator connector 4 Loosen the alternator brace bolt and support bolt Push the alternator toward the engine and remove the fan belt 5 Dismount the alternator Alternator Disassembly 1 Remove the three through bolts 2 Heat the rear bracket around the rear bearing up to 50 60260 C with a solder ironand separate the bracket from the stator coil CAUTION Ammeter Checking for Output Characteristic Terminal Current I voltage VAI I 15A 14 0 I I I Noload 135A 14 8 I output I 50A 135 24 15A 14 15 maximum Loaded 35A 14 30 output maximum 50A 135 50 maximum 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 Speed rpm1300 maximum 1300 maximum 1300 maximum 2500 maximum 2500 maximum 2500 maximum OnEngine 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 highvoltage 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 ter255minal of the battery and terminal B or the alter255nator b Ground the alternator terminal L through a voltmeter 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 stoppedd Shortcircuit the ammeter and start the engine L R Checking for Regulated Voltage Ammeter e Read the voltmeter indication regulated voltageunder 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 terminalB through a voltmeter c Connect the battery grounding cable d Start the engine 79 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 b Measure end play by moving the pinion shaft in the axial direction If the end play exceeds 05 mm increase the number of adjusting washers inserted 2 Greasing Whenever the starter has been overhauled apply grease to the following parts 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 2 Inspecting the armature a Check the armature with a growler tester If its 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 00 and the depth of undercut Repair or replace it if the service limit is exceeded Also check the commutator out255side surface for dirtiness and roughness If rough polish the commutator with finegrain sandpaper 3 Brush holder inspection a Check the brushes If worn out beyond the ser255vice 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 brushof coil and yoke b Check for conduction between both ends brushesof coil c Check the poles and coil for tightness Starter Adjustment and Assembly Reassembly the starter assembly in the reverse order of disassembly giving care to the following 1 Pinion shaft end play adjustment Set the end play thrust gapto 05 mm or less by inserting an adjust255ing washer between the center bracket and reduc255tion gear a Fit the pinion shaft reduction gear washer and snap ring to the center bracket Westerbeke Engines 76 Checking Armature Coil Checking Field Coil Adjusting Gear washer O5mm maximum fl Adjusting Pinion Shaft End Play 1 Starter Disassembly 1 Disconnect the wire from the magnetic switch terminaIIM 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 pressfitted in the front bracket If that bearing has worn off replace the front bracket assembly Westerbeke Engines 74 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 CAUTION 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 CAUTION Do not apply battery current for more than 1 0 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 hand CAUTION Do not apply battery current for more than 1 0 seconds 73 Starter Attraction Test Starter Holding Test Starter Return Test Westerbeke Engines Starter Adjustment and Repair If any abnormality is assumed by the following tests adjust the starter or disassemble and repair it 1 Pinion gap inspection a Interpose a battery 12 Vbetween the starter terminallS and the starter body and the pinion will protrude and stop CAUTION Never apply battery voltage for over 10 seconds continuously Push back Lightly O520mm Inspecting Pinion Gap b Lightly push the pinion back and measure the return stroke called pinion gapc If the pinion gap is not within the standard range 05 to 20 mmadjust it by increasing or decreasing the number of packings on the magnetic switch The gap is decreased as the number of packings increases 2 Noload 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 moreIfthe current or starter speed is out of specification disassemble the starter and repair it CAUTION No267load Test 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 directdrive type starter When detecting starter rotation at the pinion tip take care of protrusion of the pinion Westerbeke Engines 72 STARTER lIlID 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 a Install the seals ref 7and spacer