Westerbeke Diesel 90a Four Parts Manual

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SERVICE MANUAL gOA FOUR MARINE DIESEL ENGINE and 320 KW60 Hz BEDA 250 KW50 Hz BEDAMARINE DIESEL GENERATORS SINGLE AND THREE PHASE PUBLICATION NO 43750 15t 2000 r WESTERBEKE I WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE NMMA Member National Marine Manufacturen Associlltion CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNINGExhaust gasses contain Carbon Monoxide an odorless andcolorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in TemplesNausea Muscular Vomiting Weakness and Sleepiness Inability to Think CoherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persistseek medical attention Shut down the unit and do not restartuntil it has been inspected and repaired This WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in theWARNING9 IIvingsleeping quarters of your vessel They are inexpensive and easily mmtJ obtainable at your local marine store SAFETY PREVENT BURNS FIRERead these safety instructions carefuUy Most accidents arecaused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or deathtions Know when dangerous conditions exist and take thenecessary precautions to protect yourself your personnel Prevent flash fires Do not smoke or permit flames orand your machinery sparks to occur near the carburetor fuel line filter fuelThe following safety instructions are in compliance with the pump or other potential sources of spilled fuel or fuelAmerican Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filtersPREVENT ELECTRIC SHOCK Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death A WARNING Do not touch AC electrical connections Do not operate with the air removed while engine is running or when connected to shore Backfire can cause severe injury or death power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the Do not operate this machinery without electrical clean and free of debris to minimize the enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil Shut off electrical power before accessing electrical Be aware diesel fuel will bum equipment Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION equipment Make sure your clothing and skin are dry not damp particularly shoes when handling electrical equipment A WARNING Explosions from fuel vapors can cause injury or death Remove wristwatch and all jewelry when working on electrical equipment Follow refueling safety instructions Keep the vessels Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before result if this procedure is not followed starting your engine Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven with an insulated tool tilated area away from sparkproducing equipment and out of the reach of BURNS HOT ENGINE Do not fill the fuel tanks while the engine is running Shut off the fuel service valve at the engine when servicing A WARNING Do not touch hot engine parts or the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other exhaust system components A running engine gets sources of fire near the fuel system or engine when servic very hot ing Ensure proper ventilation exists when servicing the fuel system Always check the engine coolant level at the coolant Do not alter or modify the fuel system recovery tank Be sure all fuel supplies have a positive shutoff valve Be certain fuel line fittings are adequately tightened and A WARNING Steam can cause injury or death free ofleaks Make sure a fire extinguisher is installed nearby and is In case of an engine overheat allow the engine to cool properly maintained Be familiar with its proper use before touching the engine or checking the coolant Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment Engines Generators SAFETY STARTING TOXIC EXHAUST GASES A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas or death Ensure that the exhaust system is adequte to expel gases Disconnect the battery cables before servicing the engine discharged from the engine Check the exhaust system generator Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust manifolds it last are securely attached and no warping exists Pay close Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and starting exhaust pipe nipple Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated installed before starting the engine In addition to routine inspection of the exhaust system install a carbon monoxide detector Consult your boatBATTERY EXPLOSION builder or dealer for installation of approved detectors For additional infonnation refer to ABYC T22 educa A WARNING Battery explosion can cause injury tional infonnation on Carbon Monoxide or death Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces nulike symptoms highly explosive gas which can be ignited by electrical nausea or death arcing or by lit tobacco products Shut off all electrical equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel ing servicing fumes can rapidly destroy copper tubing in exhaust sys Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft is being charged Although diesel engine exhaust gases are not as loxic as Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide bums or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning the battery are Always turn the battery charger off before disconnecting Dizziness Throbbing in Temples the battery connections Remove the negative lead first Nausea Muscular Twitching and reconnect it last when servicing the battery Weakness and Sleepiness ACID Headache Inability to Think Coherently A WARNING Sulfuric acid in batteries can cause AVOID MOVING PARTS severe injury or death A WARNING Rotating parts can cause injury When servicing the battery or checking the electrolyte or death level wear rubber gloves a rubber apron and eye protec tion Batteries contain sulfuric acid which is destructive Do not service the engine while it is running If a situa If it comes in contact with your skin wash it off at once tion arises in which it is absolutely necessary to make with water Acid may splash on the skin or into the eyes operating adjustments use extreme care to avoid touching inadvertently when removing electrolyte caps moving parts and hot exhaust system components Engines Generators ii SAFETY INSTRUCTIONS Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that INSTALLING DIESEL ENGINES could be caught in moving parts Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their recommenda Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective tions when installing your engine places at all times ABYC American Boat and Yacht Council Do not check fluid levels or the drive belts tension while Safety Standards for Small Craft the engine is operating Order from Stay clear of the drive shaft and the transmission coupling ABYC when the engine is running hair and clothing can easily 3069 Solomons Island Rd be caught in these rotating parts Edgewater MD 21037HAZARDOUS NOISE NFPA National Fire Protection Association Fire Protection Standard for Motor Craft A WARNING High noise levels can cause hearing Order from NFPA loss 11 Tracy Drive Never operate an engine without its muffler installed Avon Industrial Park Avon MA 02322 Do not run an engine with the air intake silencer removed USCG United States Coast Guard USCG 33CFR183 Do not run engines for long periods with their enclosures open Order from US Government Printing Office A WARNING 00 not work on machinery when you are Washington DC 20404 mentally or physically incapaCitated by MANUALMany of the preceding safety tips and warnings are repeatedin your Operators Manual along with other cautions andnotes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thorough examination of the American Boat and Yacht CouncilsABYC standards These standards are a combination ofsources including the USCG and the NFPASections of the ABYC standards of particular interest are H2 Ventilation Pl Exhaust systems P4 Inboard engines E9 DC Electrical systemsAll installations must comply with the Federal Code ofRegulations FCR Engines Generators iii installing WESTERBEKE engines and generators it is important that strict attention bepaid to the following AND regulations ABYC guidelines and safety codes must be complied with when and generators in a marine installations where the exhaust exhaust elbow is close to or will bebelow the vessels waterline provisions must be made to install a siphonbreak in the raW watersupply hose to the exhaust elbow This hose must be looped a minimum of20 in 51 em abovethe vessels waterline Failure to use a siphonbreak when the exhaust manifold injectionport is at or below the load waterline will result in raw water damage to the engine andpossible flooding ofthe boatIf you have any doubt about the position of the waterinjected exhaust elbow relative to thevessels waterline under any of the vessels various operating conditions or when the vessel is notunderway install a siphonbreak This precaution is necessary to protect your engineNOTE A Siphonbreak requires periodic inspection and cleaning to ensure proper to properly maintain a siphonbreak can result in catastrophic engine damage Consultthe siphonbreak manufacturer for a proper maintenance SYSTEMThe exhaust hose must be certified for marine use The system must be designed to preventwater from entering the exhaust under any sea conditions and at any angle of the vessels hull A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv TABLE OF 2 32 KW BEDA Generator Parts Identification 10290A Four Propulsion Engine Specifications 4 Generator Information 10390A Four Propulsion Engine Parts Identification 5 Generator Control Panel Switches 104Testing for Overhaul 6 Control Panel 105Engine 7 The BE Generator Single and Three Phase 106Engine Disassembly 14 Generator AC Voltage Connections l07Engine Inspection and Repair 20 Voltage Regulator Adjustments 109Engine Reassembly 31 Internal Wiring Schematics 110Exhaust Manifold 47 BE 112Engine Adjustments 48 Electronic Governor 113Lubrication System 51 the Electronic Governor 114Cooling System 54 Shore Power Transfer Switch 115Fuel System 59 32 KW BEDA Generator Wiring Diagram 040425Starter Motor 64 Single Relay 116Admiral Control Panel 78 32 KW BEDA Generator Wiring Schematic 040425 Single Relay 117Captain Control Panel 79 32 KW BEDA Generator Wiring Diagram 040425Control Panel 80 Two Relays 118DC Electrical System 81 32 KW BEDA Generator Wiring Schematic 82 Two Relays 119Dual Output Alternators 84 32 KW BEDA Generator Wiring Diagram 44737 Two Relays plugin Remote StartStop Panel 12090A Four Propulsion Engine Wiring Diagram 41343 86 32 KW BEDA Generator Wiring Schematic 44737 Two RelaysPlugin Remote StartStop Panel 12190A Four Propulsion Engine Wiring Schematic 41343 87 32 KW BEDA Generator Wiring Diagram 041128 Single Relay 24 VDC Special Spec 122Hurth HSW Transmissions 88 32 KW BEDA Generator Wiring Schematic 041128Hurth HBW 250 Transmission 91 Single Relay 24 VDC Special Spec 123Borg Warner Velvet Drive Transmission 93 32 KW BEDA Generator Wiring Diagram 96 Two Relays Plugin Remote StartStop Panel 124Standard Hardware Sealants Lubricants 98 32 KW BEDA Generator Wiring Schematic 4480690A Four Torque Specifications 99 Two Relays Plugin Remote StartStop Panel 12532 KW BEDA Generator Specifications lOO Special Tools Generator 126 Index 128 Metric Conversions 130 Standard and Metric Conversion Data 131 Engines Generators 1 OVERHAUL CUSTOMER IDENTIFICATION CARDThis service manual contains detailed information relating tothe overhaul of the 90A Four Diesel Engine and the 320KW2S0 KW BEDA Diesel Generators For the major overhaul procedure refer to the ENGINE DISASSEMBLY ENGINE INSPECTION AND REPAIR and ENGINE IREASSEMBLY sections Additional service information for Customer generators and other specific components and systems MR ENGINE OWNERmay be found by referring to the TABLE OF CONTENTS andthe INDEX Refer also to your WESTERBEKE Parts MAIN STREETCatalog HOMETOWN USAThese service procedures are intended for the guidance of Model 90A FOUR equipped and staffed marine engine service and Expires 8200rebuilding facilities and should only be undertaken by suchfacilities and their personnel The WESTERBEKE engine serial number is an alphanuPRODUCT SOFTWARE meric number that can assist in determining the date of manProduct software tech data parts lists manuals brochures ufacture of your WESTERBEKE engine The catalogs provided from sources other than WESTER date code is placed at the end of the engine serial number andBEKE are not within WESTERBEKES control consists of a character followed by three numbers The char acter indicates the decade A1960s B1970s CANNOT BE RESPONSIBLE FOR THE D1990s 2000s the first number represents the year inCONTENT OF SUCH SOFTWARE MAKES NO WAR the decade and the second and third numbers represent theRANTIES OR WITH RESPECT month of INCLUDING ACCURACY TIMEliNESS ORCOMPLETENESS THEREOF AND WILL IN NO EVENT ORDERING PARTSSERIAL NUMBER LOCATIONBE LMBLE FOR ANY TYPE OF DAMAGE OR INJURY Whenever replacement parts are needed always provide theINCURRED IN CONNECTION WITH OR ARISING OUT engine model number and engine serial number as theyOF THE FURNISHING OR USE OF SUCH SOFTWARE appear on the silver and black identification nameplate customers should also keep in mind the ed on the side of the engines exhaust manifold The enginetime span between printings of WESTERBEKE product soft serial number can also be found stamped into the engineware and the unavoidable existence of earlier WESTER block just above the injection pump and on generators onBEKE manuals Product software provided with the decal located on the side of the generator You must proWESTERBEKE products whether from WESTERBEKE or vide us with this information so we may properly identifyother suppliers must not and cannot be relied upon exclu your engine In addition include a complete part as the definitive authority on the respective product It and part number for each part needed see the separately furnot only makes good sense but is imperative that appropriate nished Parts List Also insist upon WESTERBEKE of WESTERBEKE or the supplier in question aged parts because will fit or generic parts are frequently notbe consulted to determine the accuracy and currentness of the made to the same specifications as original software being consulted by the customer NOTE Component locations in this manual are CAUTION AND WARNINGS from the front of the engine which is the pulleydrive belt end Left and right sides are determined as follows imagineAs this manual takes you through the service procedures and straddling the engine facing in the same direction as of your marine engine critical information front of the engine the left side is at your left the right sidewill be highlighted by NOTES CAUTIONS and WARNINGS is at your right pexplanation followsNOTE An operating procedure essential to note A CAUTION Procedures which if not strictly observed can result in the damage or destruction of your engine AWARNING Procedures which if not properly fol lowed can result in personal injury or loss of life Engines Generators 2 INTRODUCTION Owners may find it convenient to fill in the data on the decal or shown below to provide a quick reference when using this service manual SPECIFICATION 50 HZ 60 HZ MODEL RPM KW KVA VOLTS AMPS ENG HP ENG SER NO GEN SER NO PFPHASE I WIRES RATING INSUL CLASS TEMP RISE BAITERY CID GENERATOR DECAL ENGINE IDENTIFICATION NAMEPLATE Engines Generators 3 gOA FOUR PROPULSION ENGINE SPECIFICATIONS SPECIFICATIONS FUEL SYSTEMEngine Type Diesel fourcycle fourcylinder fresh water General Closed system with bleed points cooled vertical inline overhead valve mechanism 90 hp at 3600 rpm maximum Fuel No2 diesel oil cetane rating of 45 or Naturally aspirated Fuel Injection Pump ZEXEL Model PE InLineGovernor Integral with the injection pump mechanical Fuel Injection Timing 12 BTDC flyweight type Nozzle Orifice typeBore Stroke 394 x 433 inches 1000 x 1100 mm Fuel filter on engine Full flow replaceable spinon elementPiston Displacement 2108 cubic inches 35 liters Air Intake Silencer Metal screen type cleanable Tuned intake 1342 no filterFiring OrderDirection of Rotation Clockwise when viewed from the front AirFlow 220 cfm 62 cmm engine Torque 168 Ibft 23 kgmat 3600 rpm Fuel consumption 20 US gph 75 Iph at 2500 rpmCompression Ratio 181 LUBRICATION Height 360 inches 914 em General Pressure fed system Width 230 inches 584 cm Length 393 inches 998 cm Oil pump Trochoid type Oil filter Full flow paper element spinon typeWeight 790 Ibs 3583 kgs Water cooled Oil cooler Sump Capacity 63 US qts 60 liters TUNEUP SPECIFICATIONS not including filter plus filtercooler Pressure 427 psi 30 kgcm at 200 rpm Operating Oil Pressure 50 55 psi 35 39 kgcm2Limit of difference engine hotbetween cylinders 476 psi 30 kgcm Oil Grade API Specification CF or CG4 SAE 30 10W30 15W40Valve Timing Intake Opens 19 BTDC Intake Closes 47 ABDC ELECTRICAL SYSTEM Exhaust Opens 52 BBDC Starting Battery 12 Volt negative ground Exhaust Closes 14 ATDC Battery Capacity 800 900 Cold Cranking Amps CCAEngine Timing Static timed drop valve method 0180 t 0005 inches BTDC DC Charging Alternator 51 amp rated Pressure 2450t 35 psi 1722t 25 kgcm Starting Aid Air intake heaterValve Seat Angle Intake 45 Starter 12 Volt 3 KW Exhaust 30 DC NoLoad Current t 2 of rated ampsValve Clearance Intake 0012 inches 03 mm DC Cranking Current 250 300 amps engine coldengine cold Exhaust 0014 inches 035 mmEngine Speed Idle 700 900 rpm ENGINE AIR REQUIREMENTS Cruise 2500 3000 rpm Max 3500 3600 rpm Combustion Air 220 cfm 62 cmm Engine Cooling 100 cfm 28 cmm COOLING SYSTEM Note The pressure differential between the outside of the engine compartGeneral Fresh watercooled block ment versus the inside ofthe engine compartment should not exceed 2inches controlled with heat exchanger of water 51 mm at full open throttle measured with a Temperature 170 190 F77 88 C Pump Centrifugal type metal impeller beltdrivenRaw Water Pump Positive displacement rubber impeller General Hurth Standard Transmission Case hardened helical gears with a servooperated beltdriven multiple disc clutchRaw Water Flow 200 US gpm 755 Ipm measured Gear ratio standard 274 1 HBW250 3Rat 3600 rpm before discharging into exhaust elbow Propeller Shaft Right handed standard fresh water 85 US qts 804 liters Propeller 24 D x 12 P2 blade or 22 D x 14 P3System Capacity blade propeller should allow the engine using standard to reach its full rated rpm 3600 000 EXHAUST SYSTEM transmission 100 atflill open throttle while under 274 1 reduction way in forward gear Exhaust Elbow 70 elbow Lubricating Fluid ATF type A or Dextran I or 11Exhaust Hose Size 3ID hose Transmission Sump Capacity 079 US qts 075 liters approximate Engines Generators 4 gOA FOUR PROPULSION ENGINE PARTS IDENTIFICATION IDENTIFICATION TOP ENGINE OIL FLANGE STARTER WITH SOLENOID REAR RIGHT SIDE FRONT COOLANT TEMPERATURE SWITCH OIL OIL PRElSUFlIEI ENGINE OIL SENDER SWITCH FILTER FRONT LEFT SIDE REAR Engines Generators 5 TESTING FOR OVERHAULHOW TO DETERMINE WHEN Measuring Compression PressureTO OVERHAUL THE ENGINE To check the compression pressure see ENGINE COMPRESCause of Low Compression SION TEST under ENGINE the time at which an engine should be overhauled NOTE Do not guess the conditions of other cylinders from ais determined by various conditions such as lowered engine result of testing one cylinder Be sure to measure the compower output decreased compression pressure and increased pression pressure for each cylinder Lookfor cylinders withfuel and oil consumption The lowered engine power output dramatically at least 20 lower compression than the averin the case of diesel engines is not necessarily due to trouble age of the other cylinders If the weak cylinder is flanked bywith the engine itself but is sometimes caused by injector healthy cylinders the problem is either valve or wear or injection pump wear It is most reasonable to related Very low compression in an adjacent cylinder indijudge by a decrease in compression pressure The decrease in cates gasket failure Abnormally high readings on all pressure is caused by many factors It is there ders indicate heavy carbon accumulations a condition thatfore necessary to determine a cause or causes on the basis of might be accompanied by high pressures and noisedata produced by periodic inspection and maintenance Oil NOTE In case of severe vibrations and detonation noiseanalysis on a seasonal basis is a good means of monitoring have the injectors overhauled by an authorized fuel internal wear When caused by worn cylinders or pis service center Poor fuel quality contaminants and loss ofton rings the following symptoms will occur positive fuel pressure to the injection pump will result in Low engine power output injector faults Increased fuel consumption OVERHAUL CONDITIONS Increased oil consumption Compression pressure tends to increase a little in a new Hard engine starting engine until the piston rings and valve seats have been bro ken in Thereafter it decreases gradually with the progressive Noisy engine operation wear of these partsThese symptoms often appear together Increased fuel con When the decrease of compression pressure reaches its limitsumption and hard engine starting can also result from exces see SERVICE STANDARDS the engine must be oversive fuel injection improper injection timing and wear of the hauled The engine also requires an overhaul when oil coninjection pump and nozzles They are also caused by defec sumption is high when blowby is evident and whentive electrical components such as the battery alternator compression values are at a minimum or belowstarter and air intake heater Therefore it is desirable to judgethe optimum engine overhaul time by the lowered compres NOTE Refer to the SERVICE STANDARDS chart during ansion pressure caused by worn cylinders and pistons plus engine overhaul It gives the measurements and values forincreased oil consumption In diesel engines satisfactory the repair or replacement of the engine is obtained only under sufficient compression NOTE The ENGINE section may bepressure If an engine lacks compression pressure incomplete helpful in determining the need for an engine of fuel will take place even if other parts of theengine are operating properly To determine the period ofengine overhaul it is important to measure the engine compression pressure regularly At the same time the enginespeed at which the measurement of compression pressure ismade should be checked because the compression pressurevaries with engine rpm The engine rpm can be measured atthe front end of the crankshaft Engines Generators 6 ENGINE following table describes certain problems NOTE The engineS electrical system is protected by a 20relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracketlems and the to overcome these problems The preheat solenoid is mounted on the same bracket PROBLEM PROBABLE CAUSE HARD STARTING LOW CRANKING SPEED 1 Engine oil viscosity too high 1 Replace engine oil wfth less viscous oil 2 Rundown battery 2 Recharge battery 3 Worn battery 3 Replace battery 4 Battery terminals loosely connected 4 Clean terminals and tighten cables 5 Defective starter 5 Repair or replace starter DEFECTIVE FUEL INJECTION SYSTEM 1 No fuel at injectors 1 Check a through e a No fuel in fuel tank andor fuel shutoff a Fill fuel tank Open shutoff and bleed system b Fuel filterWater separator clogged b Replace filter and bleed c Injection pump fuel filter clogged c Bleed injection pump Check fittings for suction leak on fuel supply d Fuel shutoff solenoid not working d Check solenoid e Injection pump faulty e Inspect pump Repair or replace pump as needed 2 Fuel injectors faulty inadequate spray 2 Remove and test nozzles Repair nozzles as needed 3 Low injection pressure 3 Adjust injection pressure 4 Injection timing incorrect 4 Check and adjust timing 5 Poor quality fuel 5 Drain and replace with proper fuel 6 Water andor air in fuel system 6 Remove water andor bleed air from fuel system Check fuel system for leaks and fuel tank for water contamination MAIN ENGINE TROUBLES 1 Low compression 1 Check a through k a Leaking compression from fuel injector gasket a Tighten fuel injector or replace gasket b Incorrect valve clearance b Adjust valve clearance c Inadequate contact of valve seat c Lap valve d Valve stem seized d Replace valve and valve guide e Weak or broken valve spring e Replace valve spring I Bent push rod I Replace push rod g Compression leaks through cylinder head gasket g Replace gasket h Cracked or worn piston h Replace piston i Piston ring seized i Replace piston and piston ring j Worn piston ring or cylinder liner j Replace piston ring or cylinder liner Ie Cracked or distorted cylinder head Ie Replace cylinder head 2 Carbon accumulation in combustion chamber 2 Clean 3 Faulty air intake heater 3 Check terminal connections replace heater continued Engines Generators 7 ENGINE PROBLEM PROBABLE CAUSE IDLING 1 Idle speed too low 1 Adjust idle stop as neededTOO LOW 2 Fuel filter clogged 2 Replace filter and bleed fuel system 3 Incorrect injection pump timing 3 Check timing and adjust as needed 4 High pressure injection line leaking 4 Slacken attaching nut and retighten 5 Fuel injector leaking at sealing gasket in head 5 Retighten injector andor replace sealing washer 6 Injection nozzle not operating properly 6 Check nozzle and adjust as needed 7 Engine air intake obstructed 7 Check air intake silencer and air flow into engine IDLING MALFUNCTION OF ENGINERELATED COMPONENTS 1 Improper valve clearance 1 Adjust clearance 2 Poor valve to valve seat contact 2 Repair or replace valve 3 Failure of cylinder head gasket 3 Replace gasket FUEL INJECTION SYSTEM PROBLEM 1 Faulty idling speed 1 Adjust idling speed 2 Faulty injection timing 2 Adjust injection timing 3 Clogged fuel line or fuel filter 3 Clean fuel line or replace fuel filter 4 Leak in fuel line or fuel filter 4 Repair fuel line or replace fuel filter 5 Air in injector fuel line injection pump fuel filter 5 Bleed air or fuel filterwater separator 6 Seized or leaky delivery valve 6 Clean or replace delivery valve 7 Faulty injection starting pressure 7 Adjust starting pressure 8 Injection nozzle malfunction 8 Clean or replace injection nozzle 9 Feed pump malfunction 9 Clean or replace feed pump 10 Injection pump timer malfunction 10 Replace timer 11 Injection pump malfunction 11 Take to a fuel injection pump service facility or replace the pumpENGINE SLOWS 1 Fuel lift pump failure 1 Check fuel pump operationAND STOPS 2 Switches andor wiring loose or disconnected 2 Inspect wiring for short circuits and loose connections Inspect switches for proper operation 3 Fuel starvation 3 Check fuel supply fuel valves fuel lift pump 4 20 amp circuit breaker tripping 4 Check for high DC amperage draw during operation Ensure breaker is not overly sensi tive to heat which would cause tripping 5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at exhaust elbow 6 Water in fuel 6 Pump water from fuel tanks change filters and bleed fuel system continued Engines Generators 8 ENGINE PROBLEM PROBABLE CAUSE OUTPUT LOW COMPRESSION See Low Compression under HARD STARTING INJECTION SYSTEM OUT OF ADJUSTMENT 1 Incorrect injection timing 1 Adjust injection timing 2 Insufficient injection 2 Repair or replace injection pump 3 Low injection pressure 3 Check injection nozzle and adjust pressure INSUFFICIENT FUEL 1 Air trapped in fuel system 1 Bleed and check for source 2 Clogged filter 2 Clean or replace filter element 3 Contaminated or inferior fuel 3 Purge fuel system and replace with quality fuel 4 Contaminated fuel tank 4 Clean fuel tank OVERHEATING 1 Low coolant level 1 Add coolant 2 Loose Vbelt 2 Adjust or replace Vbelt 3 Incorrect injection timing 3 Adjust injection timing 4 Low engine oil level 4 Add engine oil OTHER 1 Insufficient intake air 1 Increase engine compartment air supplyKNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles 1 Check a and b a Overheated cylinder a See ENGINE OVERHEATSSHUTS DOWN LOW OUTPUT b Carbon depOSits in cylinder b Clean 2 Injection timing too early 2 Correct the timing 3 Injection pressure too high 3 Correct the pressure 4 Improper fuel 4 Replace with proper fuel KNOCKING WITH DARK SMOKE 1 Poor compression 1 See Low Compression under HARD STARTING 2 Injection pump malfunctioning 2 AdjusVRepair 3 Nozzle malfunctioning 3 Check a through d a Poor spray a Clean or replace nozzle b Chattering b Repair or replace nozzle c Afterinjection drip c Repair or replace nozzle d Nozzle needle valve seized d Replace needle valveABNORMAL SOUND CRANKSHAFT AND MAIN BEARINGOR NOISE 1 Badly worn main bearing 1 Replace bearing and grind crankshaft 2 Badly worn crankshaft 2 Grind crankshaft 3 Melted bearing 3 Replace bearing and check lubrication system 4 Excessive crankshaft end play 4 Repair or replace crankshaft continued Engines Generators 9 ENGINE PROBLEM PROBABLE CAUSE SOUND CONNECTING ROD AND CONNECTING ROD BEARINGOR NOISE Contd 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace 4 Excessive connecting rod bearing oil clearance 4 Repair or replace bearing 5 Connecting rod bearing seized or heatdamaged 5 Replace bearing PISTON PISTON PIN PISTON RING CYLINDER LINER 1 Worn cylinder liner 1 Repair or replace liner 2 Worn piston or piston pin 2 Replace piston 3 Piston seized 3 Replace piston and rebore cylinder 4 Piston seized and ring worn or damaged 4 Replace piston and rings VALVES OR TIMINGRELATED PARTS 1 Worn camshaft 1 Replace camshaft 2 Excessive valve clearance 2 Adjust valve clearance 3 Worn timing gear 3 Replace timing gear 4 Broken valve spring 4 Replace valve spring 5 Excessive clearance between rocker arm and 5 Replace bushing bushing 6 Excessive clearance between idler gear bushing and 6 Replace bushing spindle FUEL SYSTEM 1 Poor quality andor incorrect fuel 1 Use No2 diesel fuel 2 Incorrect injection timing Timing too advanced 2 Check and correct injection timing 3 Fuel injector stuck open 3 Locate and remove faulty injector Rebuild or replace OTHER 1 Coolant pump bearing worn or seized 1 See Coolant Pump under COOLING SYSTEM 2 Improper drivebelt tension 2 Adjust 3 Malfunction of alternator bearing 3 See Alternator under DC ELECTRICAL SYSTEM 4 Exhaust gas leakage 4 RepairROUGH OPERATION INJECTION PUMPHUNTING 1 Uneven injection 1 Adjust injection or replace parts 2 Inadequate injection nozzle spray 2 Replace injection nozzle GOVERNING SYSTEM 1 Governor lever malfunctioning 1 Check governor shaft and adjust 2 Fatigued