ref 14in the pump housing Push the impeller side seal into the housing Rotate the pump and install the spacer ref 14against the seal face Push the bearing side seal into the housing from the bearing side NOTE The seals flat surfaces having printing and numbers face towards each other b Install shaft ref 8into bearings Support bearings ref 2at 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 1932 in2615 mm 1132 inc Support the pump housing at the impeller side Apply a small amount of petroleum jelly to the seals ref 7inner lips and to impeller shaft ref 8Carefully 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 3d Position the cam ref 6in the housing and secure it in place with the screw ref 4and sealing washer ref 5NOTE 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 10Push the assembly into the housing with the drive screw mating in the slot of the drive shaft f Install the cover gasket ref 11cover ref 12and secure them with the six cover screws ref 13Westerbeke Engines 70 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 13cover plate ref 12and the cover plate gasket ref 11NOTE 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 its allowed to dry the gasket will shrink and not be reusable b Remove the impeller ref 9with its drive screw ref 10from the pump housing c Remove the screw ref 4and sealing washer ref 5and draw the cam ref 6from the pump housing d Remove the circlip ref 3e Support the pump housing at the mounting flange end on an arbor press and with a drift press out the shaft ref 8and bearings ref 2from the pump housing from the impeller end f With the pump housing supported push the seals ref 7out of the pump housing Push the impeller side seal out that side and then lift the spacer ref 14out Then push the bearing side seal out that side g Supporting the bearings inner face ref 2push the shaft ref 8out of the bearings NOTE Inspect all parts and replace those showing wear or corrosion 69 Westerbeke Engines Fresh Water Pump Drive BeH Tension Generator models come equipped with belt guards that cover over the beltson the front of the engine Out of sightout of mind The belt guard is not installed for that are advised that the inspection service and maintenance spoken of below should be followed IWARNINGI Never attempt to adjust the drive belts 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 pumps 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 38 inch and no more than 12 inch 10 mm 12 mmas 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 selfpriming geardriven rotary pump with a nonferrous 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 kitImpeller failures occur when lubricant raw wateris not present Such failures are not warrantable and the operators are cautioned to make sure raw water flow is present at startup 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 pumps housing Westerbeke Engines 68 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 generators Parts List for part numbers and part descriptions if you need to order cooling system parts for your engine 7 INJECTED PRESSURE CAP INCOMING RAW WATER FRESH WATER RAW WATER EXHAUST MANIFOLD WATER TEMPERATURE SWITCH FRESH WATER DRAIN RAW WATER DRAIN Typical Cooling System 67 Westerbeke Engines AdobeUCSGLOW 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 15 20 kgm Checking Glow Plug Westerbeke Engines 66 GOVERNOR Check springs for fatigue 7 Check springs for fatigue Check shaft for flaws Check sliding sleeve joint for wear and damage Inspection Governor System Parts Governor Removal and Installation Check weight for wear and damage Check sliding sleeve for wear damage and smooth movement Check levers for smooth movements 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 pressfitting each grooved pin check the shaft for smooth rotation Coat the Orings 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 5260is minimized Instaling Speed Control Lever 65 5 StandardNo play exceeding 5 permitted Westerbeke Engines AdobeUCS3 Leaving the dial gauge set condition unvaried depress the spring stopper 1and slide the torque spring set support spring case 2Read 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 measureFor the models which do not require any torque spring action set the projection 8to a value in the range of 0 to 04 4 After adjustment tighten nut 4to a torque of 08 to 12 kgm 5 Check to see that the spring stopper 1can be depressed smoothly and that the end face of the stopper 1can become flush with the end face of the spring case 26 For the purpose of identification of projection 8apply paint of the color specified to the surface shown in the figure at the right of paragraph 1MQdeL 206 Two 306 Three projection 8 mm o 04 Identification color Red Replace the gear case and inspect the governor When removing the gear case be sure to remove the tierod cover by the side of the fuel pump and disconnect the tierod 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 the follow255A B SYSTEM I 256 GOVERNOR SYSTEM COMPONENT PARTS 1 Sealing metal 11 Tierod clip 21 Stop lever assembly 2 Sealing wire 12 Tierod cover 22 Oring 3 Low and high speed 13 Tierod 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 206 Stopper 16 Governor spring lever 26 Grooved pin 3 x 147 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 Tierod 20 Return spring Westerbeke Engines 62 Injection Nozzle Adjustment Adjust injection start pressure by increasing or decreasing the thickness of the shim washer to be inserted Varying shim thickness by 01 mm causes injection start pressure to change 10 kgcm 10 kinds of shims available from 125 mm to 17 mm in thickness 005 mm step Injection start pressure Standard Allowable limit 130 kg an or less Injection Nozzle Installation Tightening torque 2530kgm Return pipe Assembling the Nozzle Tightening torque 3540kgm 1 Clean the nozzle holder fitting surface of the cylinder head Install the nozzle holder with a gasket interposed Tightening torque 50 60 kgm 2 Connect the fuel return pipe and injection pipe Tightening torque Injection pipe Fuel return pipe 25 35 kgm 25 30 kgm 61 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 keroseneTake special care not to scratch the needle valve in the nozzle assembly Injection Nozzle Inspection Inspect the removed parts If any part is found defec255tive replace it Injection Nozzle Assembly 1 Insert the nozzle assembly into the retaining nut so 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 4 Grip the nozzle holder in a vise Tighten the retain255ing nut to the specified torque Tightening torque 35 40 kgm Westerbeke Engines 60 Fatigue and gl break 251 Poor contact 9 Inspecting Nozzle Deformation and break While immersed in kerosene check for smooth sliding 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 Pump Assembly 1 I nsert the plunger barrel into the housing 2 Install the delivery valve and valve spring Temporarily tighten the holder 3 Insert the control rack 4 I nsert 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 35 39 kgm Injection Pump Installation Install the injection pump assembly in the reverse order of removal 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 with the plunger leadAfter installation check for proper injection timing Westerbeke Engines 58 Stamp Rack side Direction of Installation of Plunger Injection Pump Inspection while on the Engine Never attempt to disassemble the pump unless it is necessary If the pump is assumed defective it is recommended to replace the pump assembly Injection Pump Removal 1 Disconnect the fuel injection pipes 2 Remove the tierod clip cover 3 Remove the tierod clip and tierod Injection Pump Disassembly 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 injection quantity by utilizing a pump tester and cam box All parts removed from the pump should be kept classified by cylinders and im255mersed in clean fuel Injection Pump Inspection 57 Inspection Inspection procedure Criterial Idling speed Measure engine speed 900sgrpm IQuickly accelerate No remarkably black267 Exhaust smoke color engine without load 2Apply load to engine smoke exhaust permitted Fuel cut 267off Turn ignition switch to OFF A solenoid acting solenoid from ON sound IJ Pipes I I I Control of Injection Pump 0OringCracks and deterioration 251 fjWear and scratch 11 wear scratch rust seizure I8J I 256 o eInterference riJc wear Westerbeke Engines AdobeUCSFUEL 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 Oring 14 Plunger spring 21 Stop wire bracket Westerbeke Engines 56 Reboring finish allowance 02 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 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 Direction of installation of cap Front Crankshaft end play 0050175 Installation of Crankshaft Cap tightening torque 5055kgm Thrust bearing only for No2 cap 53 Side seals coated J with sealant 7ONO 9 Round end down Make cap flush with cylinder block end face common to front and rear end Engines the crankshaft for wear To check the crankpins