governor spring 2 Replace spring continued Engines Generators 10 ENGINE PROBLEM PROBABLE CAUSE EXHAUST WHITISH OR PURPLISH 1 Engine is running cold 1 Warmup engine 2 Excessive engine oil 2 Correct oil level 3 Excessive rise of oil into combustion chamber 3 Check a through f a Poor piston contact a Check b Seized piston ring b Clean or replace c Excessive clearance c Correct or replace d Worn valve stem and valve guide d Replace valve stem and guide e Low engine oil viscosity e Replace engine oil f Excessive oil pressure f Inspect the lubrication system See LUBRICATION SYSTEM 4 Injection timing is too late 4 Adjust timing 5 Insufficient compression 5 See Low Compression under HARD STARTING BLUE 1 Incorrect grade of engine oil 1 Use the correct grade of oil see LUBRICATION SYSTEM under 90A FOUR ENGINE SPECIFICATlONS 2 Crankcase is overfilled with engine oil oil is blow 2 Decrease oil level ing out through the exhaust BLACKISH OR DARK GRAYISH 1 Poor compression 1 See Low Compression under HARD STARTING 2 Improper valve clearance 2 Adjust valve clearance 3 Improper injection timing 3 Adjust injection timing 4 Improper fuel 4 Replace with proper fuel 5 High backpressure in exhaust 5 Check for restrictions in exhaust system 6 Insufficient intake air 6 Increae engine compartment air supply 7 Overload 7 Reduce load BLACK LARGE AMOUNT 1 Clogged fuel filter 1 Replace fuel filter and bleed system 2 Restricted air intake 2 Remove air obstruction 3 Engine overloaded 3 Check engine propeller size and engine performance noload through fully loaded 4 Injection timing 4 Check the injection pump timing and adjust as needed 5 Fuel injectors not operating properly 5 Check nozzle spray pressure SMOKE 1 Faulty injection timing 1 Adjust timing 2 Water in injection pump fuel filter or fuel filterwater 2 Drain fuel system separator 3 Faulty injection starting pressure 3 Adjust starting pressure 4 Injection pump malfunctioning 4 Replace injection pump continued Engines Generators 11 ENGINE PROBLEM PROBABLE CAUSE SOUND 1 Fuel filter clogged 1 Clean or replace filter 2 Fuel line sucks air 2 Retighten fuel line joints or replace fuel line 3 Water mixed in fuel 3 Replace fuelEXCESSIVE FUEL ENGINE 1 Noisy knocking 1 See KNOCKING 2 Smoky exhaust 2 See SMOKY EXHAUST 3 Moving parts nearly seized or excessively worn 3 Repair or replace 4 Poor compression 4 See Low Compression under HARD STARTING 5 Improper valve timing 5 Adjust timing 6 Improper valve clearance 6 Adjust clearance INSUFFICIENT INTAKE AIR 1 Air intake obstructed 1 Remove obstruction FUEL INJECTION PROBLEMS 1 Injection timing incorrect 1 Adjust timing 2 Faulty injection starting pressure 2 Adjust starting pressure 3 Seized nozzle 3 Replace nozzle 4 Worn nozzle 4 Replace nozzle 5 Nozzle leaking 5 Tighten nozzle or replace sealing gasket 6 Injector not operating properly 6 Adjust nozzle spray pressure 7 Clogged fuel filter 7 Replace filter 8 High idling speed 8 Adjust idling speed FUEL PROBLEMS 1 Improper fuel 1 Replace with proper fuel 2 Fuel leaks 2 Find fuel leaks ENGINE OVERLOADED 1 Propeller size 1 Check propeller size and engine performance at rated rpmEXCESSIVE OIL OIL 1 Defective oil seals 1 Replace oil seals 2 Broken gear case gasket 2 Replace gasket 3 Loose gear case attaching bolts 3 Retighten bolts 4 Loose drain plug 4 Retighten plug 5 Loose oil line connector 5 Retighten oil line connections 6 Broken rocker cover gasket 6 Replace gasket 7 Loose rocker cover attaching bolts 7 Retighten attaching bolts continued Engines Generators 12 ENGINE PROBLEM PROBABLE CAUSE OIL OIL LEVEL 1 Incorrectly positioned piston ring gaps 1 Correct ring gap positions 2 Displaced or twisted connecting rod 2 Replace connecting rod 3 Worn piston ring or piston ring groove 3 Replace ring or piston 4 Worn piston or cylinder liner 4 Repair or replace OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 2 Replace valve and valve guideLOW OIL PRESSURE 1 Worn main or connecting rod bearings 1 Replace bearings 2 Relief valve malfunction 2 Overhaul oil pump 3 Clogged oil cooler 3 Clean 4 Diesel fuel is diluting the oil 4 Injection pump repairENGINE OVERHEATS 1 Vbelt slackening or slippery with oil 1 Adjust replace or clean beltSHUTS DOWN 2 Add or change oil 2 Low oil level or poor oil quality 3 Knocking 3 See KNOCKING 4 Moving parts seized or damaged 4 Replace 5 Lack of coolant 5 Add coolant 6 Raw water not circulating 6 Check a and b a Raw water pump failure Check impeller replace if necessary b Obstruction at raw water intake or raw water filter 7 Coolant not circulating 7 Check a through d a Thermostat remove and test in hot water Replace thermostat b Loss of coolant check hoses hose clamps drain plug etc for leaks c Broken or loose belts tightenreplace d Air leak in system run engine and open the pressure cap to bleed air Add coolant as needed Engines Generators 13 ENGINE DISASSEMBLY PROCEDURE 5 Drain the engine oil and the coolant from the engineNOTE Before disassembly and cleaning carefully check 6 Carefully support and then unbolt the generator backfor defects which cannot be found after disassembly and end from the engine See SPECIAL TOOLScleaning GENERATOR in this manual All disassembled parts should be carefully arranged in For generator maintenance and service refer to the the order of reassembly Mark or label the parts as GENERATOR section of this manual needed to insure proper mating and reassembly in the proper directions and positions If the disassembly procedure is complex requiring many parts to be disassembled the parts should be disassem STARTER MOTOR bled in a way that will allow them to be efficiently SOLENOID reassembled without any change in the engines external appearance or its performance Do not remove or disassemble parts that require no disassembly Carefully inspect each part after removal for damage deformation and other problems Carefully check gaskets packings and oil seals even if checking is not specified Replace with new ones if defective Be careful not to damage the disassembled parts Keep the parts clean Use the proper tools Apply oil when necessary Take special care to keep the fuel system parts free from the intrusion of dust and REMOVAL1 Unplug the instrument panel wiring harness2 Drain the transmission fluid and the transmission oil cooler hoses3 Detach the oil cooler hoses4 Unbolt the transmission from the engineNOTE For transmission service and maintenance refer toyour transmission owners manual To rebuild a transmission contact your WESTERBEKE dealer or a transmission service facilityIf the transmission is not being rebuilt it should be Flush out and pressuretest the oil cooler andreplace the coolant hoses Inspect and lubricate the gear shift GENERATOR REMOVALlinkage and the propeller shaft coupling Clean and repaintthe transmission and change the transmission fluid Refer tothe TRANSMISSIONS section in this manual ENGINE REMOVAL With the transmission or generator separated from the engine begin the following stepbystep procedure of the1 Disconnect the AC wiring and unplug the engines DC engine disassembly wiring harness at the generator control panel 1 Clean the exterior of the engine of any deposits of dirt2 Disconnect the battery cable connections and the and oil engine ground cables 2 Mount the engine on a suitable engine stand for3 Separate the exhaust hose at the water injected elbow disassembly4 Disconnect the fuel supply and return lines NOTE Label any lines hoses or cables as you separ ate them Engines Generators 14 ENGINE DISASSEMBLY 8 Remove the transmission damper plate propulsion engines only DAMPER PLATE BOLTS TRANSMISSION DAMPER PLATE PROPULSION NGINES ONLY 9 Remove the flywheel and flywheel washer3 Drain the coolant from the engine and engine hoses and from the heat exchanger Drain the fuel and drain or pump out the engine oil ONE BOLT DEVIATES 5 FROM THE 60 SET UP4 Remove the engine wiring hamess in its entirety Label the terminal connections to insure proper reattachment FLYWHEEL WASHER LABEL THE TERMINAL CONNECTIONS5 Remove the engine heat exchanger and the engine oil cooleroil fllter assembly If possible leave one end of WHEN REMOVING each hose connection attached to the part being removed THE MOUNTING BOLTS LOCK THE FLYWHEEL WITH A RING GEAR6 Remove the starter motor BREAK TOOL7 Remove the engine bellhousing propulsion engines only REMOVING THE FLYWHEEL 10 Remove the engine back plate 11 Remove the exhaust manifold 12 Remove the alternator and alternator adjusting strap 13 Remove the raw water pump 14 Remove all the high pressure injector lines from the injection pump to the injectors Leave the upper line clamps in place NOTE Cap the ends of the lines and the connections at the injection pump and at the injectors to prevent entry offoreign material 15 Remove the oil level dipstick 16 Remove the injection pump oil line 17 Remove the fuel line to the injection pump Note the arrangement of the sealing washers on the banjo bolts TRANSMISSION DAMPER PLATE at the fuel fllter and the injection pump PROPULSION NGINES ONLY 18 Remove the fuel return lines from the top of the injectors and from the fuel injection pump Note the washer ar rangement on the fuel return line banjo bolts Cap all openings on the fuel return line injectors and injection pump 19 Remove the enginemounted fuel fllter and fuel fllter ENGINE DISASSEMBLY bracket Engines Generators 15 ENGINE DISASSEMBLY20 Remove the thermostat housing gasket and the thermo 28 Loosen the cylinder head bolts gradually in the numbered stat Leave the temperature sending unit in place sequence shown in the illustration 3 7 11 15 18 14 10 6 4 8 12 16 17 13 9 5 1 LOOSENING THE CYLINDER HEAD BOLTS THERMOSTAT ASSEMBLY 29 Remove the rocker arm and shaft assembly21 Remove the air intake silencer 30 Remove the push rods Label each rod as to which valve it belongs22 Remove the two front lifting eyes and the rear lifting eye23 Remove the intake manifold24 Remove the alternator bracket25 Remove the crankcase breather hose26 Remove the rocker covers and gaskets27 Remove the fuel injectors Orings and gaskets from the cylinder head ROCKER COVER COVER ROCKER COVER INNER SPRING puODi LOWER SEAT 31 Remove the cylinder head by tapping it from below with a plastic hammer 32 Remove the cylinder head gasket Engines Generators 16 ENGINE DISASSEMBLY33 Valves Disassembly b Remove the valve oil seals intake only by grasping a Mark the valves with their cylinder numbers then them with pliers and working them out remove the valves stem caps cotters spring seats and springs from the cylinder head using the valve spring lifter Mazda 49 0636 100A and pivot Mazda 49 0107 222A or an appropriate valve spring compres sion tool c When removing the valves make sure each valve is marked so it can be returned to its original position if reused NOTE Valve guides are only to be removed if neces sary after completing the procedure described under Valves and Valve Guides in the ENGINE INSPECTION AND REPAIR section34 Timing Mechanism Disassembly Remove the following components that are related to the timing mechanism a Coolant pump b Crankshaft pulley c Timing gear cover and gasket d Fuel injection pump NOTE See Fuel Injection Pump Removal under FUEL SYSTEM for detailed instructions on removing the fuel injection pump e Camshaft gear lock plate f Camshaft friction gear g Camshaft gear h Idler gear plate i Idler gear j Idler gear hub k Crankshaft slinger l Crankshaft friction gear spring m Crankshaft friction gear D Crankshaft gear and key o Timing gear case and gasket TIMING MECHANISM DISASSEMBLY Engines Generators 17 ENGINE DISASSEMBLY35 Lubrication System Disassembly Remove the following lubrication system components a Oil filter housing g Lower block b Lube oil cooler and gasket h Block to lower block left and right gaskets c Oil filter housing gasket i Block to lower block front and rear gaskets d Sump stiffeners j Oil jets e Lube oil sump and gasket k Oil pressure sender f Lube oil pump assembly I Oil pressure switch f h FT gw LUBRICATION SYSTEM DISASSEMBLY Engines Generators 18 ENGINE DISASSEMBLY36 Camshaft Crankshaft and Pistons Disassembly Remove the following components that are related to the camshaft crankshaft and pistons When removing the parts connected to the crankshaft secure the crank shaft using the two holes in the end of the crankshaft a Back plate b Crankshaft rear oil seal flange gasket and oil seal c Camshaft retaining plate d Camshaft e Tappets f Connecting rod bearing caps g Connecting rod bearings h Connecting rods and pistons i Piston rings j Snap rings k Piston Pins Use the following method to remove a piston pin 1 Remove the snap rings 2 Heat the piston and connecting rod assembly to 1220 1580 F 500 700 C e 3 Remove the piston pin I Connecting rods m Main bearing caps D Main bearings CAMSHAFT CRANKSHAFT 8 PISTONS DISASSEMBLY o Thrust washers p Crankshaft q Cylinder Liners Cylinder liners should be removable by hand However if difficulty is encountered use a cylinder liner replacer Mazda 49 W065 015 or equivalent and press the liner out A CAUTION 00 not directly hit the cylinder liner with a hammer If the cylinder liner is difficult to remove make sure the special tool is used otherwise it will be damaged Engines Generators 19 ENGINE INSPECTION AND REPAIR GENERAL INSPECTION PROCEDURE1 Before inspection clean each part taking care to remove any gasket fragments dirt oil or grease carbon moisture residue or other foreign materials MANIFOLD CONTACT SURFACE DISTORTION2 Be careful not to damage the joints or sliding parts of aluminum alloy components such as the cylinder head Valve Seats and the pistons 1 Measure the protruding length Dimension L of each valve3 Inspection and repair should be done in the order indi stem above the cylinder head If the measured length is cated more than the specified value take the following steps Dimension L Head Intake 1892 in 4805 mm1 Inspect the cylinder head for water leakage fuel leakage Exhaust 1888 in 4795 mm damage and cracks Replace it if necessary2 Measure the cylinder head for distortion in six directions using a thickness gauge and a straightedge as shown in f DIMENSION L the illustration Distortion limit 0004 in 010 mm C a When Dimension L is up to 0 0020 in 0 05 mm longer the valve can be used as it is b When Dimension L is 0020 0059 in 05 15 mm longer set a washer inner dia 0504 in 128 mm outer dia 1535 in 39 mm under the lower spring seat to adjust Dimension L to within the standard value THICKNESS GAUGE WASHER MEASURING THE CYLINDER HEAD DISTORTION3 If the cylinder head distortion exceeds the limit replace it A CAUTION Do not attempt to repair the cylin c When Dimension Lis 0059 in 15 mm longer or der head by milling or grinding more replace the old valve with a new valve and measure Dimension L again If the protruding length Clearance between the bottom of the cylinder head is still outside the acceptable limit then replace the and the top of the piston at TDC 00303 00374 in cylinder head 0770 0950 mm 2 Check the valve seat for roughness or damage If neces4 Measure the manifold contact surface distortion in six sary use a valve seat cutter or valve seat grinder to re directions as shown in the illustration If the distortion store the valve seat to the specified shape exceeds the limit grind the surface or replace the cylind erhead Distortion limit 0004 in 010 mm Engines Generators 20 ENGINE INSPECTION AND REPAIR NOTE To check the contact width apply a thin coating b Inspect each valve for roughness or damage on its of red lead to the valve seat and press the valve against face If a problem is slight repair the valve with a the valve seat Be sure not to tum the valve when doing valve refacer so 2 Measure the valve length and the valve margin Replace When grinding a valve seat use a 15 45 or 80 valve the valve if necessary seat cutter for the intake side and a 12 or 60 valve seat Valve length cutter for the exhaust side or alternately use a valve seat Intake standard 4512 in 1146 rom grinder to grind away the roughness andor scars to the Exhaust standard 4508 in 1145 rom minimum limit of the seat surface always checking the contact width and the contact position while grinding Valve margin Intake limit 0039 in 10 rom Standard valve seat contact width Exhaust limit 0047 in 12 mm 00669 in 17 mm ItLVE MARGIN VALVE LENGTH 1 3 Check the valve stem oil clearance a Measure the outer diameters of each valve stem INTAKE EXHAUST GRINDING THE VALVE SEAT Standard valve stem diameter Intake 0353 0354 in 8955 8980 mm3 To seat the valves apply a thin coating of engine oil Exhaust 0352 0353 in 8935 8960 mm mixed with a small amount of compound to the seat sur face then lightly tap while turning the valve RED LEAD 0 t SEATING THE VALVES A CAUTION When seating the valve be careful not to let compound adhere to the valve stem Valve contact position in relation to the valve seat must be at the center of the circumference and the contact width must be the standard value Check that the protruding length of the valve is within the specified limits CHECKING VALVE STEM OIL CLEARANCEValve and Valve Guides b Measure the inner diameters of each valve guide1 Inspection and repair of the valves Standard valve guide diameter a Inspect each valve and replace any that show damage 0355 0356 in 9018 9040 mm bending or dents Engines Generators 21 ENGINE INSPECTION AND REPAIR c Calculate the oil clearance by subtracting the outer diameter of the valve stem from the inner diameter of the valve guide Replace the valve or valve guide if the oil clearance is outside the specified limits Oil clearance Intake standard 00015 00033 in 0038 0085 mm Intake limit 00050 in 0127 mm Exhaust standard 00023 00041 in 0058 0105 mm Exhaust limit 00050 in 0127 mm INDICATED SCALE MEASURING INNER DIAMETER OF VALVE GUIDE4 Replacement of valve guides INSTALLING VALVE GUIDE a Removal Remove the valve guide at the side opposite the com bustion chamber using the valve guide replacer A CAUTION When the valve guide is replac ed recheck the clearance between the valve Mazda 490107 45lA or equivalent and the valve guide The valve seal should be installed after inspec A CAUTION Do not remove a valve guide tion and repair of the valve seat unless it is to be replaced The intake and exhaust valve guides have the same shape Valve Springs 1 Inspect each valve spring for cracking or any other dam age Replace if necessary 2 Measure each springs free length and angle limit Re place if necessary Free length Inner spring Standard 183 in 466 mm Limit 176 in 447 mm Outer spring REMOVING VALVE GUIDE Standard 209 in 531 mm b Instalkltion Limit 201 in 510 mm Fit the clip onto the valve guide Use the valve guide replacer Mazda 490107 45lA to tap the valve guide in from the side opposite the combustion chamber until the valve guide height reaches the in dicated scale 065 in 165 mm height on the valve guide replacer v WESTERBEKE Engines Generators 22 ENGINE INSPECTION AND REPAIR 3 Check the camshaft bearing oil clearance a Measure the outer diameter of each camshaft journal Standard journal diameter No1 2044 2045 in 51910 51940 mm No2 2034 2035 in 51660 51690 mm No3 2024 2025 in 51410 51440 mm No4 2014 2015 in 51160 51190 mm MEASURING SPRINGS FREE LENGTH Angle limit Inner spring 0064 in 163 mm Outer spring 0073 in 185 mm ANGLE VARIATION FROM PERPENDICULAR MEASURING CAMSHAFT JOURNAL VALVE SPRING b Measure the inner diameter of the camshaft bearing on the cylinder block Standard camshaft bearing diameter No1 2047 2048 in 52000 52030 nun No2 2037 2038 in 51750 51780 nun SPRING ANGLE LIMIT No3 2028 2029 in 51500 51530 mmCamshaft No4 2018 2019 in 51250 51280 mm1 Check the camshaft for wear and damage Measure the c Calculate the oil clearance by subtracting the outer cam height and replace if the height is less than the limit diameter of the camshaft journal from the inner dia meter of the camshaft bearing If the oil clearance is Cam height outside the specified limits replace the camshaft or Standard 1737 in 44116 mm the cylinder block Limit 1717 in 43616 mm Standard oil clearance 00024 00047 in 0060 0120 mm MEASURING INNER DIAMETER OF MEASURING THE CAM HEIGHT CAMSHAFT BEARING Tappets 1 Check the condition of the tappets2 Check the camshaft deflection Limit 0003 in 008 mm at A and B a Check each tappet for cracking or any other damage Replace if necessary b Check the extent of the wear on the surface that is in contact with the cam and replace any tappet showing abnormal wear 2 Check the oil clearance between the tappets and the tap pet guides a Measure the outer diameter of each tappet Standard tappet outer diameter CHECKING CAMSHAFT DEFLECTION 0559 0560 in 14218 14233 mm y WESTERBEKE Engnes Generators 23 ENGINE INSPECTION AND REPAIR MEASURING OUTER DIAMETER OF TAPPET CHECKING DEFLECTION OF PUSH ROD b Measure the inner diameter of each tappet guide Standard inner diameter of tappet guide Rocker Arms and Shafts 0563 0564 in 14288 14319 mm 1 Check the condition of the rocker arms and shafts a Check each part of the rocker arm assembly for cracking wear or any other damage Replace if nec essary b Check to see if the oil holes of the rocker arm and shaft are clogged Clean if necessary MEASURING INNER DIAMETER OF TAPPET GUIDE c Calculate the oil clearance by subtracting the outer diameter of the tappet from the outer diameter of the tappet guide ROCKER ARM ASSEMBLY Standard oil clearance 00022 to 00040 in 0055 0101 mm 2 Check the oil clearance between the rocker arms and Oil clearance limit 00059 in 015 mm shafts a Measure the outer diameter of each rocker shaftPush Rods Standard rocker shaft diameter1 Check each push rod to see if either end is worn or dam 0746 0747 in 18959 18980 mm aged Replace if necessary D a CHECKING PUSH RODS2 Check the deflection of each push rod using a dial gauge as shown Rotate the push rod slowly and measure the MEASURING OUTER DIAMETER maximum deflection If the measured value exceeds the OF ROCKER SHAFT specified limit replace the push rod Deflection limit 0016 in 040 mm Engines Generators 24 ENGINE INSPECTION AND REPAIR b Measure the inner diameter of each rocker arm bushing Standard rocker arm bushing diameter 0748 0749 in 19000 19021 mm CORRECTING THE ROCKER ARM BUSHING DIAMETER Pistons and Piston Rings MEASURING INNER DIAMETERDF 1 Check the condition of the pistons and the piston rings ROCKER ARM BUSHING a Check the sliding surface of the piston ring grooves and other parts of the piston for cracking or any c Calculate the oil clearance by subtracting the outer other damage Replace the piston if necessary diameter of the rocker shaft from the inner diameter b Check the piston rings for broken parts thermal of the rocker arm bushing If the oil clearance is out damage and wear Replace the rings if necessary side the specified limits replace the rocker arm bush ing or the rocker arm shaft Standard oil clearance 00002 00024 in 0020 0062 mm Oil clearance limit 00039 in 010 mm3 Replace the rocker arm bushing a Remove the bushing by pressing it out using a pipe having an appropriate diameter 2 Check the clearance between the piston and the cylinder liner a Measure each pistons diameter at the skirt side of the piston 106 in 27 mm above the bottom end of the piston Standard piston outer diameter Z 39345 39350 in 99937 99950 mm REPLACING ROCKER ARM BUSHING Y 39350 39355 in 99950 99963 mm b Align the oil holes of the rocker arm and a new bush ing so that the oil hole of the bushing will be open to the hole in the rocker arm when installedoil must be able to flow through these openings c When the pressfitting is complete correct the dia meter of the bushing with a pin hole grinder or a spi ral expansion reamer so that the clearance between the bushing and the shaft meets the standard value 106 in Standard clearance 27mm 00008 00024 in 0020 0062 mm MEASURING PISTON DIAMETER Engines Generators 25 ENGINE INSPECTION AND REPAIR b Measure the inner diameter of the corresponding Cylinder Liners cylinder liner See Cylinder Liners in this section 1 Check the interior of each cylinder liner for scratches c Calculate the piston clearance If the clearance wear or any other damage Replace if necessary exceeds the limit replace the piston or the cylinder 2 Measure the inner diameter of each cylinder liner at liner three positions top middle and bottom At each Piston clearance position measure the inner diameter in XX and YY Standard directions see illustration for a total of six measurements 00020 00030 in 0050 0076 mm a Extent of wear Limit 00017 and 00032 in 0044 and 0082 mm The extent of wear of a cylinder liner equals the max imum measured value minus the maximum standard NOTE Oversized pistons and cylinder liners are not value available Z or Y marks are stamped on top of the piston Standard cylinder liner inner diameter Z 39370 39375 in 100000 100013 mm3 Checking the piston ring end gap Y 39375 39380 in 100013 100026 mm Position the piston ring in the cylinder liner and meas ure the piston ring end gap a When reusing a piston ring measure the end gap when the ring is set in the most worn part of the cylinder liner b When replacing a piston ring measure the end gap when the ring is set in the least worn part of the cylinder liner Piston ring end gap limit 0059 in 15 mm MEASURING CYLINDER LINER INNER DIAMETER b Extent of uneven wear The extent of uneven wear of a cylinder liner equals the maximum measured value minus the minimum measured value If the extent of unequal wear ex ceeds 00079 in 020 mm replace the cylinder liner CYLINDER BLOCK MEASURE THE END GAP NOTE Z or Y is painted on the outside of each CHECKING PISTON RING END GAP cylinder liner4 Check the clearance between the piston ring grooves and the piston rings a Fit the piston ring on the piston b Measure the clearance between the piston ring groove and the piston ring with a feeler gauge If the clearance exceeds the specified limit replace the pis ton or the whole set of piston rings Clearance limit 3 Check the clearance between the cylinder liners and the Top ring 00098 in 025 mm cylinders Second ring 00079 in 020 mm a Measure the outer diameter of each cylinder liner Oil ring 00079 in 020 mm Standard outer diameter of cylinder liner A type 40777 40782 in 103474 103487 mm B type 40743 40748 in 103487 103500 mm NOTE A or B is painted on the outside of each cylinder liner CHECKING PISTON RING AND GROOVE CLEARANCE Engines Generators 26 ENGINE INSPECTION AND REPAIR b Measure the inner diameter of the cylinder Standard cylinder bore Connecting rod torsion limit 0002 in 005 mm per 197 in 50 mm A type 40748 40753 in 103500 103513 mm B type 40753 40758 in 103513 103525 mm NOTE A or B is stamped on the cylinder block above each cylinde xEB x y 3 Check the clearance between the connecting rod bushings and the piston pins a Measure the inner diameter of the bushings Standard connecting rod bushing diameter 13391 13399 in 34012 34033 mm MEASURING CYLINDER INNER DIAMETER c Calqllate the oil clearance by subtracting the outer diameter of the cylinder liner from the inner diameter of the cylinder If the oil clearance exceeds the limit replace the cylinder liner or the cylinder block Clearance limit A type 000051 in 0013 mm B type 000154 in 0039 mm MEASURING CDNNECTING ROOConnecting Rods BUSHING INNER DIAMETER1 Check the side surfaces of the big end and the small end b Measure the outer diameter of the piston pins of each connecting rod for cracking or any other damage Standard piston pin diameter Replace if necessary 13383 13386 in 33993 34000 mm2 Check the connecting rod for bending and torsion using a connecting rod aligner If bending or torsion exceeds the specified limit correct with a press or replace Connecting rod bending limit MEASURING PISTON PIN OUTER DIAMETER 0002 in 005 mm per 197 in 50 mm Engines Generators 27 ENGINE INSPECTION AND REPAIR c Calculate the oil clearance by subtracting the outer 2 Check the crankshaft for deflection diameter of the bushings from the inner diameter of a Support both ends of the crankshaft on Vblocks the piston pins If the oil clearance is outside the specified limits replace the bushing or the piston pin b Set a dial gauge on the middle main journal and measure the deflection by slowly turning the crank Standard clearance shaft Read the maximum value and if the deflection 00005 00016 in 0012 0040 mm exceeds the specified limit replace the crankshaft Clearance limit Deflection limit 00020 in 005 mm 00024 in 006 mm4 Replacement of the connecting rod bushing a Use a press and a suitable pipe having a diameter of 122 126 in 31 32 mm A CAUTION Before installing apply a coating of clean engine oil to the connecting rod bushing and the connecting rod Align the connecting rod bushing oil hole with the connecting rod oil hole CHECKING CRANKSHAFT DEFLECTION 3 Check the crankshaft for wear a Measure wear on the crankpin see illustration If wear exceeds the limit replace or grind the crank shaft until it agrees with the undersize bearing Standard journal diameters 1 Main journal diameter REPLACING 2984 2985 in 75805 75825 mm THE CONNECTING ROD BUSHING 2 Crankpin diameter 24060 24065 in 61112 61125 mm 3 Rear flange oil seal sliding surface5 After pressing the bushing in correct its inner diameter 39985 39995 in 101562 101587 mm with a spiral expansion reamer so that the clearance will 1 be within the standard value 2 STANDARD JOURNAL DIAMETERS Journal wear limit 00012 in 003 mm Journal grinding limit 00295 in 075 mm Undersize 0010 in 025 mm 0020 in 050 mm1 Check the condition of the crankshaft 00295 in 075 mm a Check each part of the crankshaft for cracking cuts or any other damage Replace if necessary b Check to see if the oil holes are clogged Clean if A CAUTION When grinding a journal or pin pay attention to each fillet R dimension necessary Fillet R dimension Journal 0146 0157 in 37 40 mm Pin 0126 0138 in 32 35 mm Engines Generators 28 ENGINE INSPECTION AND REPAIR MAIN JOURNAL CRANKPIN Cylinder Block 1 Cylinder block inspection and repair a Check each cylinder for dampness damage and cracks Replace the cylinder block if necessary b Measure the distortion of the top surface of the cylin der block in six directions using a thickness gauge and a straightedge see illustration If the distortion exceeds the limit replace the cylinder block FILLET R DIMENSION Distortion limit 00039 in 010 mm4 Check the inside surfaces of the main and connecting rod bearings for streaking flaking pin holes etc Replace all bearings as a set if necessary A CAUTION Do not grind the surface of the cylinder block If ground the pistons will hit UPPER the valves J1 rn rn ffi jJmm MAIN BEARINGS THRUST WASHERSRear Oil Seal Crankshaft1 Inspecting the oil seal a Check the oil seal lip for wear fraying or other dam age and if necessary replace it2 Oil seal replacement a Strike out the old rear oil seal with a suitable mandrel b Apply engine oil onto the outside of a new seal and pressfit the seal in the rear oil seal flange eqUally NOTE In case the crankshaft is worn the oil seal must be fitted on the oil seal flange with its fitting position moved by approximately 01181 in 3mm so that the seal MEASURING CYLINDER BLOCK DISTORTION does not touch the worn down portion of the crankshaft Flywheel An alternative is to install a metal seal saver on the crank 1 Check the outerfacing side of the flywheel for scratches shaft to restore it This will make the surface of the crank dirt wear of the ring teeth or any other damage Replace shaft smooth again if necessary 2 Measure the distortion of the outerfacing side of the fly wheel with a thickness gauge and a straightedge If distortion exceeds the limit replace the flywheel Limit 0008 in 020 mm MEASURING FLYWHEEL INSTALLATION DISTORTION REMOVAL REAR OIL SEAL CRANKSHAFT Engines Generators 29 ENGINE INSPECTION AND REPAIRTiming Gears 4 Check the oil clearance between the idler gear and the idler gear hub1 Check the timing gears for cracking damage to the teeth or any other damage Replace if necessary a Measure the inner diameter of the idler gear Standard idler gear diameter 1732 1734 in 44009 44034 mm TIMING GEARS2 Measure the backlash of the idle gear and the other gears with a dial gauge Gears not being measured should be kept disengaged MEASURING Backlash IDLER GEAR INNER DIAMETER Standard 00039 00079 in 010 020 mm Limit 00118 in 030 mm b Measure the outer diameter of the idler gear hub Standard idler gear hub diameter 1730 1731 in 43950 43975 mm MEASURING TIMING GEAR BACKLASH MEASURING3 Measure the end play of the idler gear with a dial guage IDLER GEAR HUB OUTER DIAMETER Standard end play 00020 00071 in 005 018 mm c Calculate the oil clearance by subtracting the outer End play limit 00098 in 025 mm diameter of the idler gear hub from the inner diame ter of the idler gear If the clearance exceeds the specified limit replace the idler gear bushing and the idler gear hub Oil clearance Standard 00013 00033 in 0034 0084 mm Limit 00059 in 015 mm Oil Jets 1 Inspect each oil jet for cracking or any other damage 2 Check that the valve in the oil jet moves smoothly MEASURING IDLER GEAR END PLAY Engines Generators 30 ENGINE REASSEMBLY PROCEDURE Clean or wash the parts to be reassembled Apply lubri A CAUTION Be sure to use the special tool for cating oil when specified or as needed to the surfaces of the installation of the valve seals If a valve seal is moving parts during reassembly Heavily oil sliding not installed correctly oil might leak down into the turning rotating and reciprocating parts lightly oil head cylinders during operation bolts and other fasteners except those that penetrate into the water jacket These fasteners should be sealed with Permatex No2 or a hightack equivalent Make sure that moving parts after assembly onto the engine are not sub ject to binding or excessive tension Carefully check gaskets packings and oil seals even if checking is not specified Use new gaskets lockwashers and Orings Be careful not to mix bolts and nuts Both metric and SAE bolts are used on various engine assemblies INSTALLING Replace plain bearings if they are peeling burned or VALVE SEALS otherwise damaged Reassemble parts eg pistons piston rings bearings bearing caps in their proper order positions and direc Valves tions relative to the engine block Avoid reversed orienta 1 Insert the valve after applying molybdenum disulphide tion note that the cylinder head gasket head bolt wash grease to the valve stem ers and thermostat are assymetrical Any mating marks 2 Install the valve springs and the upper spring seats that were drawn or scribed during disassembly should be positioned correctly for reassembly Position gaskets 3 Using the valve spring lifter Mazda 49 0636 100A carefully especially the head gasket so they will not be and pivot Mazda 49 0107 222A or an appropriate damaged during assembly valve spring compression tool press each valve spring then install the valve cotters securely and the stem caps Inspect all critical clearances end plays oil clearances and bends Use liquid sealants when specified or needed on nuts bolts and gaskets Use Permatex No2 or equivalent Dont use tape sealants Refer to SEAlANTS LUBRICANTS in this manual Tighten the bolts and nuts on the important parts of the engine to the specified torques using a reliable torque wrench Tighten fasteners in the specified torque sequences and in three steps 112 23 and 111 torque Exceptions are torquetoyield head bolts and rocker arm INSTAWNG VALVE COTTERS shaft fasteners The former are torqued as indicated The latter rocker shaft fasteners should be brought down in very small increments working from the center bolts out Where a tightening torque is not specified tighten evenly Oil Jets to an ordinary torque Install the oil jets to the cylinder block After completion of reassembly recheck for any abnor NOTE Make sure the protrusion on the oil jet is in its hole in malities Prepare for starting the engine and idle the the cylinder block engine sufficiently for a test run Oil jet tightening torqueENGINE REASSEMBLY 81 130 ftIb 12 18 mkgValve SealsNOTE Always replace the valve seals during an engine 0overhaul1 Apply engine oil to the valve guides2 Install the lower spring seats3 Using the valve seal pusher Mazda 49 SE01 160 install the valve seals to the intake valve guides INSTALLING OIL JETS Engines Generators 31 ENGINE engine oil to the tappets and insert them into theiroriginal locations INSTALLING MAIN BEARINGS 2 Check the oil clearance of the crankshaft and main bear ings with a plastigauge INSTAUING TAPPETS a Remove any foreign material from the main journal or b Position the plastigauge on top of the main journal1 Apply engine oil to the camshaft and insert it into the in the journals axial direction cylinder block c Set the main bearing caps in position then tighten the bolts to the specified torque in the sequence shown in the illustration Main bearing cap tightening torque 72 77 ftIb 100 107 mkg INSTAUING CAMSHAFT 42 Install the camshaft retaining plate with the flush side facing the cylinder block Camshaft retaining plate tightening torque 14 19 ftIb 19 26 mkg MAIN BEARING CAP TIGHTENING SEQUENCE d Remove the main bearing cap and measure the oil clearance Standard main bearing cap oil clearance 00023 00035 in 0059 0090 mm Oil clearance limit 00047 in 012 mm INSTALLING CAMSHAFT RETAINING PLATE Crankshaft1 Install the main bearings A CAUTION Make sure no oil or dirt is on the back surface of the main bearings MEASURING THE OIL CLEARANCE Engines Generators 32 ENGINE REASSEMBLY e If the oil clearance exceeds the limit replace the 5 With the main bearing caps set move the crankshaft entire set of main bearings then measure the oil backward and forward to improve the setting Then clearance again tighten the bolts to the specified torque If the entire set of main bearings is replaced and the 6 Measure the end play of the crankshaft and confirm that oil clearance still exceeds the oil clearance limit it is within the standard range Also check that the crank grind the crankshaft and use undersize bearings shaft turns lightly Standard crankshaft end play A CAUTION 00055 00150 in 014 039 mm End play limit 0015 in 040 mm a Position the plastigauge horizontally on the crankshaft away from the oil hole b Do not rotate the crankshaft when mea suring the oil clearance c Install the main bearing cap referring to the cap number and arrow MEASURING CRANKSHAFT END PLAY 7 If the end play is not within the standard range select a suitable thrust washer Standard thrust washer width 00896 00915 in 2275 2325 mm 1 MAIN BEARING CAP NUMBER ARROW Oversize thrust washer width 00966 00985 in 2453 2503 mm3 After checking and correcting the oil clearance apply A CAUTION When replacing the thrust washers engine oil to the main bearings and main journals then on one side only always install them at the rear install the crankshaft side Cylinder Liners 1 If a new cylinder liner is to be installed select a cylinder OILING THE MAIN BEARINGS liner with the same letter A or B as is printed on top of4 Apply engine oil to the thrust washers then install them the CCk 1J to the center part of the main journal G J s 0 A OA A CAUTION Install the thrust washers so that the inner surface of the oil groove faces the cylin der block l J Engines Generators 33 ENGINE REASSEMBLY2 Apply engine oil thoroughly to the cylinder liners d Position the piston and connecting rod assembly so that the matching number on the big end of the con necting rod faces the same side as the combustion chamber cutout t1 COMBUSTION CHAMBER CUTOUT OILING THE CYLINDER LINERS3 Check to see that the cylinder walls are free of carbon and dirt Then install the cylinder liners to their original locations making sure the letters on the cylinder liners POSITIONING PISTON match the letters on the cylinder block CONNECTING ROD MATCHING NUMBER e Assemble the piston and connecting rod with the piston pin and lock the snap rings so the pin wont come out INSTALLING CYLINDER LINERSPistons and Connecting Rods1 Assemble the pistons and connecting rods ASSEMBLING PISTON a Heat the piston to 1220 1580 F 500 700 C CONNECTING ROD f Check to make sure the connecting rod can be easily moved b Apply engine oil to the small end of the connecting rod and around the piston c Insert a snap ring into one of the piston pin holes CHECKING CONNECTING ROD MOVEMENT 2 Assemble the piston rings a Assemble the piston rings to the piston using the pis ton ring inserting tool commercially available The order of assembly is oil ring expander oil ring sec ond ring and top ring Engines Generators 34 ENGINE REASSEMBLY A CAUTION a Pistons must be inserted so that the front marks F face front b Apply engine oil liberally to the cylinder liner walls piston circumference and rings c Check to be sure that each oil jet aligns PISTON to the oil path in the piston at SOC If not RINGS replace the oil jet with a new one A CAUTION a Apply engine oil liberally during installation b The rings must be mounted so the Nil mark faces upward b Align the piston ring openings as shown in the illustra tion FRONT ALIGNING THE OIL JETS 4 Install each connecting rod bearing cap as follows a Measure and adjust the connecting rod bearing and crankshaft pin journal oil clearance by the same pro cedure used to measure and adjust the crankshaft and main bearing oil clearance Connecting rod bearing cap tightening torque REAR 59 65 ftIb 82 90 mkg PISTON RING OPENINGS Standard oil clearance3 Install the pistons and connecting rods 00014 00030 in 0036 0076 mm a Fit the connecting rod bearing to the connecting rod Oil clearance limit 00020 in 005 mm and apply engine oil Undersize connecting rod bearings b After cleaning the inner surface of the cylinder liner 0010 in 0254 mm 0020 in 0508 mm apply engine oil 0030 in 0762 mm c Insert each piston and connecting rod assembly into the cylinder block using a piston insertion tool com INSERTING PISTON AND CONNECTING ROD ASSEMBLY MEASURING CONNECTING ROD BEARING CRANKSHAFT PIN JOURNAL DlL CLEARANCE Engines Generators 35 ENGINE REASSEMBLY b Check the connecting rod end play Back Plate Standard connecting rod end play Install the back plate 00094 00130 in 0239 0379 mm Back plate tightening torque End play limit 00157 in 040 mm 28 38 ftIb 38 53 mkg NOTE Measure each connecting rods end play be fore installing the connecting rod bearing cap CHECKING CONNECTING ROD END PLAY c Install the connecting rod bearing cap and tighten it Flywheel and Flywheel Washer to the specified torque When doing so apply engine oil to the threaded part of the bolts and nuts and to the 1 Install the flywheel and flywheel washer Temporarily bearing surfaces tighten the bolts by hand Connecting rod bearing cap tightening torque 59 65 ftIb 82 90 mkg A CAUTION Install the connecting rod bearing cap after aligning the cap and con necting rod mating marks 2 Turn the flywheel until the first cylinder is at TDC 1 MATING MARKS 3 Secure the flywheel with the ring gear brake Mazda 49 VIOl 060A and collar Mazda 49 W065 062 4 Tighten the bolts on the flywheel INSTALLING CONNECTING ROD BEARING CAP Flywheel tightening torque 130 145 ftIb 18 20 mkgCrankshaft Rear Oil Seal FlangeInstall the crankshaft rear oil seal flange with its gasket andoil sealNOTE Apply engine oil to the oil seal before assembly SECURING THE FLYWHEEL Engines Generators 36 ENGINE Gear Case 4 Trim off the protruding parts of the gasket between the cylinder block and the timing gear case1 Attach the idler gear hub making sure that the oil holes are aligned Temporarily tighten the bolts TRIMMING THE BLOCK TO TIMING GEAR CASE GASKET ATTACHING IDLER GEAR HUB 5 Apply a siliconbased sealant to the areas where the gasket was trimmed off2 APPLYING SEALAN Lower Block INSTAUING TIMING 1 Apply a siliconbased sealant to the ends of the blockto GEAR CASE GASKET lowerblock front and rear gaskets and install them Apply the sealant to both ends of each gasket3 Install the timing gear case Timing gear case tightening torque REAR GASKET 14 19 ftlb 19 26 mkg EALANT AREA AP in 3 mm SILICONBASED SEALANT BOTH ENDS INSTAWNG TIMING GEAR CASE INSTALLING GASKET REAR GASKET SHOWN Engines Generators 37 ENGINE REASSEMBLY2 Install the right and left gaskets onto Oil Cooler the cylinder block and then install the lower block Install the lube oil cooler housing and gasket Lower block tightening torque 14 19 ftIb 19 26 mkg Oil Filter Housing Install the oil filter housing gasket and oil filter Oil filter housing tightening torque 14 19 ftIb 19 26 mkg OIL FILTER HOUSINGOil PumpRemove the oil pipe from the oil pump and install theoil pump Reinstall the oil pipeNOTE Install the oil pipe after coating the Oring withengine oil LL Oil pump tightening torque INSTALLING OIL FILTER HOUSING Large bolts 14 19 ftIb 19 26 mkg Oil pipe tightening torque Timing Gears Small bolts 58 80 ftIb 08 11 mkg 1 CRANKSHAFT GEARSet the rubber gasket between the lower block and the oil INSTALLING CRANKSHAFT GEARsump then set the sump stiffeners and install the sump 2 Remove the bolts on the idler gear hub and install the idler Oil sump tightening torque gear and idler gear plate making sure that the A marks 14 19 ftIb 19 26 mkg are aligned Tighten the bolts A CAUTION Be sure the oil sump attaching bolts do not twist the gasket INSTALLING IDLER GEAR INSTALLING OIL SUMP Engines Generators 38 ENGINE REASSEMBLY3 Install the camshaft gear and key making sure that the b Tighten the fuel injection pump bolts to the specified B marks are aligned torques see illustration Tightening torques A 14 19 ftIb 19 26 mkg B 27 38 ftIb 38 53 mkg A H MARKS INSTAWNG CAMSHAFT GEAR TIGHTENING FUEL4 Install the camshaft friction gear and lock plate to the INJECTION PUMP BOLTS camshaft gear and tighten the bolt 6 INSTALLING FRICTION GEAR AND SLINGER INSTAUING FRICTION GEAR Timing Gear Cover5 Fuel injection pump installation Install the timing gear cover and gasket a Install the fuel injection pump by first aligning the Timing gear cover tightening torque notch on the injection pump gear with the mark on 14 19 ftIb 19 26 mkg the casing Carefully insert the injection pump making sure the gear has not turned Check that the NOTE Apply engine oil to the lip of the oil seal before installa C marks are aligned If not remove the pump tion and try again INSTAUING TIMING GEAR COVER INSTAUING FUEL INJECTION PUMP Engines Generators 39 ENGINE Pulley Cylinder HeadInstall the crankshaft pulley and tighten the bolts Install the cylinder head and gasket onto the cylinder block Crankshaft pulley tightening torque NOTE Remove any dirt or grease from the top of the cylinder 253 289 ftlb 35 40 mkg block and the bottom of the cylinder head A CAUTION Use a new cylinder head gasket INSTALLING CRANKSHAFT PULLEY CYLINDER HEAD GASKETCoolant PumpInstall the coolant pump and gasket Push Rods Coolant pump tightening torque Insert the push rods 14 19 ftlb 19 26 mkg A CAUTION Make sure the ends of the push rods are set in the hollowed portion of the tappets INSTALLING COOLANT PUMPAlternator BracketInstall the alternator bracket INSERTING PUSH RODS r Alternator bracket tightening torque 27 38 ftIb 38 53 mkg r INSTALLING ALTERNATOR BRACKET II 111111 INCORRECT CORRECT INSERTING PUSH RODS Engines Generators 40 ENGINE REASSEMBLY Valve Stem Caps Cylinder Head Bolts Apply engine oil to the valve stem caps and install them 1 Measure the length of each cylinder head bolt from below the head If the measured value is within the specified limit apply engine oil to the threads and insert the bolt into its original location Length of the cylinder head bolt measured from below the head Standard Long size 593 596 in 1507 1513 mm Short size 479 482 in 1217 1223 mm Limit Long size 598 in 1520 mm Short size 484 in 1230 mm INSTALLING VALVE CAPS A CAUTION If the length of the bolt below the head exceeds the specified limit it must be Rocker Arm and Shaft Assembly replaced Reassemble the rocker arm and shaft assembly if it was dis assembled and install it on the cylinder head Tighten the two nuts to the specified torque Rocker arm tightening torque 14 19 ftIb 19 26 mkg Note that the front end of the rocker shaft is identified by a pin protruding from the top and a larger oil hole between the supply holes serving 1 and 2 rocker arms This pin fits a slot in the 1 rocker shaft support which prevents the shaft from turning and cutting off the lube oil to the rocker arms and valves CYLINDER HEAD BOLT LENGTH BELOW HEAD Use the following order of assembly 1 Spring CYLINDER HEAD BOLTS 2 Rocker 3 Rocker shaft support 2 Tighten the cylinder head bolts to a tightening torque of 43 ftIb 60 mkg iIi the sequence shown in the 4 Rocker illustration 5 Wave washer 16 12 8 1 5 9 13 17 4 6 Snap ring VJAMNUT I BUSHING Cl IllIrt SPRING TAPER PIN 1nRECESS 1 ROCKERWAVE WASHER i SHAFT SAOP SNAP ROCKER SUPPORT TAPER PIN RING HOLE 15 11 7 3 2 6 10 14 INSTALLING ROCKER ARM ASSEMBLY CYLINDER HEAD BOLTS TIGHTENING SEQUENCE Engines Generators 41 ENGINE REASSEMBLY3 INSTALLING INTAKE MANIFOLD MARKING THE CYLINDER HEAD BOLTS Air Intake Silencer4 Using these marks as reference points tighten the cylin der head bolts 90 90 105 in the same sequence5 Once again tighten them 90 90 105 in the same sequence A CAUTION a Be absolutely sure to tighten in the sequence shown in the illustration b Make sure the rocker arms and push rods are squarely engaged while tightening Lifting Eyes Fuel FilterFuel Injectors 1 Install both front lifting eyesInstall the fuel injectors Orings gaskets injector brackets Front lifting eye tightening torqueand fuel return line Water pump sideNOTE Be sure the notch on the injector bracket is engaged Small bolt 14 19 ftIb 19 26 mkgin the hole in the cylinder head Large bolt 47 66 ftIb 65 91 mkg Fuel injector tightening torque Alternator side 34 40 ftIb 47 55 mkg 27 38 ftIb 38 53 mkg INSTALLING FUEL INJECTORSFuel Return Lines LEFT SIDE RIGHT SIDEInstall the fuel injectors return lines INSTALLING FRONT LIFTING EYESIntake the intake manifold and gasket Intake manifold tightening torque 14 19 ftIb 19 26 mkg Engines Generators 42 ENGINE REASSEMBLY2 Install the rear lifting eye and the fuel filter assembly 5 Install the fuel injection pump oil line Rear lifting eye tightening torque Injection pump oil line tightening torque Lifting eye bolt 14 19 ftlb 19 26 mkg Joining bolts Fuel filter bolts 27 38 ftIb 38 53 mkg A 17 26 ftlb 24 36 mkg B 9 13 ftlb 12 18 mkg PII Bracket bolts C 14 19 ftlb 19 26 mkg D 59 80 ftlb 08 11 mkg REAR LIFTING EYE D INSTALLING REAR LIFTING EYE FUEL FILTER ASSEMBLYFuel Feed Line1 Install the fuel feed line from the fuel lift pump to the NSTALLING INJECTION PUMP OIL LINE enginemounted fuel filter Fuel feed line tightening torque 6 Install the fuel injection lines and their clamps from Joining bolts 22 25 ftlb 30 35 mkg the injection pump to the injectors Bracket bolts Small 58 80 ftlb 08 11 mkg Large 14 19 ftlb 19 26 mkg A CAUTION Be careful not to damage the fuel injection lines when installing them Injection line tightening torque Joining nuts 18 22 ftlb 25 30 mkg FEED LINE INSTALLING FUEL FEED LINE2 Install the fuel line from the fuel filter to the injection pump INSTALLING FUEL INJECTION LINES3 Install the injection pump return line4 Install the fuel supply line to the fuel lift pump Oil Level Dipstick Fuel line tightening torque 1 Install the oil level dipstick Joining bolt 217 253 ftlb 30 35 mkg Oil level dipstick tightening torque Bracket bolt 58 80 ftlb 08 to 11 mkg 14 19 ftlb 19 26 mkg NOTE Apply engine oil to the Oring before installation INSTALLING OIL LEVEL DIPSTICK INSTALLING FUEL SUPPLY LINE TO FUEL LIFT PUMP Engines Generators 43 ENGINE REASSEMBLYRaw Water Pump 1 Install the alternator cap screw through the alternator leg underside and spacer into the alternator bracketInstall the raw water pump and drive belt Make sure the rawwater pumps pulley is in proper alignment with the crank 2 Swing the alternator into position on the adjusting strapshaft pulley Check the belt tension See the RAW WATER and fasten Lightly tightenPUMP page for pump servicing information 3 Install the drive belt and adjust the belt tension 4 Tighten both bolts and recheck the belt tension NOTE Make certain the belts are perfectly aligned with the alternator and engine pulleys If not insert or remove spacers as needed to align the alternator See ALTERNATOR for testing information Alternato strap tightening torque 14 19 ftIb 19 26 mkg Alternator tightening torque Strap bolt 14 19 ftIb 19 26 mkg Long bolt and nut 27 38 ftIb 38 53 mkg RAW WATER PUMPCoolant Pump Connector and Hose INSTALLING ALTERNATOR Thermostat If the thermostat was removed reinstall the thermostat gas ket and housing Thermostat tightening torque 58 80 ftIb 08 11 mkg COOLANT PUMP CONNECTOR 11 the alternator alternator adjusting strap and drive beltas follows THERMOSTAT HOUSING A CAUTION Connect the alternator properly Should the polarity be reversed a powerful current would flow from the battery into the alternator dam aging the diodes and wiring harness INSTALLING THERMOSTAT Engines Generators 44 ENGINE Cover and Crankcase Breather Hose Bellhousing propulsion engines only1 Apply Three Bond 1382 to the rocker cover gasket at Install the bellhousing the locations shown in the illustration Heat Exchanger2 Install the rocker cover and its gasket Mount the engine heat exchanger The heat exchanger should3 Install the crankcase breather hose be serviced when the engine is overhauled see HEAT EX CHANGER under COOliNG SYSTEM for inspection and servicing information Install the hose connector elbow and nrnn3 the hose from the coolant pump c t t J Starter Motor Install the starter motor Oil Pressure Switch and Oil Pressure Sender Install the oil pressure switch and sender INSTALLING ROCKER COVER Oil pressure switch and sender tightening torque4 Put the rocker cover outer gasket on the rocker covers 9 13 ftIb 12 18 mkg cover and install Engine Wiring Harness Rocker covers cover tightening torque 14 25 ftIb 02 035 mkg Assemble the engine wiring harness and ground wires Re connect all DC wiring harness terminals to their engine components A CAUTION Check all AC and DC wiring con nections by referring to the WESTERBEKE wiring diagrams and schematics ROCKER COVER OUTER GASKET PROPULSION ENGINES 1 Assemble the damper plate to the flywheel Damper plate tightening torque INSTALLING ROCKER COVERS COVER 14 20 ftIb 17 27 mkg 2 Reinstall the marine transmission and fill with theExhaust Manifold proper the exhaust manifold see EXHAUST MANIFOW NOTE Some transmissions such as the Borg Warnerpage Velvet Drive require oil coolers Oil coolers should be Exhaust manifold tightening torque cleaned pressure tested and repainted at engine over 17 20 ftIb 23 27 mkg haul The transmission oil cooler hoses should also be inspected Refer to the text on Heat Exchangers A CAUTION Retighten the exhaust manifold using the same torque after idling for twenty minutes TRANSMISSION COOLERBack PlateAttach the back plate 3 Fill the engine cooling system with premixed coolant Back plate tightening torque 916 socket 5050 good quality antifreeze and distilled water Fill 27 38 ftIb 38 53 mkg the engine oil sump to the mark on the dipstick with lube oil AP1 spec CF or CG4Fuel filter Assembly The engine should be test run under load prior to reinMount the fuel filter assembly installing At this time readjust the valve clearances on Fuel rJter tightening torque the hot engine 33 49 ftIb 46 68mkg Allow the engine to cool to room temperature and re torque the cylinder head bolts and recheck the Damper Plate propulsion engines only clearances see ENGINE the transmission darnper plate Damper plate tightening torque 14 20 ftIb 17 27 mkg Engines Generators 45 ENGINE Mount the generator back end assembly with its control panel Reconnect all DC wiring and reconnect all AC connections A CAUTION Check all AC and DC wiring con nections by referring to the WESTERBEKE wiring diagrams and schematics2 Fill the engine cooling system with premixed coolant 5050 good quality antifreeze and distilled water Fill the engine oil sump to the mark on the dipstick with lube oil API spec CF or CG4 The engine should be test run under load prior to rein stalling At this time readjust the valve clearances on the hot engine Allow the engine to cool to room temperature then re torque the cylinder head bolts and recheck the valve clearances see ENGINE MANIFOLDSee the EXHAUST MANIFOW page for inspection andassembly information Engines Generators 46 EXHAUST ASSEMBLYThe exhaust manifold which was disassembled from the 1 If the manifold was removed as an assembly and leftcylinder head should be inspected before reassembly intact it can be replaced on the cylinder head in the1 Remove the exhaust nipples elbows and plugs from the reverse order of removal manifold Do not reuse the gaskets install new ones2 Examine all parts for defects corrosion and wear and a Loosely attach the manifold elbows to the cylinder replace as needed head using new gaskets Do not use any gasket seal3 Flush out the manifolds interior with a liquid cleaner and ant on these gaskets rinse thoroughly with fresh water b Gradually tighten each fitting to ensure proper4 Use a pipe cleaner to clear the passage that connects the alignment of all the parts This should be done in filler neck to the coolant recovery tank tubing three stepsS Flush out the coolant recovery tank and its connecting Manifold mounting bolts torque tube 12 17 ftlb 16 24 mkg 2 Reinstall the exhaust connections Use new gaskets and check the exhaust clamps condition CLEAR THIS Replace it if necessary PASSAGE 3 Check the manifold pressure cap Open the valve by pulling it and make sure it closes when released Make certain the upper and lower seals are in good condition If any doubt replace the cap COOLANT RECOVERY TANK REPLACE GASKETS CHECKINQJH PRESSURE CAP Engines Generators 47 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be peiformed by a competent engine mechanic The information below is provided to assist the mechanicVALVE CLEARANCE ADJUSTMENT DRIVE BELT ADJUSTMENT1 Remove the cylinder head cover Proper inspection service and maintenance of the drive belts2 Set the piston of No 1 cylinder to the Top Dead Center is important for the efficient operation of your engine see TDC of its compression stroke Drive Belts under MAINTENANCE SCHEDULE3 Check the valve clearances only for the valves shown Drive belts must be properly tensioned Loose drive belts will below Adjust these valves if their clearances deviate not provide proper alternator charging and will eventually from the specified values damage the alternator Drive belts that are too tight will pull the alternator out of alignment andor cause the alternator to Intake No1 and No2 cylinders wear out prematurely Excessive drive belt tension can also Exhaust No1 and No3 cylinders cause rapid wear of the belt and reduce the service life of the Valve clearance engine cold coolant pumps bearing A slack belt or the presence of oil on Intake 0012 in 030 mm the belt can cause belt slipping resulting in high operating Exhaust 0014 in 03S mm temperatures and tachometer variations The drive belt is properly adjusted if the belt can be deflected no less than 38 inch IOmm and no more than 112 inch 12mm as the belt is depressed with the thumb at the mid point between the two pulleys on the longest span of the belt A spare belt or belts should always be carried on board A WARNING Never attempt to check or adjust the drive belts tension while the engine is in operation Adjusting Belt Tension 1 Loosen the alternator adjusting strap bolt and the base mounting bolt CHECKING THE VALVE CLEARANCE 2 With the belt loose inspect for wear cracks and frayed edges 3 Pivot the alternator on the base mounting bolt to the left A CAUTION Do NOT retorque the cylinder head or right as required to loosen or tighten bolts They are stretch bolts and do not require 4 Tighten the base mounting bolt and the adjusting strap retorquing bolt S Run the engine for about 5 minutes then shut down and4 Turn the crankshaft one turn so that the piston of No4 recheck the belt tensions cylinder is at the TDC of its compression stroke Check the valve clearance of the remaining valves as illustrated and adjust them if necessary Intake No3 and No4 cylinders Exhaust No2 and No4 cylinders Check these valve clearances when the pistonof No1 Cylinder is at the TOC of its compression stroke I i I I 1 IN 1 EX 2 IN 3 EX 11 38 TO 12 DEFLECTION ADJUSTING BELT TENSION iFRONT OFENGINES Install the cylinder head cover Engines Generators 48 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the THE CYLINDER HEAD BOLTS IDLE SPEED ADJUSTMENT TACHOMETER CHECK New Installation ACAUTION 00 NOT retorque the cylinder head bolts Checking the Idle Speed They are stretch bolts and do not require retorquing Use a tachometer to check the idle speed NOTE In a new installation having new instrument panelsENGINE COMPRESSION TEST the tachometer may not always be correctly calibrated to the engines rpm This calibration should be checked in all newTo check the engines compression