and main journals for tapering wear and outofround 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 Diameter of crankpin and main journal mmDescription Standard Service limit Main journal 43 070 dia Crankpin dia 40 070 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 out255ofround wear the inside diameter of each main bear255ing or rod bearing should be measured after its 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 regrind the crankshaft to the next under size and replace the bearing with one of the corresponding under sizes CAUTION Checking Crankshaft for Wear Under267size diameters mmDescription Main journal Crankpin 025 US 4271542730 39 71539 730 050 US 4246542480 3946539480 2 Measuring Main Bearing 10 A crankshaft which has been sized cannot be reground to any under size Tightening torque kgmOil clearance mmDescription Standard Description Service limit Main bearing cap bolt 5055 Main bearing 010 Rod bearing cap nut 3235 Rod bearing O 15 Westerbeke Engines 52 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 225 Journals and pinsDamage and uneven wear 225 Cracks clogging of oil hole and bend 225 Wear of journal contact surface Inspection of Crankshaft and Flywheel 51 Damaged to tooth face Wear and damage Wobble Westerbeke Engines CRANKSHAFT 256 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 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 Olriif Front No2 ring Proper Arrangement of Ring Gaps No1 ring gap J 0 0011 expander of oil ring 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 I n the case of a new rod which does not have a mark position the notches provided for preventing the bearing from rotatingon the same side 49 I I I I I I I I I Connecting Rod 256 Westerbeke Engines AdobeUCSFRONT mark arrow2 Installation of piston rings FRONT mark Rod front mark Align notches accurately with each other Tightening torque O 3235kgm 01 Installation of Piston Rings and Connecting Rod Cap Westerbeke Engines Pressing Push rod Connecting rod Tool body Ring set positions r mark and d OS size mark No1 ring No2 ring oil ring 48 r mark and OS size mark OS size identification paint Color of discrimination STO Without color O25White O50Blue exceeds 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 and rod assembly and draw the assembly upward from the cylinder Take care not to allow the con255necting rod to scratch the crankshaft pin and cylinder Keep the removed parts connecting rod rod cap piston etcclassified by cylinders 6 Remove the rings from each piston with the piston ring pliers 7 Using the piston setting tool pull out the piston pin from each piston Piston and Connecting Rod Inspection FRONT mark arrowPiston Removing Piston Pin Pressing Inspect the removed parts If any parts are found defective replace or repair them Damage wear 08 and ring gap 225 Wear seIzure and streaks 8 225 Clearance between piston and cylinder 225 Wear of pston ring grooves Damage and wear V Inspection of Piston and Connecting Rod Westerbeke Engines 46 225 Bend and twist 225 Big end play Standard 01 O35mm 225 Contact and seizure 225 Flaking and fusion 225 Oil clearance Standard O0220052mm 256 Damage AdobeUCSPISTON AND CONNECTING ROD Os J20031l1 200I 8PISTON AND CONNECTING ROD COMPONENT PARTS 1 Piston ring No1 5 Piston pin 8 Connecting rod cap 2 Piston ring No2 6 Connecting rod 9 Connecting rod bolt 3 Oil ring 7 Connecting rod bearing 10 Connecting rod nut 4 Piston 45 Westerbeke Engines Installation When installing the camshafts give care to the fol255lowing 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 Camshafts Inspection Each ball bearingWear and noise Inspection of Camshafts Cam lobeWear and damage Oldhams couplingWear Major diameter of injection pump cam Standard value 30 Service limit 07 BendEnd faceWear and damage Journal bearingWear and damage Cam lobeWear and damage Cam contact surfaceWear and damage Major diameter of valve cam Standard value 2737 Service limit 10 43 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 Valve and Pump I rID 1CAMSHAFT COMPONENT PARTS 1 Camshaft valve8 Tappet 2 Camshaft gear 9 Push rod 3 Ball bearing 10 camshaft injection pump4 Woodruff key 11 camshaft gear 5 Sunk key 12 Ball bearing rear6 Camshaft stopper 13 Snap ring 41 Westerbeke Engines AdobeUCSTiming Gears Installation 1 Pressfit the crankshaft gear onto the shaft 2 Pressfit 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 b Install the valve camshaft and injection pump 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 Idler Gear Note timing marks1240 TIMING GEARS 4 CjTIMING GEAR COMPONENT PARTS 1 Crankshaft gear 3 Camshaft gear 2 Idle gear 4 Injection pump camshaft gear Westerbeke Engines 38 Governor Levers Disassembly and Reassembly 1 Removal of the shaft a Remove the expansion plug taking care not to scratch the gear case b Pull out the grooved pin 2 Installation of the shaft a Install the shaft in the reverse order of removal b After installing the shaft pressfit the expansion plug into the shaft hole in the gear case Gear Case Installation Tightening torque 45kgm Sealant HERMESEA H1 or THREEBOND 1344 Gear Case Assembly Tightening torque O810kgm Taper plug tightening torque 1522kgm 37 Expansion plug Gear case Installing Governor Shaft Grooved pin Projection approx2mm Section AA Westerbeke Engines AdobeUCSFront Oil Seal Replacement 1 Remove the front oil seal 2 Pressfit 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 bush255ings out 2 Pressfit the new bushings into positions shown in the figure at right Governor System Inspection Check the governor system parts If any parts are found defective repair or replace them Westerbeke Engines 36 To be flush with this plane To be in contact with bottom Press267 fitting Governor Shaft Bushing Check springs for fatigue Check shaft for flaws Check sliding sleeve joint for wear and damage Check weight for wear and damage Gear Case and Oil Pump Removal and Inspection 1 Remove the crankshaft pulley 2 Remove the fan and fan belt 3 Remove the tierod 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 251 rJW f7lr Srio I Smooth movement I Seal surface interference Inspection of Gear Case and Oil Pump Wear damage and clearance Thoroughly clean oil line 35 Westerbeke Engines AdobeUCSGEAR CASE AND OIL PUMP IiGEAR 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 Highpressure pump gear housing 4 Front oil seal 8 Oil pump outer gear 12 Housing gasket Westerbeke Engines 34 VALVE CLEARANCE ADJUSTMENT Valve Clearance Adjustment Cylinder head bolts lIlUSt be retightened before adjust255ing 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 numerical order illustrated at right Tightening torque M 10 bolt 542 615 Ibft 75 85 kgmM8 bolt 108 159 Ibft 20 30 kgmThe rocker assembly the rocker arms shaft and staysis to be kept removed when the cylinder head bolts are retightened Rocker stay tightening torque M8 bolt 108 159 Ibft 15 22 kgm1 Set the cylinder to be adjusted to the top dead center of the compression stroke Valve clearance 00098 in 025 mmcoldfor both intake and exhaust valves 2 The top dead center of the compression stroke can be obtained by aligning the TOC Top Oead Centermark notchon the crankshaft pulley with the mark on the gear case 3 First align the TOC mark for the No 1 cylinder Confirm that the valves do not move up and down when the crankshaft is turned about 20260 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 TOC for the NO1 cylinder turn the crankshaft 180260 clockwise and the NO2 cylinder is set to TOC b Three Cylinder Engine From the TOC for the No 1 cylinder turn the crankshaft 240260 clockwise to set the No3 cylinder TOC Further turn the crankshaft 240260 clockwise and the No 2 cylinder is set to TOC 33 4 o 02 01 Cylinder Head Bolt Tightening Sequence Cylinder Head Bolt Tightening Sequence ADJUST EXHUSl VUVES TO 0012 INCH 11111 ADJUST INTAKE VALVES TO 0010 ISCHES MMInjection Timing Mark 208 308 Westerbeke Engines AdobeUCS1 If the valve face is found worn down resurface it with a valve refacer If the margin of the resur255faced valve exceeds the service limit replace the valve 2 If the valve stem end has been indented by wear flatten it with an oil stone I255f t45 225 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 Press this surface Driving in stem seal Installation of Valve Spring Westerbeke Engines Installing spring 32 With retainer depressed to compress spring install retainer lock Installing spring retainer AdobeUCSValve Removal 1 Dismount the cylinder head assembly 2 Depress the valve retainer to compress the valve springand remove the retainer lock 3 Remove the valve Valve Inspection and Repair If any parts are found defective repair or replace them Margin Inspection of Valve and Valve Spring Valve fatigue and damage Inspection item Standard Service limit Free length Dim405 I Load kg mm594355 15 Squareness 2 3 Margin mm10 05 QWear and damage Without for agricultural Dents and wear IRidge and damage valve spring te5ter 31 Westerbeke Engines AdobeUCSVALVES AND