pressure warm up the shut off the raw water throughhull remove all thefuel injectors disconnect the fuel shutoff solenoid wire and 1 Warm up the engine to normal operating a compression adapter in the injector hole Connect a Remove any specks on the crankshaft pulley with a tester on the adapter and crank the engine with cloth and place a piece of suitable reflecting tape on thethe starter motor until the pressure reaches a maximum value pulley to facilitate the use of the this process for each cylinder Look for cylinders 2 Start and idle the enginewith dramatically at least 20 lower compression than the 3 Aim the light of the tachometer onto the reflecting tape toaverage of the others confirm the engine speed Check the instrument panel Compression pressure tachometer reading Adjust the tachometer in the panel Standard 4261bin230 kglcm2 290 rpm by using the instrument calibration pod as needed to bring Limit 384 Ibin227 kglcm2 290 rpm the instrument panel tachometer into the same rpm read ing as the engine 4 Adjust the idle speed if the engine speed is not within the specified value Normal idle speed 700 900 rpmIf a weak cylinder is flanked by healthy cylinders the problem is either valve or pistonrelated Check the valve clearances for the weak cylinder adjust as needed and test again CHECKING THE IDLE SPEEDIf the cylinder is still low apply a small amount of oil into the cylinder to seal the rings and repeat the test If the compression comes up the rings are high readings on all cylinders indicate heavycarbon accumulation a condition that might be accompaniedby high pressures and noiseNOTE In case of severe vibrations and detonation noise havethe injectors checked and overhauled by an service center Poor fuel quality contaminants andloss of positive fuel pressure to the injection pump will resultin injector faults Engines Generators 49 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the the Idle Speed1 Loosen the locknut on the idle adjustment bolt on the fuel injection pump2 Turn the idle adjustment bolt until the idling speed is within the standard range The idle speed will increase when the adjusting bolt is turned clockwise and decrease when turned Tighten the locknut4 Race the engine several times to ensure the idle speed remains as setNOTE Should the engine rpm be in question verify thetachometer readings as shown at the instrument panelwith a mechanical or strobetype tachometer at theengine crankshaft FUEL INJECTION PUMP IDLE SPEED ADJUSTMENT Engines Generators 50 LUBRICATION The lubricating system is a pressure feeding system using anoil pump The engine oil is drawn from the oil sump by the DlL PRESSURE SWITCHoil pump which drives the oil under pressure through the PROPULSION ENGINEoil filter oil cooler and various lubricating points in theengine The oil then returns to the oil sump to repeat the continuous cycle When the oil pressure exceeds the the oil pushes open the relief valve in the oil pump YOPEN and returns to the oil sump keeping the oil pressure withinits specified range FUEL SOLENOIO 1TESTING THE OIL PRESSURE OIL PRESSURE SWITCH JUL GENERATORTo test the oil pressure remove the oil pressure sender theninstall a mechanical oil pressure gauge in its place Afterwarming up the engine set the engine speed at 1800 rpm OIL PUMPgenerators or 3600 rpm propulsion engines and read theoil pressure gauge If the pressure is not within the specified Removing the Oil Pumprange check each part and repair if necessary Remove the following components from the engine in the Oil pressure numbered sequence see illustration 30 35 Ibin2 21 25 kgcm at 1800 rpm 1 Stiffeners 50 55 lbin 35 39 kgcm at 3600 rpm 2 Oil pan 3 Oil pan gasket 4 Oil pipe attatching bolts 5 Oil pipe 6 Oil pump TESTING THE OIL PRESSURELow Oil PressureThe specified safe minimum oil pressure is 4314 psi0301 kgcm A gradual loss of oil pressure usually indicates worn bearings For additional information on low oil pressure readings see the ENGINE sectionOIL PRESSURE performing an engine overhaul replace the oil pressureswitch and the oil pressure senderWhen installing the new parts apply teflon sealant to the threaded ends being careful not to close off the oil hole in the sender Oil pressure switch and sender torque 9 13 ftIb 12 18 mkg A CAUTION Oil Pressure Switch 00 not use 3 lock pliers vise grips or pipe wrenches on the oil pressure switch Use the correct socket which is available from SnapOn Proto New Britain and others Damage to the switch will cause oil leaks andor switch failure REMOVING THE OIL PUMP Engines Generators 51 LUBRICATION b Check the relief valve for wear or the oil pump components in the following c Check for a weak or broken relief valve springnumbered sequence see illustration Measure the springs free length 1 Oil strainer Standard relief valve spring free length 2 Oil strainer gasket 169 176 in 428 448 mm 3 Pump cover RELIEF VALVE RELIEF VALVE 4 Outer rotor 5 Drive gear use a press and a suitable mandrel 6 Pumpbody 7 Innerrotor5 8 Screw SCREW 9 Relief valve spring FREE LENGTH 10 Relief valve plunger 6 2 Inspect the clearance between the pump body and the shaft Measure the clearance with a dial gauge and mag net base If the clearance exceeds the limit replace the pump drive shaft inner rotor pump body and drive gear Standard clearance 00015 00030 in 004 008 mm Clearance limit 00039 in 010 mm OIL PUMP 4 3 2 1 j10 3 Inspect the clearance between the inner rotor and 1 1 9 the outer rotor Check the clearance between the lobes of the rotors with a feeler gauge If the clearance 8 exceeds the limit replace both rotors Standard clearance 00016 00079 in 004 020 mmInspection Clearance limit 00098 in 025 mm1 VISually check the disassembled parts and replace any faulty parts a Check the pump body and pump cover for distortion or damage Repair or replace if necessary Check the sliding surface of the pump cover with special care and replace the cover if the surface has steps or excessive streaks Minor steps or streaks may be repaired by rubbing them with compound on a sur face plate INNER ROTOR 17 TALLY MARKS o Engines Generators 52 LUBRICATION SYSTEM4 Inspect the clearance between the outer rotor and STRAIGHTEDGE the pump body Check the clearance between the outer rotor and the pump body with a feeler gauge If the clearance exceeds the limit replace the rotor or pump body Standard clearance 00039 00083 in 010 021 mm Clearance limit 00098 in 025 mm Reassembly Reassemble the oil pump in the reverse of the order of disas sembly5 Check the clearance between the rotors and the NOTE When installing the rotors into the body be sure that pump cover Inspect the end float of the rotors Place the tally marks on the rotors are positioned toward the cover a straightedge across the pump body and measure the Pump cover tightening torque clearance between the rotor and the straightedge with a 58 87 ftlb 08 12 mkg feeler gauge If the clearance exceeds the limit replace the drive gear drive shaft inner rotor outer rotor and Installing the Oil Pump pump body Install the six components in the reverse of the order of Standard clearance removal 00012 00039 in 003 010 mm NOTE When installing the oil pump set screw apply sealing Clearance limit 00059 in 015 mm compound on the set screw SYSTEM SPECIFICATIONS Lubrication system type Pressurefed Type Trochoid Oil pump Relief valve opening pressure 924 Ibin2 65 kgcm2 Type Full flow paper element spinon type Oil filter Oil filter relief valve opening pressure 142 Ibin2 10 kgcm2 Oil cooler Type Water cooled Oil filter body Relief valve opening pressure 569 Ibin2 40 kgcm2 Oil sump capacity not including oil filtercooler assembly 63 US Quarts 60 liters Oil filter capacity 11 US Quarts 10 liters Oil Grade API Specification CF or CG4 SAE 30 10W30 15W40 Engines Generators 53 COOLING The raw water pump is a selfpriming rotary pump with a nonferrous housing and a neoprene impeller The marine diesel engines are designed and equipped has flexible vanes which wipe against a curved cam platefor fresh water cooling Heat produced in the engine by com within the impeller housing producing the pumping actionbustion and friction is transferred to fresh water coolant This pump must not be run dry as water acts as a lubricantwhich circulates throughout the engine This circulating fresh for the impellerwater coolant cools the engine block its internal movingparts and the engine oil The coolant is in tum cooled by Heat Exchangerraw water and the raw water carries the transferred heat over The engine heat is transferred externally from the fresh waterboard through the exhaust system The fresh water coolant coolant to the raw water in the heat exchanger The rawand raw water circuits are independent of each other Using water flows through tubes in the heat exchanger while theonly fresh water coolant within the engine allows the cooling fresh water coolant flows around the tubes The engine heatwater passages to stay clean and free from harmful deposits is conducted from the fresh water coolant through the tubeCoolant Pump walls to the raw waterThe fresh water coolant is pumped through the engine by a pump The coolant passes through the thermostat A thermostat located near the manifold at the front of theinto the manifold to the heat exchanger where it is cooled engine controls the coolant temperature as the coolant continand returned to the engine block via the suction side of the uously flows through the closed cooling circuit When thecirculating pump engine is first started the closed thermostat prevents coolantRaw Water Pump from flowing some coolant is bypassed through a hole in the thermostat to prevent the exhaust manifold from overThe raw water flow is created by a positive displacement heatingAs the engine warms up the thermostat pump This pump draws water directly from the opensraw water source ocean lake or river through a hose to thewater strainer The raw water passes from the strainer When the engine is started cold external coolant flow is prethrough the raw water pump to the heat exchanger then to the vented by the closed thermostat although some coolant oil cooler propulsion engines only The raw is bypassed around the thermostat to prevent the exhaustwater is then discharged into the waterinjected exhaust el manifold from overheating As the engine warms up thebow mixing with and cooling the exhaust gasses This mix thermostat gradually opens allowing the engines coolant toture of exhaust gas and raw water is discharged overboard by flow unrestricted to the external portion of the cooling systemthe engines exhaust gas discharge pressure COOLANT TEMPERATURE SWITCH COOLANT RAW WATER NOTE Antislphon valve is not shown TO TRANSMISSION COOLING SYSTEM OIL COOLER PROPULSION ENGINES ONLY WESTERBEKE COOLANT DRAIN Located under Engines Generators heat exchanger near engines back plate 54 COOLING SYSTEMHEAT EXCHANGER Replacing The ThermostatThe heat exchanger should be inspected and serviced during Remove the cap screws and disassemble the thermostatan engine overhaul housing as shown When installing the new thermostat and1 Disconnect the hoses and remove the hose fittings gasket apply a thin coat of sealant on both sides of the gas petcock drain plugs and zinc anode Also remove the ket before pressing it into place Do not overtighten the cap covers and gaskets screws2 Inspect the tube casing for wear and dents if necessary Run the engine and check for normal temperatures and that replace the heat exchanger there are no leaks at the thermostat housing3 Clean out any zinc debris and pressure test the coolant and raw water passages4 When reassembling install new gaskets and Orings Apply some lubricant to the new gaskets and to the petcocks and fittings as you install themS Install a new zinc anodeNOTE All of the above can be accomplished by sending theheat exchanger to a heat service shop GASKETThey will also service the transmission and engine oil PUT A THIN COAT OF SEALANT ON GASKETcoolers THERMOSTAT BEFORE ASSEMBLY HOUSING6 Repaint the assembled heat exchanger with Westerbeke heatresistant spray enamel7 Reconnect all hoses replacing them as needed8 Refill the system with coolant9 Pressure test the system and check for leaks DroZINC ANODE THERMOSTAT ASSEMBLY COOLANT PUMP The coolant fresh water pump is a pump and is beltdriven Removal 1 Drain the engine coolant into a suitable container 2 Remove the following components in sequence a C00lant pump pulley b Alternator drive belt c Spacer d Coolant pump HEAT EXCHANGER e Coolant pump check the thermostat for damage Then put it inwater and raise the water temperature gradually to test itsvalve opening temperature Replace if defective A CAUTION The wax pellettype thermostat remains closed if its heatsensing part is defective Leaving REMOVING COOLANT PUMP this uncorrected would cause the engine to overheat Engines Generators 55 COOLING 3 Tap out the seal using a pipe of the specified the coolant pump in the following sequence NOTE The outer diameter of the pipe should be below 1 Pulley flange 11 in 28 mm and the inner diameter of the pipe 2 Shaftlbearing IMPELLER should be above 055 in 14 mm 3 Housing and gasket 4 Impeller seal 5 Impeller HOUSING Inspection Inspect the coolant pump parts for the following conditions and replace if necessary 1 Cracking of the water pump body1 Press out the coolant pump pulley flange using a suitable puller and a press 2 Wear in the areas that the impeller contacts the seal 3 Breakage of the seal spring 4 Check that the shaftlbearing rotates easily and check for abnormal noise Reassembly2 Press out the water pump impeller and shaftlbearing using 1 Use a pipe of the specified diameter to press the shaft the water pump impeller support block Mazda 49 bearing into the water pump body 0823 146 and a press A CAUTION Use a pipe with an inner diameter of 10 in 26 mm or more and press the end of the pipe against the outer race of the shaft bearing Make sure the shaft bearing is inserted straight When the inserting force suddenly increases the shaft bearing is pressed in PRESS OUTER RACE Engines Generators 56 COOLING SYSTEM2 Apply gasket cement to the contact surface between the 7 Press in the water pump flange using a pipe of the speci seal and the pump body fied size3 Apply coolant to the seal4 Press the seal into the pump body using a pipe of the speci fied size A CAUTION a Use a pipe with an inner diameter greater than 075 in 19 mm and an outer diameter of less A CAUTION than 118 in 30 mm a Check to be sure that there is no oil on the b Press in the flange until the length of the pro seals sliding surface truding portion is about 0413 in 105 mm b Using a pipe with an inner diameter of 11 in 27 mm or more press in the seal making sure it goes in straight5 Dry off both the seal and the impellers sliding surface with compressed air Installation The coolant pump installation sequence is the reverse of the removal sequence6 Press the impeller onto the shaftlbearing A CAUTION a When preSSing make sure the lower edge of the shaft rests on a block b Press the water pump impeller until its edge is flush with the shaft c After installing check that the impeller can be easily moved by hand Engines Generators 57 COOLING SYSTEMRAW WATER PUMP NOTE It may be necessary to use a drift and arbor press to press the bearing and seal assembly from the shaftNOTE Since completely rebuilding a damaged or worn pumpfrom individually purchased parts would almost match the 6 Inspect all parts and replace those showing wear orprice of a new pump Westerbeke recommends that a new erosionpump be disassembling the raw water pump inspect the pumpby rotating the drive shaft If it is rough frozen or seems to A CAUTION If any of the vanes have been bro ken off the impeller they must be found to preventhave excessive play a major overhaul may be needed blockage in the cooling circuit They often can beDisassembly found in the heat exchangerThe pump as removed from the engine will have hoseattachment nipples threaded into its inlet and outlet ports 7 Use the illustration to assist in reassembling the raw waterThe nipples may be left in place or removed if they interfere pumpwith the pump disassembly Note the port location and posi a Apply a small amount of petroleum jelly to the seatstioning if removed surface and to the impeller shaft at reassembly1 Loosen the set screw with an allen wrench and remove b When positioning the cam in the housing use a small the water pump pulley from the shaft taking care not to amount of Permatex 1 on the inner cam surface and lose the key cam screw head remove any excess from the impeller2 Remove the four impeller cover screws the impeller housing cover and its gasket c Apply a light film of silicon or petroleum jelly to the NOTE Replacement of the impeller cover gasket is inner surface of the housing for the impeller recommended however if you are going to reuse it keep d Apply a thin coating of lubricant to the impeller cover the gasket well lubricated until the pump is reassembled gasket s If it allowed to dry the gasket will shrink and not be S When the pump is assembled reposition and tighten the reusable hose nipples into the pump housing use Teflon sealant on3 Pull out the impeller with longnose pliers or a pair of the nipple thread Assemble the pump to the engine and screwdrivers attach the hoses and the belt4 Remove the cam screw and cam5 Remove the bearing housing releasing the shaft bearing IMPELLER COVER and seal assembly This will allow the bearing and seal assembly to be inspected CAM SCREW 1lA RAW WATER PUMP Engines Generators 58 FUEL The fuel system uses 5hole type injection nozzles and combustion chamber improving combustion and an inline injection pump Bosch type The injection increasing power pump generates a high injection pressure of 2417 lbin 2 The fuel which is drawn up through the fuel filterwater 170 kgcm and the fuel is injected from the injection separator from the fuel tank is filtered and then supplied nozzles as a fine spray and at a wide angle into the to the injection pump FUEL FILTER FUEL INJECTION PUMP FUEL SYSTEMCHANGING THE FUEL FILTER1 Shut off the fuel supply2 Open the bleed screw on the top of the filter Place a con tainer under the fuel filter and open the drain on the bot tom of the bowl and drain the fuel3 Close the drain and unscrew the bolt that secures the bowl The bowl and the filter will drop down4 Clean the base Install a new sealing ring in the base making certain that it lies squarely on the base recess5 Replace the upper sealing ring and the oring in the filter head Install the new filter element and reinstall the retaining bolt NOTE Apply fuel to the seal rings and oring before installing6 Bleed the air from the filter assembly FUEL FILTER Engines Generators 59 FUEL SYSTEMFUEL FEED PUMP STRAINER Bleeding air from the fuel line between the enginemount ed fuel filter and the injection pumpAn additional fuel screen is located in the feed pump Thisscreen strainer is removed for cleaning by releasing the 1 Confirm that the plugs on the fuel filterwater separatorbanjo bolt at the bottom This screen should be cleaned every are closed and that the fuel lines are connected250 operating hours Use compressed air andor clean with 2 Tum the fuel lift pump primer to rekerosene lease it 3 Disconnect the fuel return hoseTO FUEL ASCREEN l FUEL IN FUEL FEED PUMP STRAINER 4 Repeatedly depress and release the primer until only fuelBLEEDING THE FUEL SYSTEM no air bubbles flows out of the air bleeding plug holeIf air is present in the fuel lines the engine may be difficult 5 Connect the fuel return hoseto start there may be insufficient power or hunting may oc 6 Depress the primer and tum it clockwise to lock itcur when idlingAir bleeding must be performed after the injection pumphas been installed and after checking or adjusting the injec A CAUTION If hunting occurs when idling ortion timing there is less engine power after air bleeding thenBleeding air from the fuel line between the fuel tank and loosen the injector ends of all fuel lines and bleedthe enginemounted fuel filter air by using the engine starter to crank the engine until only fuel comes out1 Confirm that the plugs on the fuel filterwater separator are closed and that the fuel lines are connected After bleeding the air start the engine and check for fuel leaks2 Tum the primer on the fuel lift pump to release it3 Loosen the air bleeding plug on the fuel filter4 Repeatedly depress and release the primer until only fuel no air bubbles flows out of the air bleeding plug hole5 Retighten the air bleeding plug6 Depress the primer and tum it clockwise to lock it LOOSEN THE INJECTOR ENDS OF AU FUEL LINES Engines Generators 60 FUEL SYSTEMTESTING THE FUEL INJECTORS Fuel Injector ComponentsNOTE The fuel injectors must be serviced in a clean room The fuel injector consists of the following the Fuel Injectors1 Disconnect the high pressure fuel lines from the injectors then loosen the lines at their attachment to the injection pump and move them out of the way of the injectors fi NOZZLE BODY GUmMl Avoid bending the lines2 Remove the fuel return line in its entirety from the top of the injectors Take care not to lose the two sealing wash NEEDLE VAlVE ers and banjo bolt that attaches the fuel return line to each injector DISTANCE PIECE 3 Remove the fuel injector holder bracket mounting nuts then remove the holder brackets PRESSURE PIN4 Remove the fuel injectors PRESSURE SPRINGB NOTE Clean the area around the base of the injector prior to lifting it out of the cylinder head to help prevent SHIM any rust or debris from falling down into the injector NOZZLE HOLDER hole If the injector will not lift out easily and is held in by carbon buildup or the like work the injector sideto FUEL INJECTOR COMPONENTS side with the aid of the socket wrench to free it and then lift it out The injector seats in the cylinder head on a copper seal ing washer This washer should be removed with the injector and replaced with a new washer when the injec tor is reinstalled Checking the Injection Starting Pressure5 Remove the gaskets 1 Set the nozzle tester in a clean place where there is no dust or dirt6 Remove the Orings HIGH PRESSURE lINE 2 Mount the nozzle and the nozzle holder on the nozzle tester fJ 3 Use new fuel that has an approximate temperature of FUEL 68F 20C INJECTOR 4 Bleed the air in the nozzle line by pumping the nozzle tester handle several times 5 Slowly lower the nozzle tester handle and check the read ing on the pressure gauge when the injection starts Injection starting pressure 2417 24891bin2 170 175 kglcm2 A CAUTION The spray nozzle velocity is such that it may penetrate deeply into the skin of the fingers and hands destroying tissue If it enters the bloodstream it may cause blood poisoning REMOVING THE FUEL INJECTORS Engines Generators 61 FUEL SYSTEM Inspecting the Spray Pattern 1 Mount the nozzle and nozzle holder on the nozzle tester 2 Bleed the air in the nozzle line by pumping the nozzle tester handle several times 3 Keep the reading on the pressure gauge of the nozzle tester just below the injection starting pressure while pumping the handle of the nozzle tester as quickly as possible so that a pulsating whistling sound is heard Check the atomization of the fuel injected from the noz zle see illustration FUEL INJECTOR INJECTION PRESSURE TEST6 If the injection starting pressure is not within the speci fied range adjust it by replacing the shim with one of a more appropriate thickness The shims have 21 different thicknesses at intervals of 0002 in 005mm from 00197 in 050mm to 0059 in NORMAL FAULTY FAULTY 150 mm If the thickness of a shim is increased 0002 in PAmRN PATTERN PAmRN 005 mm the injection pressure increases approximately FUEL INJECTOR SPRAY PATIERNS 711lbin2 50 kgcm2 ADJUSTING SHIM Normal Pattern The fuel is sprayed uniformly and finely from all five injection nozzle holes Faulty Pattern The number of fuel sprays and fineness of the injected fuel is substandard If the condition of the injected fuel is substandard disas semble wash and recheck the injection nozzle or replace it FUEL INJECTOR ADJUSTING SHIM Checking the Nozzle Body and Needle Valve 1 Check for damage to the valve seat of the needle valveTightness of the Valve Seat and check for damage to other partsApply a pressure of 2133 lbin2 150 kgcm2 and check if 2 Check for damage to the nozzle body Hold the nozzlefuel leaks from the injection nozzle holes If fuel leaks disas body upright and insert fourfifths of the needle valvesemble wash and recheck the injector nozzle or replace it Then release the needle valve and check that it drops into the valve seat under its own weight NOZZLE BODY CHECKING THE TIGHTNESS CHECKING THE NOmE BODY AND NEEDLE VALVE OF THE VALVE SEAT Engines Generators 62 FUEL FUEL INJECTION PUMPBe sure to do the following when reassembling the fuel injector NOTE The fuel injection pump is a very important compo1 Tighten the nozzle body onto the nozzle holder to the nent of the diesel engine requiring the utmost care in specified torque handling It has been thoroughly benchtested and the Nozzle torque 29 36 ftlb 40 50 kgm owneroperator is cautioned not to attempt to service it If the fuel injection pump requires servicing remove it and take it to an authorized Kiki fuel injection pump service facility The only adjustment the servicing mechanic should make to the fuel injection pump are the adjustments for idle speed see IDLE SPEED ADJUSTMENT under ENGINE ADJUSTMENTS and injection timing see INJECTION TIMING ADJUSTMENT below TIGHTENING THE NOZZLE BODY ONTO THE NOZZLE HOLDER2 After assembling the fuel injector check the injection starting pressure and the spray fuel injector installation sequence is the reverse of theremoval sequence Make sure to include the following1 Use new gaskets do not reuse the old gaskets2 Replace the copper sealing washer for each injector3 Tighten the fuel injector holder bracket mounting nuts to the specified torque Bracket mounting nuts torque 340 400 ftlb 47 55 kgm FUEL INJECTION PUMP SCRIBE MARK ALIGN THE SCRIBE MARK ON THE INJECTION PUMP FLANGE WITH THE SCRIBE MARK ON THE GEAR CASE THIS WILL PLACE THE INJECTION PUMP IN PROPER TIMING WITH THE ENGINE TORQUING THE FUEL INJECTOR HOLDER BRACKET Engines Generator REVISED 12002 STARTER MOTOR START SWITCH BATIERY CONTROL SWITCH FIGURE 1 STARTER WIRING Continuity CheckTo independently test the starter it is necessary to remove Disconnect the field lead on the starter from the solenoid Mit from the engine However before doing this checks terminal and insulate it carefully to prevent accidental contactshould be made to ensure that the problem is with the starter Set the transmission in neutral Use a voltmeter to check forand not with the engine battery wiring or switches When voltage at the solenoid S terminal while the start switch isthe other possible problem sources have been eliminated held in the START position If voltage is not present at the Sthen remove and test the starter Comparison of test results terminal use the voltmeter and the wiring diagram to tracewith the chart will aid in isolating the prob the control circuit and locate the point of voltage loss and corlem within the starter to specific components This will rect it as the repair or repairs needed to restore the starter to Starter If the battery wiring and switches are in satisfactory condiBattery Test tion and the engine is known to be functioning testing as well as successful operation requires a remove the starter for further testingfully charged battery capable of supplying the current needs Starter NoLoad Testof the starting system Step one in the starting system is to test the battery Follow the battery manufac With the starter removed from the engine the noload testturers instructions can reveal damage that can be corrected by repair or it may indicate the need for component testing after the starter is disWiring and Switches assembled Repair and component test procedures areVISual Inspection described in the UNIT REPAIR section The noload test is also used to test units for normal operation after repair orVisually inspect all wiring and switches in the starting cir overhaul Comparison of test results with the Troublecuit for damage and loose or corroded connections This shooting chart will indicate what corrective action if any isincludes all ground connections Clean and tighten the con as required Replace damaged wiring or components Engines Generators 64 STARTER MOTORTest HookUp Figure 2 NOTE During the noload test close the switch and operateConnect the starter for the noload test as shown in the the starter for cycles of 30 seconds maximum using suitable instruments battery cables and con cycles allow the starter to cool for at least two minutes othnecting wiring Do the following erwise overheating and damage to the starter may result1 Secure the starter in a suitable test stand to check its 1 Momentarily close the switch operation a If there is a high current flow and the starter fails to2 Use a momentary contact pushbutton switch in the test operate zero rpm release the switch immediately circuit for a quick release if very high current surges Internal mechanical damage is indicated Discontinue are encountered the test and refer to Make all connections or disconnections with the switch h If there is no current flow and the starter fails to oper open and the carbon pile load turned off ate zero rpm release the switch immediately An open circuit is indicated Discontinue the test and4 If sparking or current flow in the battery circuit is refer to noted when making the connections the starter sole noid switch contacts may be frozen shut refer to c If there is a current flow and the starter operates release the switch and proceed with the next step of the noload test5 As the last step in making the test connection ground the negative battery cable securely to a clean metal 2 Close the switch and observe the voltmeter Adjust the ground on the starter frame carbon pile load to obtain a 10 volt reading 20 volts on a 24volt starter Observe and record the ammeter and rpm6 The carbon pile load is used to adjust the operating readings Release the switch voltage for comparison with specifications It may not be necessary in all cases but should be used to elimi 3 Compare the ammeter and rpm readings to those listed nate the need for interpolation of test data under SPECIFICATIONS at the end of this section If the readings are outside the limits shown refer toTest Procedure to