VALVE SPRINGS 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 AdobeUCSValve Seat Repair If a valve seat is found defective reface it or replace the cylinder head Sinkage of valve Standard Service limit 05 mm 15 mm CAUTION When checking valve sinkage the valve guide must be in normal condition Resurface the valve seat so that it contacts the midportion of the valve face 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 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 29 Checking Valve Sinkage Valve sinkage Interface and wear Resurfacing Valve Seat Common to intake and exhaust valvesSequence for Tightening Cylinder Head Bolts Sequence for Tightening Cylinder Head Bolts Westerbeke Engines Cylinder Head Inspection and Repair Check guide for ware and damage Check for valve contact wear damage and sink of seat face Valve Guide Replacement If a valve guide is found defective replace it 1 Remove the valve guide by pressing at its upper end and pull it out to the valve seat side 2 Install the valve guide by press fitting the guide from the upper side ofthe cylinder head to a height of 14 261 05 mm from the valve spring seat face Westerbeke Engines 28 Check cylinder head surface for warpage between bolt holes within O05mm I Valve Guide Check for cracks damage water leak and remove oil sludge sealant deposit carbon deposit 625612666 i I I I I I 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 for Loosening Cylinder Head Bolts 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 26726720B 27 Westerbeke Engines CYLINDER HEAD CONSTRUCTION AND SERVICING 225 ejCylinder head a cross section 225 FJ CYLINDER HEAD COMPONENT PARTS 1 Cylinder head 6 Water outlet fitting 2 Valve guide 7 Cylinder head gasket 3 Cylinder head bolt main bolt8 Mouth piece 4 Cylinder head bolt subbolt9 Thermostat 5 Seat ring 3600 rpm specification engine10 Thermostat fitting Westerbeke Engines 26 AdobeUCSit if 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 engines exterior of all dirt and oil deposits 1Ij I iil i i 1111 I Oil Sump Drain Westerbeke Engines 24 Heat Exchanger Drains AdobeUCSENGINE 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 NOTES Westerbeke Engines 22 Oil Specification TEMPERATURE ENGINE OIL SRE Ic F 30 20 20 10 o 10 20 30 40 50 o 20 40 GO 80 100 120 un Dii mmmwn NBI WhWuj NOTE API SPECIFICATION OF CF OR CG4 IN ACCORDANCE WITH THE THERMAL ENVIRONMENT SEE TABLEOil Pressure Relief Valve SpringPlunger Type Oil Pump Crankshaft Driven Oil Pump and Oil Filter 21 Westerbeke Engines Specified ValueStandard RepairUmit Main Bearing Type Aluminum metal with back metal Oil clearance No2 Flanged metalUnder size 001002 025 050 mmCamshaft Driving method Gear drive Front journal Ball bearing Journal to cylinder block hole clearance 0006 Service limit015 mmMajor diameter of cam IN and EX1078 2737 mmOil clearance 0006 Service limit015 mmInjection Pump Camshaft Driving method Gear drive Bearing Ball bearing front and rearMajor diameter of cam 118 30 mmTappet 00 075 19 mmTappet to cylinder block clearance 0006 Service limit015 mmPush Rod Bend Within 00118 03 mmWesterbeke Engines 20 Specified ValueStandard Repair Limit Connecting Rod Type Forged Ibeam Bend and twist Within 0002 005 mmBig end thrust clearance 0004 0014 01 035 mmConnecting Rod Bearing Type Aluminum metal with back metal Oil clearance 0006 Service limit015 mmUndersize 001002 025 050 mmCrankshaft Type Fully Bend Within 0001 003 mmEnd play 0002 0007 005 0175 mmJournal 00 1693 0006 43 mm015 mmPin 00 1575 0006 40 mm015 mmUnder size finishing Journal US 025 16817 16823 42715 42730 mm050 16719 16724 42465 42480 mmPin US 025 15636 15642 39715 39730 mm050 15537 15543 39465 39480 mm19 Westerbeke Engines Piston Protrusion from cylinder block top surface Piston Pin Type 00 Piston pin to piston clearance Piston pin to connecting rod clearance Piston Rings Number of rings Compression 2Oil 1Ring width Compression No2Oil Ring side clearance Compression No 1 No2 Oil ring Ring gap Westerbeke Engines Specified ValueStandard 001 002 003 025 050 075 mm0035 09 mmSemifloating type 0709 18 mmPressfit load 22046 26111023Ibs 1000 261500 kgRepairUmit 0003 Service limit008 mmNo1 Chrome plated semikeystone type No2 Tapered Chrome plated ring with coil expander 18 0079 2mm0118 3mm0002 0004 005 009 mm0001 0003 003 007 mm0006 0016 015 040 mm0008 02 mmo Valves Valve clearance IN EXValve head dia INEXOverall length StemOD Stem to guide clearance INEXValve face angle Valve head thickness margin widthValve head sinkage