determine the most likely causes If the readings are within the limits the starter is operating normally A CAUTION Keep fingers and tools away from the opening in the DE drive end housing while testing The strong shifting action of the solenoid could cause personal injury or damage as the drive pinion moves into the cranking position and spins VOLTMETER CLAMP ON AMMETER SWITCH BAT S M CARBON PILE FIGURE 2 STARTER NOLOAD TEST HOOKUP Engines Generators 65 STARTER ble cause and its remedy The problems listed in the chartIf the results of the noload test are outside the limits refer apply specifically to the noload test and do not necessarilyto the following chart for the proba apply to operation under other circumstances PROBLEM PROBABLE CAUSE Normal current and speed a Starter OK a Recheck battery switches and wiring including battery cable loss Check if starter operation on engine is slow or sluggish Current flow with test circuit switch open a Solenoid switch contacts stuck closed a Test and if necessary replace solenoid assembly Failure to operate with very low or no a Open solenoid wiring a Inspect and test solenoid assembly current b Inspect and test frame and field assembly b Open field circuit c Open armature coils or high insulation c Inspect armature between commutator bars d Broken brush springs or worn brushes d Inspect brushes and brush springs Failure to operate with high current a Frozen bearing or other damage to drive a Inspect bearings armature drive shaft train and related drive parts b Direct ground in terminals or fields b Inspect and test frame and field assem bly solenoid assembly armature and brush installations for shorts Low speed with high current a Excessive friction in bearings or gear a Inspect bearing armature drive shaft reduction unit bent armature shaft or and gear reduction gears loose pole shoe bent drive shaft b Shorted armature b Inspect and test armature c Grounded armature or fields c Inspect and test frame and field coil assembly and armature Low speed with normal or low current a High internal electrical resistance caused a Inspect internal wiring electrical connec by poor connections defective leads or tions and armature commutator dirty commutator b Causes listed under Failure to operate b Remedies listed under Failure to operate with very low or no current with very low or no current High speed with high current a Shorted fields a Inspect and test field and frame assembly Refer to the UNIT REPAIR section for required disassembly inspection test and if necessary repair or replacement REPAIR This section provides instructions for complete disassembly of the starter as would be the case for overhaul If the starterNOTE Always install fasteners at their original locations is not due for an overhaul and repair affecting specific partsIf it is necessary to replace fasteners use only the correct only is required the starter may be disassembled only to thepart numbers or equivalent If the correct part number is not extent necessary to gain access to these parts Parts use only afastener of equal size and strength Use from the starter as subassemblies or groups need not be disa torque wrench to tighten fasteners when a torque value is assembled for such limited repair unless they contain thespecified Torques specified are for dry unlubricated fasten affected parts Total disassembly is recommended howeverers unless otherwise specified to ensure that all parts can be thoroughly cleaned 3 In this section the starter is broken down by main groupsFigure 3 shows the starter broken down into its component These groups are then disassembled into individual parts andparts and assemblies Do not attempt to disassemble the fol assemblies Illustrations accompany the text to show specificlowing components which are serviced as assemblies operations To see the parts relationship of the complete starter refer back to Figure 3 Solenoid assembly 1 To begin make a mark completely down one side of the Clutch Drive assembly 2 starter to ensure proper alignment of all its components at Brush Holder assembly 3 assembly Use a colored pencil or marker that will show on Armature assembly 13 all parts Frame and Field assembly 19 Engines Generators 66 STARTER MOTOR 30 31 32 15 12 I 2223 6l O 1 SOLENOID ASSEMBLY 10 7 2 CLUTCH DRIVE 35 ASSEMBLY 6 3 BRUSH HOLDER 2 ASSEMBLY 21 4 BRUSH GROUNDED 5 BRUSH INSULATED 6 DE HOUSING 18 BUSHING 21 SHIFT LEVER SCREW 7 BRUSH SPRING 22 SHIFT LEVER WASHER 34 8 DE ARMATURE 23 SHIFT LEVER NUT BEARING 25 SOLENOID SCREW 9 CE ARMATURE 26 PLATE IF USED BEARING 27 DRIVE HOUSING PLUG10 CENTER SUPPORT 28 DOWEL PIN BEARING 29 INSULATED BRUSH SCREW11 SHIFT LEVER 30 WASHER FIBER12 PINION STOP 31 WASHER THIN ONE OR13 ARMATURE TWO MAY BE USED14 CE FRAME 32 WASHER THICK15 DRIVE SHAFT 33 FRAME SEAL16 ARMATURE SUPPORT 34 BUSHING PLUG IF USED BRACKET 35 STOP RING17 DRIVE SHAFT 36 DRIVE HOUSING BOLT LONG SUPPORT 37 DRIVE HOUSING BOLT18 DRIVE HOUSING SHORTER ON SOME MODELS19 FRAME FIELD 39 GROUNDED BRUSH SCREW ASSEMBLY 41 THRU BOLT20 CE FRAME ORING 42 BRUSH PLATE SCREW FIGURE 3 STARTER ASSEMBLY Engines Generators 67 STARTER MOTORGeneral Disassembly 5 Frame field and brush holder group A dowel pin 28Figure 4 and frame seal 33Remove or Disconnect a The armature assembly 13 may come off with the frame field and brush holder group A or may be1 The motor lead on the frame field and brush holder retained by the gear reduction and drive group B group A from the solenoid assembly 1 Reinstall the nut on the solenoid terminal 6 Armature assembly 13 with bearings 8 and 9 a Remove the nut on the solenoid slip off the motor a Do not remove the bearings from the armature lead and reinstall the nut assembly unless replacement is required refer to CLEANING INSPECTION AND REPAIR2 Thru bolts 41 7 Solenoid screws 253 Brush plate screws 42 8 Solenoid assembly 14 CE frame 14 and Oring 20 a Pivot the inside end of the solenoid assembly 1 out Important of engagement with the shift lever in the gear a In the following step use care not to lose the small reduction and drive group B and withdraw the dowel pin 28 installed between the frame field and solenoid assembly brush holder group A and the gear reduction and drive group B This dowel pin is required for assembly and must be saved If the dowel pin should be lost it must be replaced with a 2 mm 0079 in dia x 10 mm 0394 in long pin pro cured or manufactured locally 42 4 25 14 41 1 SOLENOID ASSEMBLY 8 DE ARMATURE BEARING 9 9 CE ARMATURE BEARING 13 ARMATURE ASSEMBLY 14 CE FRAME 20 CE FRAME ORING 25 SOLENOID SCREW 28 DOWEL PIN 33 FRAME SEAL 41 THRU BOLT 42 BRUSH PLATE SCREW A FRAME FIELD BRUSH HOLDER GROUP B GEAR REDUCTION DRIVE GROUP FIGURE 4 ELECTRICAL GROUP Engines Generators 68Disassembly of Frame Field and Brush Holder GroupFigure 5Remove or disconnect 191 Insulated brush screws 29 a Move the brush holder assembly 3 with the brush es 4 and 5 away from the frame and field assem bly 19 slightly to reach across with a screwdriver and remove the screws 292 Frame and field assembly 193 Grounded brush screws 39 19 FRAME FIELD4 Brushes 4 and 5 if replacement is required 3 BRUSH HOLDER ASSEMBLY ASSEMBLY a Grasp the brush end of each brush spring 7 with 4 BRUSH GROUNDED 29 INSULATED BRUSH needle nose pliers twist the spring end away from 5 BRUSH INSULATED SCREW the brush 4 or 5 and withdraw the brush 7 BRUSH SPRING 39 GROUNDED BRUSH SCREW5 Brush springs 7 if replacement is required a Grasp the brush end of each brush spring 7 with FIGURE 5 FRAME FIELD AND BRUSH HOLDER GROUP needle nose pliers twist the spring end away from the brush socket on the brush holder assembly 3 and remove the spring 11 NOTE At this stage of disassembly all electrical com ponents can be inspected and if required independently tested as specified in CLEANING INSPECTION AND of Gear Reduction and Drive GroupFigure 6Remove or disconnect I1 Housing bolts 36 and 37 182 Armature support bracket 16 Grf Important 30 a The washers 30 through 32 may stick to the arma ture support bracket or to the drive shaft and clutch group C as the armature support bracket is 31 removed In either case note the position and num 32 ber of each of these washers 63 Washers 30 through 32 21 a Save the washers they are to be installed in the same 6 DE HOUSING BUSHING position and number at assembly 11 SHIFT LEVER4 Drive housing plug 27 and plate 26 16 ARMATURE SUPPORT BRACKET a Pry out the drive housing plug using a large screw 18 DRIVE HOUSING 32 WASHER THICK driver 21 SHIFT LEVER SCREW 34 BUSHING PLUG IF5 Shift lever nut 23 washer 22 and screw 21 22 SHIFT LEVER WASHER USED 23 SHIFT LEVER NUT 36 DRIVE HOUSING BOLT6 Remove the shift lever 11 and the drive shaft and 26 PLATE IF USED LONG clutch group C from the drive housing 18 together 27 DRIVE HOUSING PLUG 37 DRIVE HOUSING BOLT then separate them 30 WASHER FIBER SHORTER ON SOME MODELS a Do not remove the bushing plug 34 or the bushing 31 WASHER THIN ONE OR C DRIVE SHAFT CLUTCH 6 from the drive housing 18 unless replacement TWO MAY BE USED GROUP is required refer to CLEANING INSPECTION AND REPAIR FIGURE 6 GEAR REDUCTION AND DRIVE GROUP Engines Generators 69 STARTER of Drive Shaft and Clutch GroupFigures 7 and 8Disassembly of the drive shaft and clutch group is notrequired unless it is necessary to clean inspect or replaceone or more parts of the group separately Then proceed or disconnect1 Stop rings 35 and pinion stop 12 a Position the drive shaft and clutch group on the work bench with the internal gear end down b Using an open tube slightly larger than the shaft see Figure 8 drive the pinion stop 12 toward the clutch drive assembly 2 until it clears the stop rings 35 2 CLUTCH DRIVE 10 ASSEMBLY 15 DRIVE SHAFT c Using care not to scratch the drive shaft 15 pry the 10 CENTER SUPPORT 17 DRIVE SHAFT stop rings out of the shaft groove and slide them off BEARING SUPPORT the end of the shaft 12 PINION STOP 35 STOP RINGS 2 PCS d Inspect the edges of the shaft groove for burrs that may have been formed through repeated cranking FIGURE 7 DRIVE SHAFT AND CLUTCH GROUP cycles Such burrs may make removal of the pinion stop and clutch drive assembly 2 difficult If burrs are found use a suitable file to carefully remove the burrs only not the base metal Thoroughly clean away metal filings e Slide the pinion stop 12 off the drive shaft 15 Discard the old pinion stop 12 and stop rings 35 New parts must be used at assembly2 Clutch drive assembly 2 from drive shaft 153 Drive shaft support 17 from drive shaft 15 a Do not remove the bearing 10 from the drive shaft 15 unless replacement is required refer to CLEAN ING INSPECTION AND REPAIR 142 MM 056 IN DIAfa 22 MM 087 IN DIA OPEN TUBE ttiZZLPINION STOP 12 DRIVE SHAFT 15 FIGURE 8 REMOVING PINION STOP Engines Generators 70 STARTER MOTORCLEANING INSPECTION TESTING AND REPAIR 6 Brushes 4 and 5 for excessive wearCleaning a The minimum allowable brush length is 12 mm 0472 in Replace excessively worn brushes inNOTE Do not clean or immerse starter parts in grease dis setssolving solvents Solvents will dissolve grease packed in thedrive assembly and may damage the armature or field coil 7 The DE housing bushing 6 for scoring or other daminsulation age Replace a damaged bushing refer to REPAIR 8 Ball bearings 8 9 and 10 as follows1 All starter parts with a soft cloth prior to testing a Hold the armature 13 or drive shaft 15 and rotate the outer bearing race by handFigure 3 b Check that the bearing turns freely without binding orInspection in the following steps refers to visual inspection the feel of flat spotsof the starter parts and assemblies to determine their serviceability Electrical tests for certain assemblies are described in c Replace damaged bearings refer to ELECTRICAL TESTING 9 Armature assembly 13 for the following1 All parts for cracks distortion other structural damage a Gear teeth that are broken or that show evidence of Replace parts or assemblies which are cracked bent or step wear or root interference otherwise damaged b Rough commutator surface Polish with a No 4002 Threaded parts for stripped crossed or otherwise dam grit polishing cloth if necessary Thoroughly clean aged threads Replace parts with thread damage that metal dust from between the commutator bars If the cannot be cleaned up using a suitable tap or die commutator surface cannot be repaired in this man Replace any hardware items that have damaged threads ner replace the armature assembly Do not tum the commutator in a lathe3 The solenoid assembly 1 for a cut or tom boot If the boot is damaged replace the solenoid assembly c Worn commutator Replace the armature assembly if the commutator OD is less than 35 mm 1378 in or4 The clutch drive assembly 2 for the following if the undercut depth at any point is less than 02 mm Replace the clutch drive assembly if damaged 0008 in Do not undercut the insulation a Pinion gear turns roughly or turns in both directions 10 Drive shaft 15 for the following Replace the drive b Pinion gear teeth broken or showing evidence of shaft if damaged step wear a Scored or damaged shaft where it turns in the c Deep scoring or other damage to the shift lever collar bushing 65 The brush holder assembly 3 for the following b Internal gear with teeth broken or showing evidence Replace the brush holder if damaged of step wear a Loose riveted joints c Damaged spline The clutch drive assembly must b Cracked or broken insulation slide smoothly and easily over the full length of the spline Engines Generators 71 STARTER MOTORComponent Electrical Testing BATIERYFigures 9 and 10 the following electrical tests on the solenoid assembly 1 armature assembly 13 and frame and field assembly 19 to determine their Using a suitable ohmmeter check the windings of the solenoid assembly 1 for continuity as follows a Check the resistance of the solenoid pullin and holdin windings in series by measuring the resist ance between the motor terminal see Figure 9 and the solenoid case The resistance should be approxi mately 095 ohms for 12volt starters and approxi mately175 ohms for 24volt starters b An extremely high resistance reading indicates a break or fault in the winding continuity A very low resistance reading indicates a short or ground in the winding circuit Either condition is cause for MOTOR TERMINAL replacement of the solenoid assembly2 Check the armature 13 as follows for shorts opens or FIGURE 9 SOLENOID TERMINALS grounds using suitable test equipment and instruments test lamp must be 110 volts or less a Rotate the armature in a growler holding a steel strip such as a hacksaw blade against the armature If a short circuit is present the steel strip will vibrate in that area b Check the armature for grounds using a test lamp or ohmmeter There shall be no continuity between the armature shaft and any point on the commutator c Check for opens by visually inspecting the points where the armature conductors join the commutator A poor connection often will be indicated by signs of arcing or burning of the commutator d Replace armatures which are shorted grounded or show evidence of opens3 Check frame and field assembly 19 for grounds or opens using a test lamp 110 volts max or ohmmeter as follows a Check that there is continuity no opens between the field terminal that connects to the solenoid and the connection points for the insulated brushes on the field coil straps b Check that there is no continuity no grounds between the frame and the field terminal that con nects to the solenoid c Replace frame and field assemblies that have grounds or opens FIGURE 10 FRAME AND FIELD ASSEMBLY Engines Generators 72 STARTER MOTORRepair Procedures Remove or 3 and 11 a The center support bearing 10 from the drive shaft1 If necessary replace the bearings 8 and 9 Figure 3 on 15 using a locally fabricated tool as shown in the annature 13 as follows Figure 11 NOTE Ball bearings which are removedfrom the Install or Connect armature must be replaced with new bearings The b The center support bearing 10 from the drive shaft removal procedure causes internal damage to the 15 using a locally fabricated tool Figure 11 With bearings the drive shaft in a suitable support fixture place theRemove or disconnect tool bolt ends through the access holes in the wide end of the drive shaft and squarely press the bearing a CE andor DE bearings 8 andor 9 from the shaft off of the surface on the center shaft of the annature 13 using a suitable bearing puller 3 If necessary replace the bushing 6 Figure 3 in theInstall or Connect drive housing 18 as follows b New CE andor DE bearings 8 andor 9 to the a From inside the drive housing 18 drive out the annature assembly 13 using a tube that bears on plug 34 if present Use a file to clean away rem the bearings inner race only Press on the bearing nants of the old stake to allow installation of a new until the inner race bottoms out against the shoulder plug Clean away any metal shavings on the annature shaft b Using a suitable open tube press out the bushing 62 If necessary replace the center support bearing 10 Figure 3 on the drive shaft 15 as follows c Using a suitable open tube press the new bushing 6 into the drive housing 18 until the end of the NOTE Ball bearings which are removedfrom the bushing is flush with the inside of the housing drive shaft must be replaced with new bearings The removal procedure causes internal damage to the d Install a new plug 34 if used to the drive housing bearings Stake housing material over the plug at three places equally spaced TOP VIEW SIDE VIEW PRESS MATERIALS NEEDED PIECE OF FLAT METAL STOCK ABOUT 5MM OR 316 IN CENTER SUPPORT THICK AND 55 MM OR 2 14 IN SQUARE OR ROUND BEARING THREE 6 MM OR 316 IN BOLTS OF EQUAL LENGTH LONG ENOUGH TO EXTEND AT LEAST 35 MM 1 38 IN CENTER BELOW THE FLAT STOCK WHEN INSTALLED THROUGH SHAFT I IT TO USE NUTS INSTEAD OF TAPPED HOLES USE LONGER BOLTS TO COMPENSATE FOR NUT THICKNESS 1 LOCATE THREE HOLES EQUALLY AROUND A 32 MM 126 IN CIRCLE ON FLAT STOCK DRILL AND TAP HOLES AS NEEDED TO MATCH BOLT THREADS 2 INSTALL BOLTS IN FLAT STOCK AND TIGHTEN ENDS OF INSTALLED BOLTS SHOULD PASS THROUGH ACCESS HOLES IN END OF DRIVE SHAFT WITHOUT BINDING FIGURE 11 TOOL FOR REMOVING CENTER SUPPORT BEARING Engines Generators 73 STARTER MOTORASSEMBLY 1 Lubricate the DE housing bushing shift lever and drive shaft as described under LUBRICATION During Assembly ASSEMBLY1 The armature bearings 8 and 9 Figure 3 and drive shaft Install or Connect support bearing 10 are pennanently lubricated Do not add lubricant to these bearings Lubricate the following 2 The arms on the shift lever 11 with the shift collar on just before or during assembly avoid excessive grease the drive shaft and clutch group C 3 DE housing bushing 6 in drive housing 3 The assembled shift lever 11 and the drive shaft and clutch group C into the drive housing 18 aligning the b The pivot hole and working surface on the ends of holes in the drive shaft support 17 Figure 7 with those the shift lever 11 in the drive housing c The internal gear shaft and spline on the drive shaft 3 Make sure that the drive shaft support is fully seated 15 in the drive housing and that the drive shaft bearingDrive Shaft and Clutch Group 10 Figure 7 remains fully seated in the drive shaftFigures 7 and 12 support1 If disassembled position the drive shaft on the work sur 4 Shift lever screw 21 washer 22 and nut 23 face with the internal gear end down and assemble the Tighten drive shaft and clutch group as follows 3 Nut to 45 Nm 40 lbin Important 5 The plate 26 if used and the drive housing plug 27 3 If the center support bearing 10 is being replaced to the drive housing 18 install it on the drive shaft 15 as specified in REPAIR PROCEDURES step 2 before proceeding with 6 Washers 30 through 32 in the same number and posi assembly tions as noted at or Connect 7 The armature support bracket 16 to the drive housing 18 aligning the mark made prior to disassembly with1 The drive shaft support 17 to the drive shaft 15 seat that on the drive housing ing the bearing 10 in the support S Drive housing bolts 36 and 372 The clutch drive assembly 2 to the drive shaft 153 A new pinion stop 12 onto the drive shaft 15 the end METAL BLOCK APPROX with the recess for the stop rings 35 up 9 MM 316 IN 3 Install the stop rings 35 in the groove in the drive shaft 15 b Pick up and support the assembly under the pinion stop 12 A metal block with a Ushaped cutout that will slide over the shaft between the pinion gear and the stop can be clamped in a vise to provide support see Figure 12 c Make sure the stop rings 35 in the drive shaft APPROX groove are fully seated in the pinion stop recess and 38 MM 1 12 IN stake the upper edge of the pinion stop 12 over the stop ring 35 at four places equally spaced Do not allow staked metal to contact the drive shaft 15Assembly of Gear Reduction and Drive GroupFigure 6 Important If the DE bushing 6 and plug 34 are being replaced install them in the drive housing 18 as specified in REPAIR PROCEDURES step 3 before proceeding with assembly FIGURE 12 PINION STOP SUPPORT BLOCK Engines Generators 74 STARTER MOTORAssembly of Frame Field and Brush Holder Group NOTE The brush leads may be damaged by 5 13 and 14 handling Do not overjlex the leads near the clip welds or the clips may break off BRUSH HOLDER 2 Brushes 4 and 5 if removed ASSEMBLY a See Figure 14 for the proper installed position of all SPRING brushes Make sure the insulated brushes 5 go into the brush sockets of the brush holder assembly 3 that are mounted on the insulation b To install each brush grasp the free end of the brush spring with needle nose pliers twist clockwise to clear the brush socket and insert the brush partly into the brush socket c Gradually release the spring so that its end contacts SPRING POST BRUSH SOCKET the side not end of the brush see Figure 13 This will hold the brushes retracted until after the brush FIGURE 13 BRUSH SPRING ON POST holder is installed over the armature commutator 3 Grounded brush screws 39Install or Connect a Position the terminals of the grounded brush leads behind the terminal tabs on the brush holder 3 see1 Brush springs 7 if removed Figure 13 a Start each brush spring onto the post on the brush b Insert the brush screws 39 through the terminal holder assembly 3 as shown in Figure 13 just tabs on the brush holder and thread them into the enough to hold the inside end of the spring from brush lead terminals turning Tighten b Grasp the free end of the spring with needle nose pliers and twist clockwise over the top of the brush c Grounded brush screws to 15 Nm 13 lbin socket c Push the spring fully onto the post and release the free end to engage the notch in the brush socket INSULATED BRUSH BRUSH SPRING GROUNDED BRUSH SPRING POST FIGURE 14 SPRINGS AND BRUSHES ON BRUSH HOLDER Engines Generators 75 STARTER MOTOR Important4 The frame and field assembly 19 to the brush holder assembly a The Oring can easily be damaged during installa tion of the CE frame 14 To prevent such dam a Position the brush holder assembly 3 with age install the Oring as described in the following installed brushes over the terminal end of the frame steps and field assembly 19 h Install the Oring on the frame field and brush hold h Attach the terminals of the insulated brush leads to er group A so that it is against the shoulder on the the conductors in the frame and field assembly with field frame that will abut the CE frame when the insulated brush screws 29 installed This is the normal installed position forTighten the Oring c The insulated brush screws to 15 Nm 13Ibin c Carefully roll the Oring out of its normal installed position up onto the major OD of the field frameStarter Assembly Allow the Oring to remain in this position until theFigures 4 and 15 CE frame is partially the gear reduction and drive group B with the 6 CE frame 14pinion gear end down and proceed as follows a Align the marks on the CE frame and frame andImportant field assembly 19 Figure 5 made prior to disasIf the armature bearings 8 and 9 are being replaced install semblythem on the armature 13 as specified in REPAIR PROCE h Start the CE frame onto the frame and field assemDURES step 1 before proceeding with assembly bly leaving a gap just slightly larger than the thickInstall or Connect ness of the Oring 201 Solenoid assembly 1 7 Brush plate screw 42 a Pivot the plunger of the solenoid assembly into a Use a scribe or similar tool to align the tapped holes engagement with the shift lever in the gear reduction in the brush holder assembly 3 Figure 5 with the and drive group B screw holes in the CE frame 14 h Position the solenoid assembly mounting flange and Tighten install the solenoid mounting screws 25 h Brush plate screws to 28 Nm 25 lbinTighten 8 Thru bolts 41 c Solenoid screws to 28 Nm 25Ibin a Install the thru bolts and tighten them by hand but do2 Frame seal 33 not close the gap between the CE frame and the frame and field assembly where the Oring 20 goes3 The armature assembly 13 with bearings 8 and 9 into the gear reduction and drive group B h Roll the Oring 20 back down into its installed position between the CE frame and the frame and a Make sure the gear teeth are aligned then seat the field assembly bearing 8 on the armature shaft fully into the hous ing recess c Align the timing ribs on the edge of the CE frame 14 with the timing spots on the frame and field4 Frame field and brush holder group A assembly A to assure proper brush alignment a Place the dowel pin 28 in the hole in the armature Refer to Figure 15 Marks are located in 2 places on support bracket of the gear reduction and drive the motor but will only match one way group B Tighten h Position the frame field and brush holder group over d Thru bolts 41 to 85 Nm 75 lbin the armature assembly 13 align the hole for the dowel pin 28 and the marks made prior to disas 9 The motor lead on the frame and field assembly 19 sembly and seat in the gear reduction and drive Figure 5 group B a Remove the nut from the terminal on the solenoid c Twist the brush springs 7 Figure 5 away from the install the motor lead terminal and reinstall the nut brushes 4 and 5 Figure 5 slide the brushes in to Tighten contact the commutator on the armature 13 and release the brush springs to contact the ends of h The nut on the terminal of the solenoid assembly to the brushes 11 Nm 100 lbinS Oring 20 Engines Generators 76 STARTER MOTORSTARTER INSTALLATION CE FRAMETesting After Repair or OverhaulAfter repair or overhaul the starter can be tested as specified in the Starter NoLoad Test found in the sectionAfter repair overhaul testing or replacement of the it using the following torques when making the elec TIMINGtrical connections to the starter MARKS A CAUTION Make sure the negative banery cable is disconnected at the banery when making the elec trical connections to the starter Otherwise injury may result If a tool is shorted at the solenoid bat tery terminal the tool will heat enough to cause a skin burnTighten a Solenoid battery B terminal nut to 18 Nm 13 lbft b Solenoid switch S terminal nut to 18 Nm 16Ibin FIGURE 15 ALIGNING TIMING MARKSSTARTER Volt models have these NoLoad Test Specifications AMPS RPM VOLTS Minimum Maximum Minimum Maximum 10 125 190 3000 5600A1l24 Volt models have these NoLoad Test Specifications AMPS RPM VOLTS Minimum Maximum Minimum Maximum 20 75 90 3600 5400Starter Solenoid current consumption PULL IN WINDING HOLD IN WINDING RATED VOLTAGE AMPS VOLTS OHMS AMPS VOLTS OHMS 12 5259 10 017 019 12 14 10 076 081 24 100 125 20 016 020 12 14 20 115 165 Engines Generators 77 ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off the water temperature gauge will continue to register the last This control panel is equipped with a temperature reading indicated by the gauge before electrical KEY switch and RPM gauge with an ELAPSED TIME power was turned off The oil pressure gauge will fall to zero meter which measures the engines running time in hours and when the key switch is turned off The temperature gauge in 1110 hours The panel also includes a WATER TEMPER will once again register the engines true temperature when ATURE gauge which indicates water temperature in degrees electrical power is restored to the gauge Fahrenheit an OlL PRESSURE gauge which measures the engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is running The buzzer will sound when the ignition key is turned on and should silence when the engine has started and the engines oil pressure rises above 15 psi 11 kglcm 2 OIL PRESSURE GAUGE THIS GAUGE IS GRADU ATED IN POUNDS PER SQUARE INCH PSI AND IS WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem TEMPERATURE IS 170 190 F77 88CRPM GAUGE REGISTERS REVOLUTIONSPER MINUTE OF THEENGINE AND CAN BERECALIBRATED FORACCURACY FROM THEREAR OF THE ELAPSED KEY SWITCH PROVIDESTIME AND SHOULD BE POWER ONLY TO THEUSED AS A GUIDE FOR INSTRUMENT PANELTHE MAINTENANCE DC VOLTMETER INDICATES THE AMOUNT THE BATTERY IS BEING CHARGED SHOULD SHOW 13V TO 14VPREHEAT BUTTON WHEN PRESSED ENERGIZES THEALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL AUTOMATIC ALARM SYSTEMSOLENOID ON THE INJECTION PUMP AND THE ENGINESAIR INTAKE HEATER IT BYPASSES THE ENGINES OIL COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEENPRESSURE ALARM SWITCH IN ADDITION THIS BUTTON SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES THE START BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CONTINUOUS SIGNALSTART BUTTON WHEN PRESSED ENERGIZES THE OIL PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH ISSTARTERS SOLENOID WHICH CRANKS THE ENGINETHIS BUTTON WILL NOT OPERATE ELECTRICALLY I LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH MONITORS THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSUREUNLESS THE PREHEAT BUTTON IS PRESSED AND HELD FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUNDAT THE SAME TIME ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL Engines Generators 78 CAPTAIN CONTROL on PRESSURE or high COOLANT lEMPERATURE The RPM gauge is illuminated when the KEY switch is turned onThis control panel is equipped with a and remains illuminated while the engine is in operationKEY switch an RPM gauge PREHEAT and START buttons an INSTRUMENT lEST button and three indicatorlamps one for ALlERNATOR DISCHARGE one for lowOn PRESSURE and one for high ENGINE It also includes an alarm buzzer for low ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE FALLS BELOW 5 10 psi 04 07 kgem IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAl THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TORPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAlPER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY FROM SOUNDING IS NORMAl ONCE THE ENGINE STARTS AND THE ENGINES OILTHE REAR OF THE PANEl PRESSURE REACHES 15 psi 11 kgem THE ALARM WILL SILENCE TEST BUTTON WHEN PRESSED TESTS THE ALTERNATOR THE OIL PRESSURE AND THE COOLANT TEMPERA TURE CONTROL CIR CUITS WHEN PRESSED THE AlTERNATOR THE OIL PRESSURE AND THE WATER TEMPERA TURE INDICATOR LIGHTS ILLUMINATE IN ADDITION TO SOUND ING THE ALARM BUZZER KEY SWITCH PROVIDES POWER ONLY TO THE INSTRUMENT PANEL CLUSTER WATER TEMPERATURE ALARM LIGHT START BUTTON WHEN PRESSED ENERGIZES THE STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUTTON WHEN PRESSED ENERGIZES THE BUTTON WILL NOT OPERATE ELECTRICAlLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMP AND THE ENGINES TIME AIR INTAKE HEATER AND BYPASSES THE ENGINES OIL PRESSURE ALARM SWITCH IN ADDITION THIS BUTTON ENERGIZES THE START BUTTON Engnes Generators 79 CONTROL PANEL Tachometer InaccurateThe used in propulsion engine instru a With a handheld tach on the front of the crankshaftment panels contains two separate electrical circuits with a pulley retaining nut or with a strobetype tach read thecommon ground One circuit operates the hourmeter and the front crankshaft pulley rpm at idleother the tachometer The hourmeter circuit operates on 12 h Adjust the tachometer with a small Phillips type screwvolts alternator charging voltage supplied to the terminal driver through the calibration access hole in the rear ofon the back of the instrument the tachometer Zero the tach and bring it to the rpmThe tachometer circuit operates on AC voltage 68 volts fed indicated by the strobe or hand tach Verify the rpm atfrom one of the diodes in the alternator and supplied to the idle and at high speed 30003600 rpm Adjust the tachtachometer input terminal while the engine is running and as neededthe alternator producing battery charging voltage 130148volts DC NOTE Current model tachometers use a coarse adjustment dial to set the tachometer to the crankshaft pulley rpms TheThe following are procedures to follow when calibrating screw is then used for fine tuninga fault in either of the two circuits in a for the proper DC voltage between and ADJUSTMENT1 Voltage present meter is defective repair or replace2 Voltage not present trace and electrical con nections for fault Jump 12 volts DC to meter TERMINAL terminal to verify the operation TjCHltlMETER Inoperative CURRENT TACHOMETER AC VOLTAGECheck for the proper AC voltage between tachometer inputterminal and terminal with the engine running1 Voltage present attempt adjusting meter through calibra tion access hole No results repair or replace meter2 AC voltage not present check for proper alternator DC output voltage3 Check for AC voltage at tach terminal on alternator to ground4 Check electrical connections from tachometer input ter rpinal to alternator Sticking1 Check for proper AC voltage between tach inp terminal EARLY MODEL TACHOMETER and terminal GROUND TERMINAL2 Check for good ground connection between meter ter minal and alternator3 Check that alternator is well grounded to engine block at alternator pivot bolt GROUND TERMINAL GROUNDl TERMINAL LIGHT h TACHOMETER INPUT AC VOLTAGE TERMINAL EARLY MODEL TACHOMETER Engines Generators 80 DC ELECTRICAL SYSTEM12 VOLT DC CONTROL CIRCUIT AIR INTAKE HEATERThe engine has a 12 volt DC electrical control circuit that is The air heater consists of a small heating coil located justshown on the wiring diagrams that follow Refer to these dia inboard of the air intake silencer housing The coil heats thegrams when or when servicing the DC elec engine intake air It is wired through the preheat solenoidtrical system When PREHEAT is pressed at the control panel this sole noid will click on and the heating coil will begin to get hot A CAUTION To avoid damage to the battery charging A CAUTION 00 not keep the air heater on for more circuit never shut off the engine battery switch while than 30 seconds the engine is running Shut off the engine battery switch however to avoid electrical shorts when working on the No maintenance is required for the air heater engines electrical minimum recommended capacity of the battery used inthe engines 12 volt DC control circuit is 600 900 ColdCranking Amps CCABattery CareReview the manufacturers and then establish a systematic maintenance schedule for your batteries and house batterieso Monitor your voltmeter for proper charging during engine operationo Check the electrolyte level and specific gravity with a hydrometero Use only distilled water to bring electrolytes to a proper level TO WIRINGo Make certain that battery cable connections are clean and HARNESS tight to the battery posts and to your engine AIR INTAKEo Keep your batteries clean and free of corrosion SILENCER HOUSING AIR INTAKE HEATER A WARNING Sulfuric acid in lead batteries can cause severe burns on skin and damage clothing Wear protective gear Engines Generators 81 charging system consists of a DC belt driven alternatorwith a voltage regulator an engine DC wiring harness a A WARNING When testing with a DC circuit breaker and a battery with connecting DC and AC circuits are often mixed together in marinecables Because of the use of integrated circuits ICs the applications Always disconnect a shore power cordelectronic voltage regulator is very compact and is mounted isolate DC and AC converters and shut down the or on the back of the alternator before performing DC testing No AC tests should be made without a proper knowledge of AC circuits14 GREY14 BLUE 1 Start the engine 14 BROWN 10 Tachometer 2 After the engine has run for a few minutes measure the14 PINK starting battery voltage at the battery terminals using a multimeter set on DC volts 51 AMP 110 RED a1f the voltage is increasing toward 14 volts the 11 OUTPUT tor is working omit Steps 3 through 8 and go directlyENGINE to Starter Motor to Checking the Service Battery on the next page h1f the voltage remains around 12 volts a problem exists with either the alternator or the charging circuit continue with Steps 3 through 8 mID o 14 BROWNI 14 PURPLEft MULTIMETER COM to Fuel Solenoid Fuel Lift Pump 51 AMP ALTERNATOR TESTING THE STARTING ENGINE RUNNING A WARNING A failed alternator can become very hot Do not touch until the alternator has cooled down GROUND 3 Tum off the engine Inspect all wiring and connectionsUse this section to determine if a problemexists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine that the alternator or voltage regulator is faulty connections are tight and cleanhave a qualified technician check itThe alternator charging circuit charges the starting battery A CAUTION To avoid damage to the batteryand the service battery An isolator with a diode a solenoid charging circuit never shut off the engine batteryor a battery selector switch is usually mounted in the circuit switch when the engine is runningto iselate the batteries so the starting battery is not with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging battery but not the service battery the problem is in ensure that it is on the correct settingthe service batterys charging circuit and not with the alterna 5 Tum on the ignition switch but do not start the enginetor 6 Check the battery voltage If the battery is in good condiTesting the Alternator tion the reading should be 12 to 13 volts A CAUTION Before starting the engine make certain that everyone is clear of moving parts Keep away from sheaves and belts during test procedures Engines Generators 82 ALTERNATOR If 12 volts is not present at the EXC terminal trace the o COM MULTIMETER wiring and look for breaks and poor connections Jump the 12 V to the Exc terminal from a known 12V source and operate the alternator If the voltage output is 1314 volts the alternator is ok Trace the cause for 12 volts not present at the Exc terminal Checking the Service Battery Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery TESTING THE charging circuit Troubleshoot the service battery charging ALTERNATOR VOLTAGE IGNITION ON ENGINE OFF circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself GROUND MULTIMETER7 Now check the voltage between the alternator output ter minal B and ground If the circuit is good the voltage at the alternator will be the sarne as the battery or if an isola tor is in the circuit the alternator voltage will be zero If neither of the above is true a problem exists in the circuit between the alternator and the battery Check all the con nections look for an opening in the charging circuit SERVICE BATTERY TESTING THE SERVICE BATTERY ENGINE RUNNING TESTING THE STARTING A CAUTION To avoid damaging the altemator diodes ENGINE RUNNING ENGINE do not use a high voltage tester ie a megger when lCI GROUND perfonning tests on the altemator charging circuit8 Start the engine again Check the voltage between the alternator output and ground ALTERNATOR INSPECTION The voltage reading for a properly operating alternator When rebuilding the engine the alternator should be cleaned should be between 135 and 145 volts If your alternator and inspected The housing can be wiped off with a solvent is over or undercharging have it repaired at a reliable and the alternator terminal studs should be cleaned with a service facility wire brush Make certain the studs are tight and clean the wiring connections that connect to the wiring harness NOTE Before removing the alternator for repair use a voltmeter to ensure that 12 volts DC excitation is present Turn the rotor pulley by hand It should tum smoothly at the EXC terminal if the previous test showed only bat Depending on when the alternator was last serviced the tery voltage at the B output terminaL brushes may need replacing If the alternator is at all suspect send it to a service shop for testing and overhaul 83 DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING output and high output alternators are available asoptional equipment on most WESTERBEKE engines can be installed during factory assembly or asaddon equipment at anytimeDual alternators can be configured to charge two banks ofbatteries at the same time or using a battery selector switchcharge each set of batteries an optional dual alternator has already been factory follow the WESTERBEKE wiring diagram and theengine installation instructionsIf the new dual alternator is being added to an existing intheboat engine carefully follow the alternator below1 Disconnect the alternators negative cable from the battery2 Remove the alternator and disconnect or tape off the output positive cable Do not reuse3 Install the new alternator4 Attach a new heavy gauge output cables from the alternators output terminal s Using the cable sizes indicated DUAL OUTPUT ALTERNATOR CHARGING ONE BATTERY5 Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable6 Mount the regulator to a flat surface in a cool dry location a Connect the black wire to the ground terminal on the alternator A CAUTION Do not connect any power source TO without first grounding the regulator h Plug the 2pin connector into the alternator make certain it is firmly seated c The red battery sense wire should be connected to the batteries positive post or the positive cable d The brown wire keyed ignition is the key circuit which actuates the regulator this wire must connect BATTERY SENSE TO BATTERY POSITIVE POST to a switched 12 volt source Refer to the WESTERBEKE WIRING DIAGRAM for the proper connection DUAL OUTPUT ALTERNATOR CHARGING TWO BATTERIES Engines Generators 84 DUAL OUTPUT Alternator TestingNOTE Before make certain that the drive The regulator is functioning properly and the batteriesbelts are tight and the batteries are in good condition are in good Testing 1 Test the voltage at the alternator plug with the engine offkey on The voltage at the alternator tenninal F andThe red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the regulatormust always read battery voltage If battery voltage is not should read the samepresent trace the wire for a bad connection 2 Hold a screw driver close 12 to the alternator pulleyThe orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field Ifvolts approximately with the key on If the readings are not the problem may be the brushes worn or the rotorincorrect trace the wire for a bad connection open circuitThe blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output tenninals shouldvoltage will vary depending on the battery charge or ctual indicate 142 volts no load A reading of 126 wouldloadrpm The readings can vary from 4 to 12 volts WIth the indicate the alternator is not perfonning properlykey on 0 volts with the key off Apply a load such as an electric bilge pump the voltageKEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or lessKEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER VOLTAGE Ignition Off Ignition On Engine Running I Brown ovolts 2 12 volts 142 volts When the engine is first started it takes a few moments A Red 126 volts 12 volts 142 volts for the alternator to kick in and take the load fa S Orange ovolts ovolts 6 8 volts noticeable change in the sound of the engine F Blue ovolts 10 11 volts 4 12 volts A slight whine from the alternator when the load is All Output 126 volts 12 volts 142 volts normal When the alternator is producing high amperage it will become very hot When replacing the alternator drive belts always purchase and replace dual belts in matched pairs Engines Generators 85 gOA FOUR PROPULSION ENGINE WIRING DIAGRAM 41343 It R D 1148RM U SEE NOTE 2 I 11 I J I 12 VDC WIW NOTE AN ONOFF SWITCH SHOULD BE IN STALLEO BETWEEN THE BATIERY AND PI t p C ALARM BUZZER ADMIRAL PANEL STARTER TO DIS CONNECT THE BAT TERY IN AN EMER GENCY AND WHEN LEAVING THE BOAT A SWITCH WITH A CONTINUOUS RATING OF 300 AMPS AT 12 VDC WILL SERVE THIS FUNCTION THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK I 0 RED THE CIRCUIT PI CAPTAIN PANEL r T UIIP Engines Generators 86 gOA FOUR PROPULSION ENGINE WIRING SCHEMATIC 41343 IZ VlC START1 17 1 r SOL M UARTER PREHEAr r I SOLr711 I I NOTES 1 TIlls product is protected by a manual reset circuit breaker located near the starter Excessive current will cause the breaker to trip and the engine will shut down The builderowner must be sure that the instrument panel FUEL SOLENOII wiring and engine are installed to prevent contact between electrical devices and seawater 2 An OnOff switch should be installed between the battery and the starter to disconnect the battery in an emergency and when leaving the boat A switch with a continuous rating of 300 amps at 12 VDC will serve this function TIlls switch should not be used to make or break the cir cuit 3 The pink wire at plug 2 is unused and should be insu lated Captain Panel only ADMIRALOAT KEY IG TACHOMETER PANEL 4 The gray wire at plug 2 is unused and should be insu lated Admiral Panel only p START o ALARM o LEECE NEVILLE 90 AMP ALT PREHEAT SWITCH 2U2IIPH 48RNlKY CAPTAIN PANEL LAMP TEST SW 114 LT BLU Tl 03 110 RED 51 AMP ALTERNATOR PRESTOLITE 72 AMP ALT STANDARD ALTERNATOR ON THE mBIjj6CICH cr 82B cr 1 4 BRM CTACtUD OPTIONAL ALTERNATORS 135A 1l00 1t0A LESTEK AL TERNATOR AVAILABLE ON THE US a uc IX 718 tL 82ft IX 100Da 10K XI ONLY Engines Generators 87 HURTH HSW INITIAL OPERATIONFor safety reasons the transmission is not filled with trans Set the shifting lever to neutral position N Start the enginemission fluid during shipment and the selector lever is tem and let it run long enough in idle to fill the cooler and hosesporarily attached to the actuating shaft with transmission fluid Shift into gear forward and reverseBefore leaving the WESTERBEKE plant each transmission shifting should be smooth and positive Direct changes fromundergoes a test run with Dextron III ATF transmission fluid forward to reverse are permissible since the multiple discThe residual fluid remaining in the transmission after drain clutch permits changing at high rpm including sudden revers ing acts as a preservative and provides protection against cor ing at high speeds in the event of dangerrosion for at least one year if properly stored After initial operation make a visual inspection of the output coupling oil cooler and hoses and the cable connections to the transmission tlolAIR VENT LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direc tion of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the boat L FLUID FILTER WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without a load such as when the boat is being sailed being towed or anchored in a river as OUTPUT well as operation of the engine with the propeller stopped COUPLING for charging the battery will have no detrimental effects on HSW MODEL 630 the COOLER NOTE When the boat is being sailed engine stopped the gear shift must be in the neutral position The propeller is atThe oil cooler mounted above the transmission provides idle and can cooling for the transmission fluid Raw waterpasses through the tubes of the cooler and discharges over DAILY OPERATIONboard The transmission fluid is cooled as it flows around thetubes and back into the transmission o Check the transmission fluid o Visually check the gear shift linkage and transmission WESTERBEKE RECOMMENDS CARRYING A SPARE OIL COOLER ABOARD RAW WATER CONNECTION o Start the engine in neutral allowing a few minutes at idle to warm the fluid o Shift into gear NOTE Too Iowan idle speed will produce a chattering noise from the transmission gear and damper plate In such cases the idle speed should be increased TRANSMISSION OIL COOLER Operating Temperature The operating temperature of the transmission should FLUID exceed 176F 80C A connection for a temperature probeFill the transmission with Dextron III ATF The fluid level is provided At maximum output of the engine the fluid mayshould be up to the mark on the dipstick After checking the reach 220F 104Clevel press the dipstick into the case and tum it to tightenDuring the first 25 operating hours inspect the bell housingoutput shaft and transmission cooler for leakage The fluid A CAUTION If the transmission fluid temperature isshould be changed after the first 25 hours and every 300 too high stop the engine immediately and check thehours thereafter transmission fluidNEUTRAL SWITCHThese transmissions are equipped with a neutral safetyswitch This is to prevent the engine from starting in gearUnless the transmission selector lever is perfectly aligned inneutral the engine starter will not activate Engines Generators 88 HURTH HSW THE TRANSMISSION FLUID Replacing the Fluid Pour in new Dextron III ATF fluid and check the quantity with the dipstick Transmission fluid quantities will vary with the use of cool ers length of hoses and the angle of the transmission Approximate Quantities HSW450 212 quarts 20 Liters HSW630 32 quarts 30 Liters HSW630V 42 quarts 40 Liters Reinsert the filter assembly into the housing Press it in place ACTUATING and tighten the Allen screw LEVER NOTE Some HSW transmissions use a T handle in place of 16mm 8 SCREW a screw on their filter assemblies After running the engine shut down and recheck the fluid level A WARNING Never pullout the dipstick while the engine is running Hot fluid will splash from the dipstick hole This could cause severe bums ORINGS MAINTENANCE HSW MODEL 450 Transmission maintenance is minimal Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks FILTER ELEMENT and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry cream Element Storage requires special care Follow these proceduresThe Hurth HSW transmission has a filter element located D Drain water from the transmission oil cooler and the dipstick 1bis filter must be replaced whenever with a proper mixture of antifreeze coolantthe fluid is changed NOTE This operation will normally occur when theRemove the filter by loosening the screw on the cover using a engine raw water cooling system is properly winterized6mm Allen wrench D Clean up the transmission and touch up unpainted areasTwist and pull out the filter and remove the element Place use heat resistant paintthe new filter onto the cover and lock it into place by turningit clockwise Check the Orings for damage and replace if D Fill the transmission with Dextn III ATF fluid to the full mark on the Replacement filters can be obtained from yourlocal WESTERBEKE dealer or ZF Hurth dealer D Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before removRemoving the Fluid ing the boat from the water Separate the flanges andPush a suction pump hose down through the pipe hole under spray with lubricantthe filter to the bottom of the housing and suck out the fluid D Inspect the gear shift cable linkage and the oil return line from the cooler and allow the oil Look for corrosion of the end fittings cracks or cuts into drain into a container then reconnect the oil return line the conduit and bending of the actuator rods Lubricate all moving partsWipe down the transmission and properly dispose of the usedfluid NOTE If the transmission is to be storedfor a long time Replacement Filter twelve months or more it should be topped offwith fluid to prevent internal corrosion Reduce the fluid level Hurth Part No 500012 before putting the engine back into service Engines Generators 89 HURTH HSW CONNECTIONS SHAFT COUPLINGSThe transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible connection betweenUpon loosening the retaining screw the actuating lever see the transmission and the propelIer shaft if the engine is can be moved to any position required for the bly mounted in order to compensate for angular elements cable or rod linkage Make certain that the The instalIation of a special propelIer thrust bearing is notactuating lever does not contact the lever hub the minimum required since the propelIer thrust will be absorbed by thedistance between the lever and hub should be 002in05mm transmission bearing provided the value specified underThe control cable or rod should be arranged at a right angle SPECIFICATIONS is not exceeded However the outputto the actuating lever when in the neutral position The neu shaft should be protected from additional loads Special caretral position of the gear shift lever on the control console should be taken to prevent torsional vibration When using ashould coincide with the neutral position of the lever on the universal joint shaft make certain to observe the turers Positions Even with the engine solidly mounted the use of a flexible A PropelIer rotation opposite of engine rotation coupling or DRNESAVER will reduce stress in the gearbox N Neutral position bearings caused by hull distortions especially in wooden B PropelIer rotation same as engine rotation boats or where the distance between the transmission output coupling and stem gland is less than about 800mmNOTE When shifting to A or B positions make sure theshift lever travel is sufficient for the lever to contact its stop NOTE When installing the transmission make certain that N shifting is not impeded by restricted movability of the cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius or other restrictions In order to mount a support for shift control cable connections use the two threaded holes located on the cable bracket mounted on the gear housing Refer to the WESTERBEKE parts list PROPELLER ROTATION ARH N NEUTRAL GEAR SHIFT LEVER B LH B ACTUATING LEVER LEVER HUB 1 O02in ACTUATING rO5mm LEVER TYPICAL STEERING STATIONA greater amount of actuating lever travel is in no waydetrimental and is recommended However if the lever travelis shorter proper clutch engagement might be impeded For additional information contactwhich in turn would mean premature wear excessive heat HURTH MARINE GEARgeneration and clutch plate failure This would be indicated ZF Industriesby slowc1utch engagement or no engagement at all see Marine US CABLES under TRANSMISSION 3131 SW 42nd Fort Lauderdale FL 33312 Tel 954 5814040NOTE Check for proper actuating lever travel at least each Fax 954 5814077season A CAUTION The position of the mechanism behind the actuating lever is to ensure equal actuating lever travel from Neutral position N to Reverse position A and Forward position B If this mechanism is in any way tampered with the transmis sion warranty will be void Engines Generators 90 HURTH HBW 250 NOTE When installing the gearbox make certain that shiftingThe 90A Four engine is also being equipped with the HBW is not impeded by restricted movability of the Bowden cable250 transmission The information below is specific to the or rod linkage by unsuitably positioned guide sheaves tooHBW 250 the TRANSMISSION small a bending radius etc In order to mount a support forSECTION applies to all models shift control cable connections use the two threaded holes located above the shift cover on top of the gear OF GEAR BOX WITH PROPELLER Refer to the WESTERBEKE parts listHBW recommend a flexible connection between the gearbox CONTROL CABLESand the propeller shaft if the engine is flexibly mounted inorder to compensate for angular deflections The installation The gearbox is suitable for single lever remote control Uponof a special propeller thrust bearing is not required since the loosening the retaining screw the actuating lever can bepropeller thrust will be taken by the transmission bearing moved to any position required for the control the value specified under SPECIFICATIONS is not cable or rod linkage Make certain that the shift lever doesexceeded However the output shaft should be protected not contact the actuating lever cover plate the minimum disfrom additional loads Special care should be taken to pre tance between lever and cover should be 05mmvent torsional vibration When using a universal joint shaft The control cable or rod should be arranged at right angle tomake certain to observe the manufacturers instructions the actuating shift lever when in the neutral position TheEven with the engine solidly mounted the use of flexible neutral position of the operating lever on the control reduces stresses in gearbox bearings caused by hull should coincide with the neutral position of this especially in wooden boats or where the distance The shifting travel as measured at the pivot point of the actubetween gearbox output flange and stem gland is less than ating lever between the neutral position and end positions Aabout 800mm and B should be at least 35mm for the outer and 30mm for the inner pivot point A greater amount of shift lever travel is in no way detrimental and is recommended However if the lever travel is shorter proper clutch engagement might be impeded which in tum would mean premature wear excessive heat generation and clutch plate failure This would be indicated by slow clutch engagement or no engagement at all NOTE Checkfor proper lever travel at least each season FORWARD B A REVERSE SHIFT LEVER ATF DRAIN A CAUTION The position of the mechanism behind the actuating lever is to ensure equal actuating lever travel from Neutral position N to Reverse position A and Forward position B If this mechanism is in any way tampered with the transmis sion warranty will be void MAKE CERTAIN THIS LEVER IS TIGHTLY FASTENED TO THE SHAFT Engines Generators 91 HURTH HBW 250 OPERATION OPERATING TEMPERATUREAll HBW marine transmissions are testrun on a test stand The maximum permissible ATF temperature should notwith the engine at the factory prior to delivery For safety exceed 230F 1lOC This temperature can only be reachedreasons the fluid is drained before shipment for a short timeFill the gearbox with Automatic Transmission FluidDEXRON II or DEXTRON ill The fluid level should beup to the index mark on the dipstick To check the fluid leveljust insert the dipstick do not screw it in Screw the dipstick A CAUTION If the transmission fluid temperature is too high stop the engine immediately and check theinto the case after the fluid level is checked and tighten Donot forget the sealing ring under the hexhead of the dipstick transmission fluidCheck for leaks and change the fluid after the first 25 hoursalso make a visual inspection of the coupling oil cooler andhoses and shift cables LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direc tion of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the boat WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without load such as when the boat is being sailed being towed or anchored in a river as well as oper ation of the engine with the transmission in neutral for charging the battery will have no detrimental effects on the transmission FLUID LEVEL DAILY OPERATION o Check the transmission fluid o Visually check the gear shift linkage and transmission TO CHECK TRANSMISSION o Start the engine in neutral allowing a few minutes at FLUIO IN OPERATION idle to warm the fluidFLUID CHANGE o Shift into gearChange the fluid for the first time after about 25 hours ofoperation then every 250 operating hours or at least once a NOTE Too Iowan idle speed will produce a chattering noiseyear or when you change engine oil from the transmission gear and damper plate In such cases theRemoving the fluid idle speed should be increasedPush a suction pump hose down through the dipstick hole to For additional information refer to the following text in thisthe bottom of the housing and suck out the fluid If space Transmission Section SHAFT COUPUNGS use the transmission drain Remove the drain plug AND TRANSMISSION the bottom of the transmission and allow the fluid todrain into a container then reinstall the plug with its sealingwasher Wipe down the transmission and properly dispose of HBW 250 TRANSMISSION used fluid After running the engine shut down andrecheck the fluid level General Hurth Standard Transmission Case hardened helical gears with a servoDrain plug torque 20 25 Mbs operated multiple disc clutch Gear ratio standard 274 1 HBW250 3RNOTE When changing the fluid take care not to lose the Propeller Shaft Right handed standard plug sealing washer The drain plug will leak without Direction of Rotationthis sealing washer Propeller 240 X 12 P2 blade or 220 x 14 P3 blade propeller should allow the engine using standard to reach its full rated rpm 3600 000 A WARNING Never pullout the dipstick while transmission 2741 reduction 100 at full open throttle while under way in forward gear the engine is running Hot fluid will splash from the lubricating Fluid ATF type A or Dextran or III dipstick hole This could cause severe burns Transmission Sump 079 US qts 075 liters approximate