From cylinder head to bottom faceValve Spring Free length length Squareness Westerbeke Engines Specified ValueStandard 16 0010 cold025 mm1051 267 mm0972 247 mm3701 94 mm0260 66 mm0039 10 mm0020 05mm 1595 405 mm13095 Ibs1398 in 594 kg355 mm32716 Ibs11 02 in 1484 kg28 mmRepair Limit 1051 Service limit267 mm0972 Service limit247 mm1547 393 mm1 2 N AdobeUCSD x P 2 D x P 3 30B THREE MARINE DIESEL SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Engine Timing spill timingInjector Pressure Nozzle Lift Pump PN 037818 Air cleaner Air Flow engine SYSTEM General Operating Temperature Fresh Water Pump PN 037015 Raw Water Pump PN 033636 Raw Water Flow at 3600 rpm measured before discharging into exhaust elbowSystem Capacity fresh SYSTEM General Open flow totally selfbleeding manual priming No2 Diesel cetane 45 or betterInline plunger type Bosch type19260 2611260 BTDC Static 1991 psi 140 Throttle type 12volt DC lift capacity 5 ft 15 mPlastic screen type cleanable 604 cfm 17 cmmFresh watercooled block with heat exchanger 170 190260 F 77 88260 CCentrifugal type metal impeller beltdriven Positive displacement rubber impeller 111 US gpm 42 Ipmapproximate 4 qts 38 litersPressure type by Trochoid pump geardriven with external pressure relief valve 13 Westerbeke Engines AdobeUCS30B THREE MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore Stroke Piston Displacement Firing Order Direction of Rotation Maximum Torque at 2200 rpmCompression Ratio Compression Pressure Valve Timing Valve Seat Angle Valve Clearance engine coldDimensions Inclination Weight Fuel Consumption propeller allowing rated rpmIdle Speed Cruise rpm Westerbeke Engines Diesel fourcycle threecylinder fresh watercooled Vertical inline overhead valve mechanism 27 hp at 3600 rpm centrifugal weight type Swirl type 299 x 276 inches 76 x 70 mm5909 cubic inches 0952 liters132 Clockwise when viewed from the front 43 Ibft 59 kgm231 398 psi 28 kgcm2at 280 rpm Intake Opens BTDC Intake Closes ABDC Exhaust Opens BBDC Exhaust Closes ATDC Intake Exhaust 450 Intake 0010 inches 025 mmExhaust 0010 inches 025 mmLength 2881 inches 73177 mmWidth 1600 inches 40640 mmHeight 1975 inches 50165 mmContinuous 150 Temporary 250 not to exceed 30 min272 Ibs 1233 kgs10 US gph 378 Iphrunning at 2500 rpm 1200 rpm 2500 3000 rpm 12 P 2 D x 8 P 3 20B TWO MARINE DIESEL SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Engine Timing spill timingInjector Pressure Nozzle Lift Pump PN 037818 Air cleaner Air Flow engine SYSTEM General Operating Temperature Fresh Water Pump PN 037015 Raw Water Pump PN 033636 Raw Water Flow at 3600 rpm measured before discharging into exhaust elbowSystem Capacity fresh SYSTEM General Westerbeke Engines Open flow totally selfbleeding manual priming No2 Diesel cetane 45 or betterInline plunger type Bosch type19260 2611260 BTDC Static 1991 psi 140 kgcm2Throttle type 12volt DC lift capacity 5 ft 15 mPlastic screen type cleanable 406 cfm 11 cmmFresh watercooled block with heat exchanger 170 190260 F 77 88260 CCentrifugal type metal impeller beltdriven Positive displacement rubber impeller 111 US gpm 42 Ipmapproximate 29 qts 27 litersPressure type by Trochoid pump geardriven with external pressure relief valve 10 1 2 UNIT 10 PLATES 225 MODEL SPEC AVO MA USA SERNO 20B TWO UNIT 10 PLATE 225 MODEL SPEC AVO MA USA SERNO 30B THREE UNIT 10 PLATE The unit 10 plate is attached to the exhaust manifold of the engine These illustrations are provided so that the owneroperator may transcribe the specifications and serial number from the 10 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 20 Amp DC Circuit Zinc Anode Gear Dipstick and Oil Filler Adjustable Engine Isolator Air Intake Silelcer Fuel Injection Pump Fresh Water Block Drain Plug 7 Solenord ThrotHe and ShutOff Connections Oil Pressure Lube Oil Drain Westerbeke Engines AdobeUCS50 Amp AdJULQU Engine Isolator Starter with Solenoid Westerbeke Engines fresh Water Fill Cap Shift lever DC Battery Ground Connection 6 AdobeUCSFreSh W Fill VI llilake Silenger Zinc Gear Dipstick and Oil Filler Engine Isolator 5 Pump Westerbeke Engines AdobeUCS T9PEngine Oil 50 Amp DC Alternator Adjustable Engine Isolator Westerbeke Diesel Engines 2674 45260 Exhaust Elbow Gear Shift Lever Battery Ground Connection AdobeUCSTABLE OF CONTENTS 71 ALTERNATOR 78 ENGINE 85 MARINE TRANSMISSIONS 88 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 89 SPARE PARTS 91 INDEX 93 3 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 DISASSEMBL Y 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 IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds such as brochures drawings technical data operators and workshop manuals parts lists and parts price lists and other information instructions and specifications provided from sources other than Westerbeke is not within Westerbekes 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 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 Westerbekes products and supplied by others such as engine blocks fuel systems and components transmissions electrical components pumps and other productsare generally supported by their manufacturers with their own software and Westerbeke must depend on such software for the design of Westerbekes own product software Such software may be outdated and no longer accurate Routine changes made by Westerbekes suppliers of which Wester255beke rarely has notice in advance are frequently not reflected in the suppliers 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 noncurrent Westerbeke software editions in the field Additionally most Westerbeke products include 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 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 SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator IWARNINGI The above symbol is used in the manual to warn of possible serious personal injury or loss of life CAUTION The above symbol is used in the manual to caution personnel of possible damage to equipment Read the manual carefully and thoroughly before attempting to operate the equipment Know when dangerous conditions can exist and take necessary precautions to protect personnel and equipment Fuels exhaust gases batteries electrical equipment and moving and hot parts are potential hazards that could result in serious personal injury or death Follow recommended proce255dures carefully Always operate bilge blowers for at least five minutes before starting a gasolinefueled engine ensure no gasoline fumes are present before starting 225 Prevent Electric Shock Shut off electric power before accessing electrical equip255ment Use insulated mats whenever working on electrical equip255ment Make sure your clothing is dry not damp particularly shoesand keep your skin surfaces dry when handling electrical equipment Remove wristwatch and jewelry when working on electri255cal equipment Do not connect utility shore power to vessels AC circuits except through a shiptoshore doublethrow transfer switch Damage to vessels AC generator may result if this is not done Be extremely careful when working on electrical com255ponents High voltage can cause injury or death 225 Exhaust Gases Are Toxjc Ensure that the exhaust system is adequate to expel gases discharged from the engine Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are wellventilated 225 Use Extreme Care When Handling Engine Fuel A constant danger of explosion or fire existsDo not fill fuel tankswhile the engine is running Do not smoke or use an open flame near the engine or the fuel tank 225 Do Not Alter or Modjfy the Fuel System Be sure all fuel supplies have a positive shutoff valve Be certain fuel line fittings are adequately tightened and free of leaks Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use rated ABC by the NFPA are appropriate for all applications encountered in this environment 225 Use Extreme Care When Servicing Batterjes Wear rubber gloves a rubber apron and eye protection when servicing batteries Lead acid batteries emit hydrogen a gas which can be ignited by electrical arcing or by a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing 225 Avoid Moving Parts Do not service the unit while the unit is running if a situation arises in which it is absolutely necessary to make operating adjustments use extreme care to avoid moving parts and hot exhaust system components Do not wear loose clothing or jewelry when servicing equipment avoid wearing loose jackets shirts or sleeves rings necklaces or bracelets that might be caught in moving parts Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective place at all times Do not check fluid levels or the drivebelts tension while the unit is operating Do not work on the equipment when mentally or physically incapacitated by fatigue TECHNICAL MANUAL WESTERBEKE 20B TWO 30B THREE MARINE DIESEL PROPULSION ENGINE Publication 037600 Edition One April 1990 j WESTERBEKE J WESTERBEKE CORPORATION267 MYLES STANDISH INDUSTRIAL PARK I 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA AdobeUCS