Capacity Engines Generators 92 BORG WARNER VELVET DRIVE TRANSMISSION SHIFT LEVER POSITION OIL COOLER The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward F Neutral N and Reverse R shifting positions A detent ball located behind the transmission lever must work freely DIPSTICK to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive REVERSE CLUTCH actuating lever through shift mechanism adjustments An PRESSURE GAUGE CONNECTION improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any FROM COOLER order Shifts should be made at the lowest practical engine CONNECTION speed Start the engine and set the throttle at idle speed allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with trans Neutralmission fluid during shipment and the selector lever is tem Move the gear shift lever to the middle position You shouldporarily attached to the actuating shaft feel the detent This centers the actuating lever on the transBefore leaving the WES1ERBEKE plant each transmission mission With the control in this position hydraulic power isundergoes a test run with Dextron III ATF transmission fluid completely interrupted and the output shaft of the transmisThe residual fluid remaining in the transmission after drain sion does not turning acts as a preservative and provides protection against NOTE Some transmissions are equipped with a neutral for at least one year if properly stored switch Unless the transmission actuating lever is FLUID aligned in neutral the engine starter will not activateCheck the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25 hours of opera Move the gear shift lever to the forward position You shouldtion keep a lookout for any leakage at the bell housing out feel the detent The actuating lever on the transmission is input shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaftchanged after the first 25 hours and approximately every 300 move the boat in a forward hours thereafter andor at winter layup Reverse Move the gear shift lever to the reverse position You should A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in and the correct size cooler is properly installed before the reverse position The output shaft and the propeller should move the boat in a reverse direction astern starting the engine NOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever Engines Generators 93 BORG WARNER VELVET DRIVE TRANSMISSION o Clean off the transmission and properly dispose of the used fluid o Refill the transmission with DEXTRON III ATF The quantity will vary depending on the transmission model and the installation angle Fill through the dipstick hole o Check the dipstick for the proper fluid level o Replace the oil filler cap and dipstick Press the dipstick into place and tum clockwise until fingertight o Run the engine shutdown and recheck the fluid levelFORWARD NEUTRAL TRANSMISSION ACTUATING LEVER POSITIONS REVERSE A WARNING Never pull out the dipstick while the engine is running Hot fluid will splash from the dipstickDAILY OPERATION hole This could cause severe bumso Check the transmission fluido Visually check the gear shift linkage and transmission Oil Capacityo Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis for the fluid to warm sions to the oil level fill mark on the dipstick Many variables NOTE Too low an idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil noise from the transmission gear and dmnper plate In will be required to fill the oil cooler and the cooler lines The such cases the idle speed should be increased angle of installation will make a difference in the quantity of oil required to fill the transmissiono Shift into gear A CAUTION Shifting gears above 1000 rpm can Make certain the rubber seal is screwed tight to the handle cause damage to the engine damper plate Pulling the throttle back to idle when shifting gears will save wear on the transmission and the damper o Visually check for oil leaks at the hydraulic connections Check for wear on the hydraulic lines and replace if worno Lubricate the detent ball and shift cable attaclunentso Inspect the shift linkageo Inspect the transmission bolts retorque if necessary A CAUTION Clutch failure will occur if the transmis OIL DIPSTICK sion shift lever does not fully engage the detent ball Oil Temperature pOSitions A maximum oil temperature of 190F 88C is recom mended Discontinue operation anytime sump oil THE TRANSMISSION FLUID ture exceeds 230F 110CAfter the initial 50 hour change the transmission fluid should PRESSURE GAUGEbe changed at every 300 operating hours thereafter or at winter haulout However the fluid must be changed whenever it An optional mechanical pressure gauge can be installed atbecomes contaminated changes color or smells rancid the control panel to constantly monitor the pressure of the transmission fluid A normal reading at 2000 rpm in forwardo Remove the oil filler cap and dipstick gear should indicate 95 120 Ibin 2 67 84 kgcm 2 and beo Remove the oil cooler return line and allow the oil to constant drain into a containero Reconnect the oil cooler return lineo Use a suction pump to remove the transmission oil through the filler capdipstick hole Engines Generators 94 BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior Service manuals are available from your BORG WARNERhousing clean check the fluid level as part of your regular dealerroutine and change the fluid every 300 operating hours For assistance inspect the transmission and the cooler for leaks BORG WARNERand corrosion Make certain the air vent is clear and when 200 Theodory Rice Blvdchecking the fluid level look for signs of water contamination New Bedford MA 02745fluid will appear as strawberry cream Tel 508 BORG WARNER is aware of the shock loads that can be placed on its gears as the result of mechanical propeller operStorage requires special care Follow these procedures ation or fully reversing of the propeller blades while shiftingo Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was NOTE This operation will usually occur when the engine caused by a shock load any warranty claim will be denied raw water cooling system is properly winterizedo Clean up the transmission and touchup unpainted areas A CAUTION Systemrelated noises or vibrations can use heat resistant paint occur at low engine speeds which can cause gear rattleo Fill the transmission with Dextron 1II ATF fluid to the resulting in damage to the engine andor transmission full mark on the dipstick BORG WARNER is not responsible for total systemo Loosen attaching hardware from the transmission related torsional vibration of this type output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges If any problems occur with the transmission see and spray with lubricant TRANSMISSION in this manualo Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE lfthe transmission is to be storedfor a long time twelve months or more it should be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service Engines Generators 95 TRANSMISSION CABLES OIL COOLERSThe majority of transmission difficulties arise as a result of The continued flow of raw water through the cooler will inimproper clutch adjustments manual transmissions or prob time erode the inside of the cooler causing cross leaks tolems with control cables hydraulic transmissions rather than occur These internal cooler leaks will cause one of the folfrom problems with the transmission itself lowing two problemsHURTH clutches in particular are very sensitive to improper 1 Transmission fluid will leak into the flow of raw watercable adjustments and be discharged overboard through the engine exhaustIf you experience operating problems with the transmission A loss of transmission fluid will cause the transmission toshut the engine down First check the level failthen have a helper move the cockpit shift lever through the 2 The raw water will leak into the transmission fluid causfull range from neutral to full forward back to neutral ing an increase in transmission fluid This full reverse and back to neutral while you observe fluid will appear as strawberry cream The actuating lever on the transmission If the remote is stiff will eventually failto operate break the cable loose at the transmission and try Either case requires an immediate responseagain If it is still stiff check the cable for kinks or excessively tight bends and check any linkage for binding A new 1 Install a new oil coolercable and perhaps a new linkage mechanism may be needed 2 Refill the transmission with DEXTRON III ATFWhile the cable is loose shift the transmission in and out of If water has contaminated the fluid the transmission fluidgear using the lever on the side of the transmission to make needs to be cleaned out and replaced with fresh fluid It willsure theres no binding inside the case take several fluid changes to get rid of the the transmission passes these tests crank the engine and Check your dipstick each time until it appears as pure transhave a helper put it in forward and reverse while you observe mission fluid Change the transmission filter and clean outthe propeller shaft if the shaft isnt turning the transmission the fluid lines that connect to the coolerneeds professional attention If it does tum but theres no If the transmission fails to shift properly it will most likelythrust check to see you still have a propeller on the end of need the attention of a qualified transmission service facilitythe shaft or if you have a folding or feathering propeller that A transmission cooler may last ten years or more but init isnt stuck in the no pitch position some circumstances depending on operating hours tropical waters maintenance etc it might only last half that time WESTERBEKE recommends having a spare cooler aboard Problem Probable Cause Transmission gears cannot be shifted 1 Shifting lever is loose 1 Tighten damping bolt on shifting lever 2 Shifting cable is broken bent or 2 Check the cable reattach or replace unattached 3 Loss of transmission fluid 3 Check for leaks at transmission seal and output shaft Tighten gear case bolts Check all oil hoses for leaks Oil cooler leak see OIL COOLER 4 Water in transmission fluid 4 Replace oil cooler see OIL COOLEFf High water in engine compartment remedy cause Shifting pressure too low see item 2 Shifting pressure too low 1 Improper fluid 1 Replace with DEXTRaN 11 ATF 2 Filter is dirty if applicable 2 Replace filter 3 Water in transmission fluid 3 Replace oil cooler see OIL COOLER 4 Transmission fluid too low 4 Add fluid 5 Air vent is clogged 5 Remove paintdirt from vent Transmission noise becomes louder 1 Fluid level too low 1 Top up with fluid to marking on dipstick so that pump sucks in air 2 Damage starting on flexible coupling due 2 Replace flexible coupling Check alignment between engine to wear or fatigue possibly due to misalign and transmission ment between engine and transmission 3 Beginning damage of bearings in trans 3 Transmission needs professional attention mission due to torsional vibrations running without fluid overload wrong alignment of transmission or excessive engine output contmued Engines Generators 96 TRANSMISSION Problem Probable Cause Chattering transmission noise 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with a chattering noise in the transmission a higher stiffness factor might be sufficient Transmission shifts into gear but 1 Output coupling is not turning 1 Transmission needs professional attention fails to propel the boat 2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping Output coupling is turning on the propeller shaft Tighten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and 3 Inspect the propeller it may be missing or damaged propeller shaft are turning A folding propeller may be jammed Variable pitch propeller may be in no pitch positionNOTE If you suspect a major problem in your contact your WESTERBEKE dealer or anauthorized marine transmission facility Engines Generators 97 STANDARD HARDWAREBOLT HEAD MARKINGSBolt strength classes are embossed on the head of each bolt Metric bolt class numbers identity bolts by their strength with 109 theCustomary inch bolts are identifed by markings two to grade eight The marks correspond to two marks less than the actual gradeLe a grade seven bolt will display five embossed marksNOTES 1 Use the torque values listed below when specific torque values are not available 2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used 3 Reduce torques by 30 or more when threading capscrews into aluminum STANDARD BOLT NUT TORQUE SPECIFICATIONS METRIC BOLT NUT TORQUE SPECIFICATIONS SAE Grade 5 SAE Grade 67 SAE GradeS Capsrew Body Size Torque Torque Torque Bolt Grade 46 Grade4S Grade 88 9S Grade 109 Inches Thread ALbNm ALbNm ALbNm Dia Wrench Size ALbNm FtLb Nm FtLbNm FtLb Nm 14 20 8 11 10 14 12 16 28 10 14 14 19 M3 55mm 03 05 05 07 1 13 15 2 M4 7mm 08 11 1 15 2 3 3 45 5116 18 17 23 19 26 24 33 M5 8mm 15 25 2 3 45 6 65 9 24 1926 27 37 3816 31 42 34 46 44 60 M8 10mm 3 4 455 75 10 11 15 24 35 47 49 66 M9 13mm 7 95 10 13 18 25 35 26 716 14 4966 55 75 7095 Ml0 16mm 14 19 18 25 37 50 55 75 20 55 75 78 106 12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 63 85 97 130 20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205 M16 24mm 59 80 85 115 159 215 232 315 916 12 110149 120 163 155 210 18 120 163 170 231 M18 27mm 81 110 118 160 225 305 321 435 51811 150 203 167 226 210 285 M20 30mm 118 160 166 225 321 435 457 620 18 170 231 240 325 M22 33mm 159 215 225 305 435 590 620 840 34 10 270 366 280 380 375 508 16 295 400 420 569 M24 36mm 203 275 288 390 553 750 789 1070 M27 41 mm 295 400 417 565 811 1100 1154 1565 78 9 395 536 440 597 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130 14 435 590 675 915 1 8 590 800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 14 660 895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720NOTE Formula to convert FtLbs to Nm Newton Meters multiply FtLb x 1356 SEALANTS based PERMATEX 2 and its HIGH TACK equivalent are excellent all Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolantpurpose sealers They are effective in just about any joint in contact with passages Do not use tape raw water oil or fuelA light coating of Ollar LIQUID TEFLON can be used on rubber gaskets BOLTS Orings Lightly oil head bolts and other fasteners as you assemble them Bolts andlOCTITE hydraulic red sealant shou Id be used on oil adapter hoses and the oil plugs that penetrate the water jacket should be sealed with PERMATEX 2 orfilter assembly HIGH TACKCoat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When assembling the flywheel coat the bolt threads with lOCTITE blueWhen installing gaskets that seal around water coolant passages coat both Antiseize compounds and thread locking adhesives such as lOCTITE protectsides with WHITE SILICONE grease threaded components yet allows them to came apart when necessary lOCTITE offers levels of locking according to the jobHighcopper ADHESIVE SPRAYS are useful for holding gaskets in position during assembly LITHIUM based grease is waterproof ideal for water pump bearings and stuff ing gasket sealers such as HYlOMAR work well in applications requiring nonhardening properties HYlOMAR is particlariy effective on Heavily oil all sliding and reciprocating components when assembling Alwayscopper cylinderhead gaskets as it resists fuel oil and water use clean engine oil Engines Generators 98 gOA FOUR TORQUE SPECIFICATIONS Component ft Ib kgm Component ft Ib kgm Alternator bracket 27 38 38 53 Injection pipe flare nut 18 22 25 30 Back plate 27 38 38 53 Injector to head 12 17 16 24 Camshaft thrust plate 14 19 19 26 Intake manifold 14 19 19 26 Connecting rod cap 59 65 82 90 Main bearing cap 72 77 100 107 Coolant temperature sender 18 29 25 40 Oil filter 8094 1113 Coolant temperature switch 18 29 25 40 or tighten firmly by hand Crankshaft pulley nut 253 289 350 400 Oil pan bolts 14 19 19 26 Cylinder head bolts 00 NOT TORQUE Oil pan drain plug 362 434 50 60 Cylinder head cover 14 25 02 035 Oil pump pipe 58 80 08 11 Damper 16 24 22 34 Oil pressure sender 9 13 12 18 Engine mounts 23 34 32 47 Oil pressure switch 9 13 12 18 Exhaust manifold 17 20 23 27 Rear oil seal cap 14 19 19 26 Flywheel 130 145 18 20 Rocker arm assembly 14 19 19 26 Coolant pump bolts 9 13 12 18 Thermostat housing 58 80 08 11 Idler gear 14 19 19 26 TIming gear case 12 17 16 24 Injection pump drive gear 29 52 40 90 Timing gear cover 14 19 19 26Conversion factor to get Nm FHb x 1356 Nm Engines Generators 99 32 KW BEDA GENERATOR SPECIFICATIONS SPECIFICATIONS FUEL SYSTEMEngine Type Diesel fourcycle fourcylinder fresh General Open flow self priming 1 bleed point watercooled Vertical inline overhead valve mechanism 46 hp at 1800 rpm maximum Fuel No2 diesel oil cetane rating of 45 or Naturally aspirated Fuel Injection Pump ZEXEL Model PE InLineGovernor Electronic Governing Fuel Injection Timing 12 BTDCCombustion Chamber Swirl type Nozzle Orifice typeBore Stroke 394 x 433 inches 1001 x 1100 mm Fuel Riter Full Row Replaceable on enginePiston Displacement 2108 cubic inches 35 liters Air cleaner Metal screen type Order 1342 Air Row 110 cfm 31 cmmDirection of Rotation Clockwise when viewed from the front engine Torque 166 Ibft 23 kgmat 1800 rpm COOLING Ratio 181 General Fresh watercooled block controlled with heat Height 300 inches 7620mm Width 220 inches 5588 mm Operating Temperature 170 190 F n 88 C Length 446 inches 1133 mm Fresh Water Pump Centrifugal type metal impeller 10381bs 4718 kgs Raw Water Pump Positive displacement rubber impeller belt driven TUNEUP SPECIFICATIONS Raw Water Flow 150 gpm 567lpm Pressure 427 psi 30 kgcm at 200 rpm at 1800 rpm before discharging into exhaust elbowLimit of difference between cylinders 472 psi 30 kgcm System Capacity 85 qts 804 liters fresh waterValve Timing Intake Opens 19 BlDC Intake Closes 47 ABDC LUBRICATION SYSTEM Exhaust Opens 52 BBDC General Pressu re fed system Exhaust Closes 14 ATDC Oil Filter Full flow paper element spinon typeEngine Timing Static timed drop valve method 0180 005 inches BlDC Sump Capacity 63 US qts 60 liters not including filter plus filtercooler Pressure 2450 35 psi 1 50 kgcm Operating Oil Pressure 30 35 psi 21 25 kgcmValve Seat Angle Intake 45 engine hot Exhaust 30 Oil Grade API Specification of CF or CG4Valve Clearance Intake 0012 inches 03 mm SAE 30 10W30 15W40engine cold Exhaust 0014 inches 035 mmEngine Speed 1800 RPM 60 Hertz 1500 RPM 50 Hertz continued Engines Generators 100 32 KW BEDA GENERATOR SPECIFICATIONS ELECTRICAL SYSTEM AC GENERATOR 3 PhaseStarting Battery 12Volt negative ground General 3 Phase Brushless six pole revolving field 200 KW 60 Hertz Sealed lubricated single bearingBattery Capacity 600 900 Cold Cranking Amps CCA 160 KW 50 Hertz design 12 Lead reconnectable for low voltageDC Charging Altemator 51 Amp rated beltdriven WYE and for Delta Solid State voltage regula tor with protection 12Volt 3 KW Voltage 3 Phase Low voltage WYE 208 voltsStarting Aid Glow plugs sheathed type 60 Hertz High voltage WYE 480 volts 12 ohm DELTA 240 voltsDC NoLoad Cu rrent 2 of rated Amps Voltage 3 Phase High voltage WYE 380 volts 50 Hertz DELTA 230 voltsDC Cranking Current 250 300 Amps engine cold Amperage 3 Phase Low voltage WYE 1110 Amps 60 Hertz High voltage WYE 481 Amps AC GENERATOR SINGLE PHASE 8 power factor DELTA 962 AmpsGeneral Single Phase Brushless fourpole revolving field Sealed Amperage 3 Phase High voltage WYE 475 Amps lubricated single bearing design 50 Hertz 820 Amps DELTA Reconnectable single phase for 1201240 volts 8 power factor with solid state voltage Single Phase 120 or 1201240 Volts 60 Hertz GENERATOR COOLING 230 Volts 50 Hertz Air Requirements 10 power factor 500 cfm 150 cmmVoltage regulation 2 no load to full load 60 Hertz at 1800 RPMFrequency regulation 3 Hertz no load to full load Note Increase air supply 15 for 50 Hertz operation 1500 rpmRating Volts AC 32 KW 60 Hertz 1800 rpm Engine Combustion Air 110 cfm 31 cmm 120 Volts 266 Amps Requirements 1201240 Volts 2661133 Amps 60 Hertz at 1800 RPM 25 KW 50 Hertz 1500 rpm 230 Volts 1087 Amps Engines Generators 101 32 KW BEDA GENERATOR PARTS IDENTIFICATION AIR INTAKE SILENCER ACTUATOR EXHAUST TEMPERATURE SWITCH20 AMP DC CIRCUIT BREAKER AC CONNECTIONS OUTLET SlOE OIL FILL GENERATOR DECAL OIL PRESSURE SENDER FRONT LEFT SIDE REAR ZINC LUBE OIL FILL CAP COOLANT FILL CAP EMERGENCY STOP ENGINE IDENTIFICATION NAMEPLATE 70 EXHAUST ELBOW DC CHARGING ALTERNATOR LED LIGHTS HEAT XHANItHI RAW WATER PUMP LUBE OIL DRAIN HOSE BLOCK DRAIN PLUG STARTER WITH SOLENOID REAR RIGHT SIDE FRONT Engines Generators 102 GENERATOR INFORMATIONUSE OF ELECTRIC MOTORS Generator Frequency AdjustmentThe power required to start an electric motor is considerably Frequency is a direct result of speed asmore than is required to keep it running after it is started indicated by the followingSome motors require much more current to start them than When the generator is run at 1800 rpm the AC voltageothers Splitphase AC motors require more current to start output frequency is 60 Hertzunder similar circumstances than other types They are When the generator is run at 1500 rpm the AC used on easystarting loads such as washing output frequency is 50 Hertzmachines or where loads are applied after the motor isstarted such as small power tools Because they require 5 to Therefore to change the generators frequency the genera7 times as much current to start as to run their use should be tors drive engines speed must be changed Along with aavoided whenever possible if the electric motor is to be dri reconfiguring of the AC output connections at the generatorven by a small generator Capacitor and a regulator board voltage output adjustment must also bemotors require from 2 to 4 times as much current to start as made See ELECTRONIC GOVERNOR in this manualto run The current required to start any motor varies with theload connected to it An electric motor connected to an air Generator for example will require more current than a Maintaining reasonable cleanliness is importantmotor to which no lad is connected Connections of terminal boards and rectifiers may becomeIn general the current required to start 115Volt motors con corroded and insulation surfaces may start conducting ifnected to medium starting loads will be approximately as salts dust engine exhaust carbon etc are allowed tofollows build up Clogged ventilation openings may cause exces MOTOR SIZE AMPS FOR AMPS FOR sive heating and reduced life of windings HP RUNNING STARTING For unusually severe conditions thin rustinhibiting AMPERES AMPERES 16 32 64 to 224 petroleumbase coatings should be sprayed or brushed 14 46 92 to 322 over all surfaces to reduce rusting and corrosion 13 52 104 to 728 In addition to periodic cleaning the generator should be 12 72 144 to 292 inspected for tightness of all connections evidence of 34 102 204 to 408 overheated terminals and loose or damaged wires 1 13 26 to 52 The drive discs on single bearing generators should be checked periodically if possible for tightness of screwsNOTE In the above table the maximum Amps for Starting is and for any evidence of incipient cracking failure Discsmore for some small motors than for larger ones The reason should not be allowed to become rusty because rust mayfor this is that the hardest starting types splitphase are not accelerate cracking The bolts which fasten the drive discmade in larger sizes to the generator shaft must be hardened steel SAE gradeBecause the heavy surge of current needed for starting 8 identified by 6 radial marks one at each of the 6 cormotors is required for only an instant the generator will not ners of the headbe damaged if it can bring the motor up to speed in a few The rear armature bearing is lubricated and sealed noseconds If difficulty is experienced in starting motors turn maintenance is required However if the bearing becomesoff all other electrical loads and if possible reduce the load noisy or roughsounding have it replacedon the electric motor Examine bearing at periodic intervals No side movement of shaft should be detected when force is applied if sideRequired Operating Speed motion is detectable bearings are wearing or wear onRun the generator first with no load applied then at half the shaft of bearing socket outside bearing has capacity and finally loaded to its full capacity as Repair must be made quickly or major components willindicted on the generators data plate The output voltage rub and cause major damage to be checked periodically to ensure proper operation ofthe generating plant and the appliances it supplies If an AC Carbon Monoxide or ampmeter is not installed to monitor voltage and WESTERBEKE recommends mounting a carbonload check it with a portable meter and ampprobe monoxide detector in the vessels living quarters CarbonNOTE When the vessel in which the generator is installed monoxide even in small amounts is deadlycontains AC equipment of 120 volts only it is recommended The presence of carbon monoxide indicates an exhaustthat the generators AC terminal block be configured to pro leak from the engine or generator from the exhaustvide one 120 volt AC hot leg for the vessels distribution elbowexhaust hose or that fumes from a nearby vesselpanel This will ensure good motor starting response from the are entering your boatgenerator If carbon monoxide is present ventilate the area with clean air and correct the problem immediately Engines Generators 103 GENERATOR CONTROL PANEL 3 START The START toggle switch is a double pole singleThis manually controlled series ofWESTERBEKE marine throw switch The switch serves two purposes startingdiesel generators is equipped with toggle switches on the the engine and defeating of bypassing the engine oil presengine control panel and optionally at remote panels The sure switch The defeat function turns on the fuel solefollowing instructions and methods of correcting minor prob noid instrument power and alternator excitationlems apply only to such toggle switch controls While the PREHEAT switch is still depressed depressing the START switch engages the start solenoid PanelAll three switches are momentary contact type and serve the power and the fuel solenoid will be activated When thefollowing functions engine begins to fire the START switch should be1 PREHEAT The PREHEAT toggle switch is a double pole released The PREHEAT switch should not be released single throw switch The switch serves two purposes pre until the oil pressure reaches alarm stops heating the engine for easy starting and defeating of bypassing the engine oil pressure switch The defeat func NOTE When the engine is shut down the water tempera tion turns on the fuel solenoid instrument power and ture gauge and the oil pressure gauge will continue to alternator excitation register the last temperature and oil pressure readings When the PREHEAT switch is depressed the voltmeter displayed They will return to zero once electrical power panel lights gauges and meters and fuel solenoid will is restored activate The PREHEAT switch should be depressed for 4 EMERGENCY STOP The EMERGENCY stop switch at twenty seconds the rear of the control box is normally closed When2 STOP The STOP toggle switch is a single pole single depressed it will open the DC circuit to the control panel throw normally closed switch The switch provides and shut the engine down As the switch is not toggled it power to the fuel solenoid instrument cluster and alterna can be used when performing maintenance tor excitation after the oil pressure switch has closed upon starting Opening of this switch opens the power REMOTE PANEL circuit to the fuel solenoid stopping the flow of fuel to For remote operation of the generator system the same three the engine and shuts down the engine switches are used The PREHEAT and START switches are To stop the engine depress the STOP switch When the connected in parallel with the gauge panels switches and STOP switch is depressed the power feed to the fuel serve the same functions as in the gauge panel The STOP solenoid is opened and the fuel flow to the engine is switch is in series with the gauge panels STOP switch and stopped The STOP switch should be depressed until the serves the same function generator stops rotating 4 o o o STOP RElEASE STARIEI 6 START MUST PRESS PRESS FIRST W 2ND 1B7 GENERATOR o o o REMOTE PANEL OPTIONAL CONTROL PANEL Engines Generators 104 CONTROL PANEL MANUAL STARTER DISCONNECT TOGGLE SWITCHES NOTE The engine control system is protected by a 20 amp manual reset circuit breaker located on the engine as close as possible to the power source Problem Probable Cause PREHEAT depressed no panel indications 1 Oil Pressure switch 1 Check switches andor battery connections electric fuel pump and preheat solenoid not energized 2 20 amp circuit breaker tripped 2 Reset breaker If it opens again check preheat solenoid cir cuit and run circuit for shorts to ground START SWITCH DEPRESSED no starter 1 Connection to solenoid faulty 1 Check connection engagement 2 Low DC voltage to solenoid terminal 2 Check Voltage Jump voltage to S terminal 3 Faulty switch 3 Check switch with ohmmeter 4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection 5 Loose battery connections 5 Check battery connections 6 Low battery 6 Check battery charge state NO IGNITION cranks does not start 1 Faulty fueling system 1 Check for fuel 2 Check for air in the fuel system 2 Allow system to bleed 3 Faulty fuel lift pump 3 Replace fuel lift pump 4 Faulty fuel solenoid 4 Check fuel solenoid NOT CHARGING BAmRY 1 Faulty alternator drive 1 Check the drive belt and its tension Be sure the alternator turns freely Check for loose connections Check the output with a voltmeter Ensure 12V are present at the regulator terminalExc Terminal BAmRY RUNS DOWN 1 Oil pressure switCh 1 Observe if the gauges and panel lights are activated when the engine is not running Test the oil pressure switch 2 High resistance leak to ground 2 Check the wiring Insert sensitive 025 amp meter in battery lines Do NOT start engine Remove connections and replace after short is located WATER TEMPERATURE AND OIL PRESSURE GAUGESIf the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge isby the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with thestep is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the senderand the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge isAssuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the following steps Assuming the gauge is OK check the conductor from the1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground situation Some starters have isolated ground terminals and if the bat2 Connect the sender terminal at the gauge to ground and tery is connected to the starter both plus and minus termi see if the gauge reads full scale which is the normal nals the ground side will not necessarily be connected to the reading for this situation block Engines Generators 105 THE BE GENERATOR SINGLE AND THREE CIRCUIT BREAKERThis generator is a fourpole brushless selfexcited generator A circuit breaker is installed on all WES1ERBEKE generawhich requires only the driving force of the engine to pro tors This circuit breaker will automatically disconnect generduce AC output The copper and laminated iron in the exciter ator power in case of an electrical overload The circuitstator are responsible for the selfexciting feature of this gen breaker can be manually shut off when servicing the generaerator The magnetic field produced causes an AC voltage to tor to ensure that no power is coming into the boatbe induced into the related excitor rotor windings duringrotation Diodes located in the exciter rotor rectify this volt NOTE This circuit breaker is available as a WESTERBEKEage to DC and supply it to the windings of the rotating field addon kitfor earlier model generations contact yourThis creates an field which rotates through WESTERBEKE dealerthe windings of the main stator inducing an AC voltage PART CIRCUIT BREAKERSwhich is supplied to a load An AC voltage is produced in the 42703 32 Kw 60 Hzauxiliary windings of the main stator and is in turn supplied 43271 25 Kw 50 Hzto a voltage regulator The regulator produces a DC voltageto further excite the exciter stator windings enabling the generator to produce a rated AC output The voltage AC voltage output and adjusts DC excitation to theexciter stator winding according to amperage load the generator is furnishing To maintain a constant voltage output Engines Generators 106 GENERATOR AC VOLTAGE CONNECTIONS DESCRIPTIONThe regulator is equipped with seven numbered terminals 0to 6 and their related brass jumpers The illustrations showconnection points and jumpers for the 3 phase the generator The sensing leads connect between pin 1and pin 2 on the AC terminal block and connection 2 and0 on the voltage regulator boardNOTE Series Delta requires the installation of a jumper onthe regulator board between tenninal B and 1 170 270 V 80 160 V NGND CASE GND L1 L2 L3 RN AVR D D BE THREE PHASE SIX WIRE 3 PHASE VOLTAGE REGULATOR CONNECTIONS FOR BOTH 60 50 HERTZ NOTE IF WIRING FOR 50 HZ THE 60 HZ JUMPER MUST BE REMOVED FROM THE REGULATOR L1 o 23 L1 13 24 L1 112 o 23 L2 5 o 67 L2 57 0 68 L2 45 0 67 N L3 o L3 N L3 0 9 10 11 89 1011 SERIES Y PARALLEL Y SERIES DELTA 480V60 Hz 208V120V 160 Hz 240V60 Hz 380V50 Hz 230V50 Hz 6 STUD 3 PHASE AC WIRING PARALLEL WYE STAR SERIES WYE STAR SERIES DELTA U0 N L L 208 VAG 38 60 Hz L L 450 VAG 311 60Hz L L 240 VAG 20 60Hz L N 120 VAG 19 60 Hz L N 265 VAG t8 60 Hz L2 L3N 120 VAG 10 60Hz L L 190 VAG 39 50 Hz L L 380 VAG 39 50Hz L L 230 VAG 39 50Hz L N 110 VAG 19 50 Hz L N 230 VAG 1 50Hz L2 L3N 115 VAG 19 50Hz BE THREE PHASE TWELVE WIRE A SERIES DELTANote the repOSitioning of the ground lead from neutral to generator housing J Jumper using 10 AWG Engines Generators 107 GENERATOR AC VOLTAGE CONNECTIONSAC VOLTAGE CONNECTIONS Generator FrequencyNOTE The frame ground wire whitegreen must be prop 1 Frequency is a direct result of speederly positioned when changing the AC output configuration 1800 rpm 60 hertz 1500 rmp 50 hertzof the AC terminal block For making connections to the AC 2 To change generator frequency follow the steps belowterminal block use terminal ends for 114 inch studs that will Configure the AC tenninal block for the desired voltageaccept multi strand copper wire sized for the amperage rating frequency as shown Ensure that the case ground wire isfrom the hot lead connection The frame ground wire is white connected to the correct terminal block neutral groundor white with a green strip It connects between the neutral studstud and the generator frame NOTE The whitegreen ground wire may be removed in those installations where the AC circuit has a separate neutral and ground circuit This will prevent the unit from being a ground source in the vessel 120240V 60Hz 120V60Hz 230V50Hz 115V 50Hz o o o 0 o o 0 L1 fl lW N L2 L1 AJUMPER IS REQUIRED il BETWEEN LOAD I I CONNECTIONS I i 00 i I I L l I II Engines Generators 108 VOLTAGE REGULATOR AmpHertzThe voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the twooptimum AC alternator performance It is equipped with protection circuits in the voltage regulator that are protection circuitry to guard against operating by the illumination of a colored LED that could be detrimental to the AC alternator 1 Delayed overload protection yellow LED 2 Low speed protection red LED Both systems have an intervention threshold which can be adjusted using the respective potentiometer Each of the two circuits are able to cause an adequate reduction in excitor voltage to safeguard the excitor windings and prevent their overheating The overload protection system has a delay which permits temporary overloading of the generator during times such as motor startup or other similar load surge demands The regu lator also has a third LED green that glows during genera tor operation to indicate correct operation of the regulator with the generatorThis potentiometer is used to adjust output voltage At properengine operating speed the output voltage should be held at Setting the Overload Protection1 from a noload condition to a full rated generator output In order to set the AMP overload protection the alternatorand from power factor 10 08 with engine drive speed vari must be loaded to its full output ratingations up to 6 1 Load the alternator to its rating then decrease the speed ofPrior to starting the engine turn the VOLT and STAB trim the engine by 1010 54 Hertz on 60 hertz units 45mers using a mini phillips screwdriver fully in a counter hertz on 50 hertz unitsclockwise Minimum direction until you feel them hit their 2 Rotate the AMP adjustment until it hitsstops its stop Wait about 1520 seconds after which the AC outTurn the AMP and HERTZ trimmers completely clockwise put of the alternator should drop and the yellow LED lightMaximum in the same manner should come onWith the alternator running at noload at normal speed and 3 Slowly rotate the AMP adjustment clockwise until thewith VOLT adjust at minimum it is possible that output volt output voltage increases to approximately 97 of the voltage will oscillate Slowly rotate the VOLT adjust clockwise age output at the start of the adjustment At this point theThe voltage output of the alternator will increase and stabi yellow LED light should come onlize Increase the voltage to the desired value In this situa 4 Return to nominal speed the yellow LED will turn offtion only the green LED will stay lit and the alternator voltage will rise to its normal value Should this not happen repeat the potentiometer permits variation of the regulators NOTE When changing from 60 hertz to 50 hertz to generator load changes so as to limit overcom remove the 60 hertz jumper bar from the regulator boardpensation and obtain a minimum recovery time to the normalvoltage output Setting the Underspeed ProtectionIn order to adjust the regulator stability the alternator must be NOTE lfthe unit is operating at 60 Hertz ensure that therunning at noload and the output must be monitored jumper strap is in place on the regulator board between theTurn the STAB adjust slowly clockwise untilthe voltage two 60 Hertz terminals In order to adjust the to fluctuate At this point rotate the STAB adjust coun setting the alternator should be running at until the voltage is stable within 1 or 2 tenths of 1 To adjust the underspeed low frequency protection circuita volt lower the engine speed at 90 of its normal running speed 54 hertz on 60 hertz units 45 hertz on 50 hertz units 2 Rotate the Hertz adjustment slowly until the alternators AC output voltage starts to decrease and at the same time the red LED light comes on 3 Increase the engine speed to its normal speed frequency The red LED light will go out and the AC voltage out put will return to normal With the above adjustments made the regulator should func tion normally VOLTAGE REGULATOR DIAGRAM v WESTERBEKE Engines Generators 109 INTERNAL WIRING SCHEMATICS SINGLE PHASEr EXCITER STATOR RED RED EXCITER ROTOR 1 I STATOR 1 I I RED RED AC I TERMINAL I BLOCK AUX L J WINDINGS W2 REGULATOR FUSE 63 AMP U1 V1 3 RED 9 BLACK GREEN RED NOTE This fuse BLUE may be located on the regulator YEllOW r THREE PHASE 6 WIRE RECONNECTABLE EXCITER STATOR 1 I STATOR I ROTOR FIELD U2 BLACKI IiBLACK UI I 1 1 I AC 1 EXCITER 1 POll 1 V2 GREEN I GREEN VI TERMINAL I ROTOR I RESISTER I I BLOCK 1 I a I 1 W2 1 rREiI RED I REO7WI b I rII1 I I I I I I I J I I AUX L WINDINGS J L REGULATOR FUSE 63 AMP NOTE This fuse l o may be located J w on the regulator J l UJ J Q green Ql yellow L Herlz Voll BLUE YElLOW Engines Generators 110 INTERNAL WIRING SCHEMATICS 3 PHASE TWELVE WIRE RECONNECTABLE ITolrI EXCITER STATOR 2 1IIi Ij I t 12 11I J Ljr1iI 3 1 rrI EXCITER ROTOR I ROTOR FIELD I I 8 ACI I I 4 4 7 TERMINAL C5 BLOCKI II I I 6 2 7 1I I 8 IIL J AUX I WINDINGS FUSE NOTE This fuse 63 AMP may be located on the regulator REGULATOR BLUE YELLOW BE GENERATOR WINDING RESISTANCE VALUES IN OHMS SINGLE PHASE 20 25 BE 32 BE EXCITER STATOR 1806 1820 EXCITER ROTOR a b 068 072 bc 068 072 ROTATING FIELD 175 201 MAIN STATOR 12 005 005 34 005 005 AUXILLARY WINDING 119 098 THREE PHASE 20 25 32 BE EXCITER STATOR 1820 EXCITER ROTOR ab 07 bc 07 ROTATING FIELD 201 MAIN STATOR 006 each winding AUXILLARY WINDING 098 Engines Generators 111 BE NOTE AC GENERATOR MUST BE PERFORMED WITH ENGINE OPERATING AT 60 HERTZ PROBLEM PROBABLE CAUSENo AC voltage output at no load 1 Short or open in the 4 Short or open in exciter main stator winding stator winding 2 Shorted poziresistor 5 Short or open in rotating on exciter rotor field winding 3 Four or more shorted or open diodes on exciter rotorResidual voltage produced at no load 1 Blown 6 AMP buse fuse 3 Shorted or open main15 20 volts AC auxiliary circuit feed to AVR stator auxiliary winding 2 Faulty voltage regulatorLow AC voltage output at no load 1 Open or shorted diodes in 3 Faulty voltage regulator60 100 VAC exciter rotor 1 to 3 diodes 2 Open or shorted exciter rotor windingHigh AC output voltage 1 Faulty voltage regulator150 VAC or higherUnstable voltage output 1 STB pod on regulator 2 Faulty voltage regulator needs adjustmentAC voltage drop under load 1 Diodes on exciter rotor60 100 volts AC breaking down when load is applied inductive 13 diodes r EXCITER STATOR RED r I I I RED I I I I EXCITER I ROTOR FIELD I 11 I ROTOR I I I I I I I I I I DIODES 6 I I I I STATOR I I RED RED I I AUX II J W2 REGULATOR w CD FUSE RED U1 BLACK GREEN Heftz RED e BLUE Vol i YELLOW Engines Generators 112 ELECTRONIC Governor SystemThe system is composed of three basic components1 ControUer Mounted in the instrument panel2 Sensor Installed on the bellhousing over the flywheel ring gear3 Actuator Mounted at the front of the engine and attached with linkage to the throttle arm of the injection pumpController Adjustment1 Speed This adjustment is used to raise or lower the engines speed to the desired hertz2 Gain This adjustment affects the reaction time of the actuator to the load changes NOTE A high gain adjustment can induce an oscillating of the actuator producing a hunting mode In such cases SENSOR lessen the gain adjustment ELECTRONIC LINEAR ACTUATOR1 With no power to the governor adjust the GAIN to 900 oclock2 Start the engine and adjust the speed by turning the speed pot clockwise to desired speed KEEP ACTUATOR NOTE Controllers are factory adjusted to minimum rpm LINKAGE WELL LUBRICATED However for safety one should be capable of disabling D the engine if an overspeed should exist3 At noload turn the GAIN potentiometer clockwise until the engine begins to hunt if the engine does not hunt physically upset the governor linkage LINEAR ACTUATOR4 Turn the GAIN potentiometer until stable TO ELECTRONIC CONTROLLER l DC 14 RED RED TO TERMINAl BOARD f1 14 BLACK 2 BLACIUWHITE SHIELDED TO GOVERNOR TO SENSOR CABLE CONTROL WHITE FLYWHEEL HOUSING ELECTRONIC GOVERNOR MAGNETIC SENSOR TO LINEAR ACTUATOR 14 PURPLE 14 PURPLE 6 PURPLE PURPLE j TERMINAL BOARD 3 SENSOR LOCKNUT O030in FLYWHEEL rr t TEETH 7 v v Engines Generators 113 THE ELECTRONIC GOVERNOR Problem Probable Cause appears dead 1 Low battery voltage at controller 1 Check wiring for cause Check battery state of chargeEngine runs at idle 2 Stuck linkage 2 Lubricate free up linkage between controller and throttle arm 3 No signal or weak signal from sensor 3 Check for improperly installed or damaged sensor in flywheel Measure AC voltage from sensor while housing Replace or adjust engine is running at idle Voltage should be 15 volts or greater 4 Check Actuator depress PREHEAT and check for battery voltage between negative black lead at terminal block a Purple lead to black 4 Replace controller if battery voltage is not present at both leads b Second purple to black 5 Perfonm the following check between terminals at the actuator and the negative DC lead at the controller terminal block Preheat depressed a Low voltage 12020 VDC at either a Broken actuator lead actuator connection b Battery voltage at both actuator b Broken actuator lead connections c Battery voltage at one actuator lead c Replace the actuator but not the otherActuator fully extends when PREHEAT 1 Check controller Lift one of the purpleis depressed and stays extended actuator leads from the tenminal block Depress PREHEAT a Actuator fully extends a Short in lead to actuator b Actuator does not fully extend and b Replace controller connections NOTE Release PREHEAT and reconnect the purple leadActuator hunts oscillates and 1 Linkage between actuator and throttle 1 running binding 2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the Controller controller 3 Inadequate DC power supply to controller complete the folloWing tests Connect a DC voltmeter across the plus and negative leads at the controller terminal block Lift both purple leads from the terminal block Connect one purple lead to the Cplus terminal and the other to the DC negative Momentarily depress PREHEAT The actuator should fully extend 3 If actuator does not fully extend check the actuator leads If the voltage is less than specified check for loose or poor connections low battery voltage voltage drop in DC circuit due to remote panel installation and small wire sizes making connections DC voltage registering on the meter should be 12 VDC System 96 VDC or higher 24 VDC System 192 VDC or higher NOTE Reconnect actuator leads properly after making this test 3a Sensor positioned marginally too far 3a Check the position of the sensor away from flywheel teeth giving erratic signal voltage to controller Engines Generators 114 SHORE POWER TRANSFER SWITCHSHORE POWER CONNECTIONS 60 HERn 120 VOLT60 HZ THREE WIRE CONFIGURATION Notice the repositioning of the white wire ground load on theGenrator NOTE Diagram shows connections for a two terminal block to the generator case wire 120 Volt system For a three wire system use dotted lines for the other hot leg i TL Generator NOTE Diagram shows connections tor a two L I wire 120Volt system from the generator with threewir 120Volt boat system r I I II I I I I I I j I I r l ShiptaShore Switch 3 Pole PH 32008 40AmpaPole PH 32009 SO Amps Pole PH 32010 Neutral 125 Amps POle I N Shp Load PH 32133 ii 200AmpaPole It L2 T l52 Sl T N r I LOd I No 240Volt Shore POwer I Ground II EqUipment Z GRNIf the installer connects shore power to the vessels AC cir cuit this must be done by means of the Shore Power Transfer Shore PowerSwitch Set the transfer switch shown in the diagrams to theOFF position This switch prevents simultaneous connectionof shore power to generator output Switching Shore Power to Generator Power A CAUTION Damage to the generator can result if A CAUTION Heavy motor leads should be shut off utility shore power and generator output are connected before switching shore power to generator power or at the same time This type of generator damage is not viceversa because voltage surges induced by switching covered under the warranty it is the installers responsi with heavy AC loads on the vessel being operated may bility to make sure all AC connections are correct cause damage to the exciter circuit components in the generator Engines Generators 115 32 KW BEDA GENERATOR WIRING DIAGRAM 040425 SINGLE RELAY 110 ORN ALTERNATOR 51A 114 PUR 114 PUR WATER TEMPERATURE 114 REDPUR aLliJl WATER TEMPERATURE llJllEB R r 14 PUR fUEL SOLENOID AIR INTAKE tAllB 01 L PRESSURE 114 RED Ie RED IIII BATTERY SWITCH r V LI C tt 114 PURWHT OIL PRESS llAlliB llJllEB IlQIQB 0 L GROUND TO B L O C K rrHIt 114BLU 114 TA rHIELDED Ill 0 112R00 112 RED ewsJf 20A CIRCUIT EMERGENCY STOP SWITCH 114 BRN REMOVE TH IS JUMPER WHEN 4 I 1 CONNECT I KG A it a REMOTE PANEL 114 REO Ii ISI 14 GftN 114 RED U r D 114 RED I III 10 t rIE 1 SlK LT83 RED RE 14 YEL 14 PUR BlK 110 REDWHT LTI rtii6RII r 61 L WHT LJ rLPUR 1 b I 10RtO 14 YEL 10 ItEOWHT PRESSURE WATER fEY illlIlABJ INSTRUMENT o o PAllEl 10 liEDWIlT VOLT METER J Engines Generators 116 32 KW BEDA GENERATOR WIRING SCHEMATIC 040425 SINGLE RELAY 1 STARTER 1 BATTERY SOLENOID STARTER SWITCH r I I L I PREHEAT AIR INTAKE SOLENOID r I HEATER ALTERNATOR B I 20 AMP I C I RCU IT START SWITCH1 I BREAKER Dr I EMERGENCY I STOP I SWI TCH r I PREHEAT SWITCH I I K 30 r81r 1 STOP I SWITCH FUEL SOLENOID I OIL PRESS EXHAUST TEMP WATER TEMP SWITCH SWITCH SWITCH K l86 85 TEMP VOLTMETER HOURMETER OIL WATER PRESS TEMP SENDER SENDER Engines Generators 117 32 KW BEDA GENERATOR WIRING DIAGRAM 040425 TWO RELAYS 110 ORN ALTfRNATOR 51AIU PURl FUfl SOl fNOI P AIR INTAKf OIL PRfSSURf U mIQ 11410 CiIIIJIIIIl 1111 8A HERr SW 1 T C H J r o Jij 114 PURWMT I 12 VDC OIL PRfSS L ijamRO sElPEB GROU TO BOC J L4 114 BlU EL 14 TAN RE U REO ZOA CIRCUIT fMfRGfNCVlY STOP SWITCH I 6M tt20 iJ I PUjjjHij REMOVE JUMPER S WHEN THI1 I r RENis E III g ED Iil JIJllcmpu IZ I i tFYY11 II eL i 1 14 IlK II RED Be BLK 14 RED lAED 141 D 114 PUR 10 REDWMT f IU WNT 1 1 1010 fit IL 101DWNT T IMTCH 1 f 1 INSTRUMfNT fA1EJI Sf IMTCH 10lEOUT ImP IMTCH Engines Generators 118 32 KW BEDA GENERATOR WIRING SCHEMATIC 040425 TWO RELAYS I E8 e BATTERY 12VDC 20 AMP CIRCUIT r I I BATTERY SWITCH BREAKER STARTER r r 0 0 1 I l J r EMERGENCY AIR INTAKE I I CH HEATER AL TERNATOR 87 KISTART 30 R K2RUH FUEL SOL 30 r87 OIL PRESS EXH TEMP WATER TEMP SW SW SW I N4002 K2RUN RELAY L rr86 r85 KISTART RELAY r86 85 OIL PRESS SENDER WATER TEMP SENDERT812 T813 T814 T822 T81S T821 T824 T82S T8110 L2r VOL TMETER HOURMETER Engines Generators 119 32 KW BEDA GENERATOR WIRING DIAGRAM 44737 TWO RELAYS PLUGIN REMOTE STARTSTOP PANEL ALTERNATOR 114 BRN Ljj l QAypC XC A WATER lilJHATURE U WATER iiffflATURE T nn 110 OftG E S J OGNDE 0 nIynr 11 I IIEDYIO R P FUEL SOb ENOl J 0 0 1lrT E OOIE TEU4 Q wlilI 0 0 aM IID00 I L ro k I ZZ YDC 0 I IU flLlIU IOlr RRfAulf 04 YDC IIIIlIm1 0 0 AUX 0 It PRESSURE SIITCH 11111 QIIUR D STARTER MOTQR lIrbnT RNH I TAli lilliE2R 1411111 I I I VIO l It III tI4 A REONT E1 If GROUND TO f rill ENGINE f lii I BLOCK 0 II T RED I 1101 RED 114 RED E II IIIL b ILI ruSE 811 r2 Blit IU Bu IFb p eUIHT VIO L VIO lrUL IIIIRIl IIID YIO 11 OIlG 1 Aillit rIELDED lliU WMT lit ILl illJNOTEI REMOVE JUIIPER IHEN CONNECTING A 5COIO REMOTE PANEL WHT2 GROUND TERMINAL or PREHEAT SOLENOID ON 2cv SYSTEM ONLY ORG II T821 0 PREHEAT swrrcH JL IBH rIWlLJ IBH rJLillL la I j START swrrcH iIIBIIO STOP swrrcH HOUR VOLT LJJTBZ8 1 Engines Generators 120 32 KW BEDA GENERATOR WIRING SCHEMATIC 44737 TWO RELAYS PLUGIN REMOTE STARTSTOP PANEL C I RCU IT BREAKER STARTER cJr ooLlIIl L J I AIR INTAKE HEATER r EMERGENCY I Ib I PREHEAT I ISOlENOI AL TERNATOR KISTART KlRUN TBII43DBT WATER TEMP EXH TEMP SWITCH Oil PRESS SWI TeH SWITCH IUDDl KlRUN RELAY 86 85 PREHEAT START SWITCH r r SWI TCH 86 J LJ AUX OP SWITCH OIL PRESS SENDERTBH T813 T61 TBl2 TBI5 TB21 TB28 WATER TEMP SENDER TB2 TBIIO WA TER TEMP GAUGE STOP SWI TCH PREHEAT START 51 reH sw reH OIL PRESS GAUGE IND LIGHT rool J TTP ICAl REMOTE STARTSTOP PANEL CORECT IONS NOTE VOL TMETER o REMOTE CONECTOR PINS HOURMETER Engines Generators 121 32 KW BEDA GENEBATOR WIRING DIAGRAM 041128 SINGLE RELAY 24 VDC SPECIAL SPEC 110 ORN ALTERNATOR 42A 24V B o O C fA 0 14 PUR 114 PUR 1111f1r6TPUT WAIER TEMeERATuRE aillIf IAF I RDPUR I l WTEB IEMPEBATUBE 0 I PUR n FUEl SQI EQIQ AIR INTAKE lllllR QIL PRESSURE L U aillIf 4 RtD 9 sow1QlQ AUlAlQB t RED a 0 lilt 1111 BATTERY SWIICH ro 1 PURHI Lq I 2 VOc GROUND TO IILOCK fl llARilll 0 14 TAN 114 BlU I z tLREO QIL PRESS fSHED 0 fWIlIf 112 AO 20A CIRCUIT aRAlIER II BRH liZ REO EMERENY STQP SWITCH if EXHAUURE T aillIf r TB1 14 PUR I O T H MTIS7IP SI 2 J rID PUI IAML I GAN IIO 114 RED TBH MIl W BQtQY urEB AQfQSS a l11JZ BEFORE CtJfEC7I1l BeMl2 STARTtSltP AIEL z BQtQ CROSS lBl N2 PR 0 8 E r D IS IU IU a ZBZ sEFClQE CCVIEClM ERE Ml 14 ell 0 FRED I RED 114 PUR 114 TtL rn GAM ST f WT HT J PuR 0BlLlE I 00 00 fAr 10 00 00 00 00 00 00 00 00 00 II r to 1 I I t U Olll ID DWM ILorell llALQABIl 1111 IUlff INSTRUMENT n D ro Ill CL PRESSUIE fMEJI I I 1 f 0 A 1111 WIIIf 0 00 00 00 IISfOTl STARTSTrJP PANEl VOLT METER Engines Generators 122 32 KW BEDA GENERATOR WIRING SCHEMATIC 041128 SINGLE RELAY 24 VDC SPECIAL SPEC STARTER SOLENOID STARTER r1 PREHEAT SOLENOID r 1 AIR INTAKE HEATER AL TERNATOR OUTPUT 87 KI I CI 20 AMP I RCU I T START SWITCH 30 0 START KI 0L BREAKER r 86 85 r L J Dr EMERGENCYI I STOPL SWI TCH rI I PREHEAT SW ITCH K2 0 30 87r STOPI I SWITCH FUEL SOLENOID OIL PRESS EXHAUST TEMP WATER TEMP SWITCH SWITCH SWITCH T826 T827 FIRE ALARM N C CONTACTS TENP VOL TMETER HOURNETER OIL WATER PRESS TEMP SENDER SENDER Engines Generators 123 32 KW BEDA GENERATOR WIRING DIAGRAM 44806 TWO RELAYS PLUGIN REMOTE STARTSTOP PANEL V WI 1 R liffflATURE uIERNAIOR 1ge1VDC b WATER itlIflATURE 0 Jt1 BRN M R Ie 10 OIG IIC eRN RrDVID i II ltD WW FUEL SOU NO Q TEYwfut 1 0 0 aHm II In G ro IUIT 0 AUX OIL PRESSURE II I L Z4 VDC 0 I IllrEUID BRtAKtR2 vDe IIIlII fi 011 dHHURf STAOOMOIOR WHT 14 TAli tRiet G SIll I I VIO III 1141 d 10 I IEDWHT r 11 GROUND TO 0 L I ENGINE 1 BLOCK t E7 I oinT K y S tIL RED TB3 ueu IIRO FUSE 86 IU REO s ID BLK BLHT IU eLK fIiRN Jl IHT yrl VIO I Ro ORG YIO 1 WMT rED illV IIIU a p 1NOTEI REMOVE JUMPER OEM CONNECT IIG A SCONO REMOTE PANEl PRaAT SWITCH 0 r1JWl0 TIUS 1LeTBI START SWITCH iJUle TIIIIO STeP SWITCH 0t821 HOlR YaT 115 0 Il0 F Engines Generators 124 32 KW BEDA GENERATOR WIRING SCHEMATIC 44806 TWO RELAYS PLUGIN REMOTE STARTSTOP PANEL BATTERY 122VDC CIRCUIT BREAKER STARTER rrnOlp L J AIR INTAKE HEATER r I EMERGENCY I ImCH I PREHEAT ISOLENOI L ALTERNATOR CD KISTART KZRUN T813O 81 WATER TENP EXH TEMP SWITCH Oil PRESS 8A 5WI rCH 5WI rCH r I SlOP I ISWITCH IUOOZ KZRUN RELAY titr826 rB21B6 85 F IRE ALARM MC CONTACTS PREHEAT START SW I rc H SW I rCH K I START RELAY r 1oi r86 85 LJ LJ AUX DP SIITCH Oil PRESS SENDERT612 T813 T814 T822 T815 1621 182e T824 T825 WATER TEMP SEMDER TBIIO 10 WATER TENP GAUGE STOP SWI TCH PREHEAT START SWITCH SWITCH I NO LIGHT OIL PRESS GAUGE r 1 r L J LJ TYP ICAL RENDTE STARTSTOP PANEL CDNECT IONS NOTE VOL TNETER o RENDTE CONECTOR PINS HOURNETER Engines Generators 125 SPECIAL TOOLS GENERATORFIELD FABRICATED TOOLSThese drawings provide a means by which simple tools canbe made to assist in the removal of the generator end from theengine and in the replacement of the generator end on theengine A local machine shop should be able to fabricate thesetools at a modest price but first check with your local WESTERBEKE dealer to see if these tools are available on loan 475 Lifting Eye Tool 125353 This tool allows a mechanic to safely remove the generator end from the engine Attach this Generator End Lifting I ffiffi I ffi I Eye to the four screw holes located under the control panel I I I I I I r To use this Lifting Eye remove the generators control panel and screw the Lifting Eye to the generator end using four M6 x 10 pitch capscrews 131 I I I I I II I ffi I I 028 6 HOLES 11250 I 1131 I 0 3251144 tiEii 0125 MATERIAL 316 STEEL IFr DIMENSIONS ARE IN INCHES I 2501 Back End Lifting Eye Tool 125 This Lifting Eye mounts to the back end of the 375 generator Attach this Lifting Eye with two M12 x 175 pitch capscrews using the two rLJttj1I holes that are adjacent to the rear carrier bearing housing MATERIAL STEEL DIMENSIONS ARE IN INCHES continued Engines Generators 126 SPECIAL TOOLS GENERATOR r2088 1 r2063i 1850 ooJl h 1285 861 1 2188 050 DIMENSIONS ARE IN INCHES 1025 MM DRill 404 125DEEP AND TAP 11112 X 175 100 DEEPPilot ToolThis tool prevents the rotor from damaging the windingswhen the generator housing is removed from the engine orwhen it is installed on the engine Screw the MI2 threadedrod into the end of the Pilot Tool then screw the Pilot Tool M12 THREADED RODinto the rotor shaft to use as a guide 158 lG OVERAll X 175 PITCHDisk Alignment ToolThis tool allows a mechanic to safely remove and install thegenerator drive disks by aligning the disks with the Drive mwmwnWm cPlate Guide Pin The Pin screws into the flywheel and acts asa guide Also the pin helps to support some of the rotor and I 25 in 635 mm APPROX I Material One M1D x 125 pitch bolt with the hex head machinedthe drive plates weight while removing or replacing these off and a screwdriver slot cut in the machined endparts Engines Generators 127 INDEXAC Voltage Connections 107 108 Fuel System continuedAir Intake Heater 81 Feed Pump Strainer 60Air Intake Silencer 42 Filter 42 45 59Alternator 44 82 Injection Pump 63Alternator Bracket 40 Injectors 42 61Alternator Dual Output 84 Lift Pump 59Back Plate 19 3645 Return Lines 42Battery 81 83 Flywheel 15 29 36BE Generator Single and Three Phase 106 Frequency Adjustment Generator 103BE Generator 112 15 45 AC Voltage Connections 107 108Camshaft 19 23 32 BE Single and Three Phase 106Circuit Breaker 106 Circuit Breaker 106Compression Test 6 49 Control Panel Switches 104Connecting Rod 192734 Frequency Adjustment 103Control Panel Admiral 78 Information 103Control Panel Captain 79 Internal Wiring Schematics ll0 111Control Panel Switches Generator 104 Maintenance 103Control Panel Engine 80 Mounting 46Control Panel Generator 105 Removal 14Coolant 4546 Special Tools 126Coolant Pump 40 54 55 Specifications 100Coolant Pump Connector and Hose 44 112Crankcase Breather Hose 45 Heat Exchanger 45 54 55Crankshaft 19 28 32 Hourmeter 80Crankshaft Pulley 40 Idle Speed Adjustment 4950Cylinder Block 29 Injection Pump 63Cylinder Head 16 20 40 Intake Manifold 42Cylinder Head Bolts 16 41 49 Lifting Eyes 42Cylinder Liner 19 26 33 Lower Block 18 37Drive Belt Adjustment 48 Main Bearing 19 32Electronic Governor 113 Metric Conversions 130 131Electronic Governor 114 OilEngine Cooler 38 Adjustments 48 Filter Housing 18 38 Disassembly 14 Jet 3031 Inspection and Repair 20 Level Dipstick 43 Overhaul 6 Pressure 51 Parts Identification 5 Pressure Gauges 105 Reassembly 31 Pressure Sender 184551 Specifications 4 Pressure Switch 184551 7 Pump 18 38 51Exhaust Manifold 45 46 47 Sump 18 38Fuel System Parts Identification Engine 5 Bleeding 60 Parts Identification Generator 102 Feed Line 43 Piston and Piston Rings 19 25 34 continued Engines Generators 128 INDEXPumps Valve Coolant 40 54 55 Valves 17 20 21 31 Fuel Lift 59 Clearance Adjustment 48 Injection 63 Guide 21 Raw Water44 54 58 Seal 31Push Rod 24 40 Seat 20Raw Water Pump 44 54 58 Spring 22Rear Oil Seal Crankshaft 19 29 36 Stem Caps 41Remote Panel 104 Voltage Regulator Adjustment l09Rocker Ann and Shaft 16 24 41 Water Temperature Gauge 105Rocker Cover 16 45 Wiring and Lubricants 98 90A Four Propulsion EngineShore Power Transfer Switch 115 Wiring Diagram 41343 86Special Tools Generator 126 90A Four Propulsion Engine Wiring Schematic 41343 32 KW BEDA Generator Wiring Diagram 040425 Engine 4 Single Relay 116 Generator 100 32 KW BEDA Generator Wiring Schematic 040425 Lubrication 53 Single Relay 117Standard Hardware 98 32 KW BEDA Generator Wiring Diagram 040425 Two Relays 118Starter Motor 45 64 32 KW BEDA Generator Wiring Schematic 4980 Two Relays 119Tappets 23 32 32 KW BEDA Generator Wiring Diagram 44737Testing for Overhaul 6 Two RelaysPlugin Remote StartStop Panel 120Thermostat 16 44 54 55 32 KW BEDA Generator Wiring Schematic 44737Timing Gear Case 17 37 Two RelaysPlugin Remote StartStop Panel 121Timing Gear Cover 17 39 32 KW BEDA Generator Wiring Diagram 041128 Single Relay 24 VDC Special Spec 122Timing Gears 17 30 38 32 KW BEDA Generator Wiring Schematic 041128Torques Single Relay 24 VDC Special Spec 123 90A Four Engine 99 32 KW BEDA Generator Wiring Diagram 44806 Standard Hardware 98 Two Relays Plugin Remote StartStop Panel 32 KW BEDA Generator Wiring Schematic 44806 Two Relays Plugin Remote StartStop Panel 125 Borg Warner Velvet Drive 93 Wiring Harness 45 Damper Plate 15 45 Hurth HBW 250 91 Hurth HSW 88 Oil Coolers 45 88 96 Removal 14 BE Generator 112 Electronic Governor 114 Engine 7 Engine Control Panel 80 Generator Control Panel 105 Transmission 96 Engines Generators 129 METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHESInches mm Inches mm mm Inches mm Inches 1 2540 15 38100 1 00394 15 05906 2 5080 20 50800 2 00787 20 07874 3 7620 25 63500 3 01181 25 09843 4 10160 30 76200 4 01575 30 11811 5 12700 35 88900 5 01969 35 13780 10 25400 40 101600 10 03937 40 15748 10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET INCHES TO METERS METERS TO INCHESInches Meters Inches Meters Meters Inches Meters Inches 1 00254 7 01778 01 3937 07 27559 2 00508 8 02032 02 7874 08 31496 3 00762 9 02286 03 11811 09 35433 4 01016 10 02540 04 15748 10 39370 5 01270 11 02794 05 19685 11 43307 6 01524 12 03048 06 23622 12 47244 TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT YARDS TO METERS METERS TO YARDSYards Meters Yards Meters Meters Yards Meters Yards 1 091440 6 548640 1 109361 6 656168 2 182880 7 640080 2 218723 7 765529 3 274320 8 731520 3 328084 8 874891 4 365760 9 822960 4 437445 9 984252 5 457200 10 914400 5 546807 10 1093614 MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0454 6 2722 1 2205 6 13228 2 0907 7 3175 2 4409 7 15432 3 1361 8 3629 3 6614 8 17637 4 1814 9 4082 4 8818 9 19842 5 2268 10 4536 5 11023 10 22046 GALLONS TO LITERS LITERS TO GALLONSGallons Liters Gallons Liters Liters Gallons Liters Gallons 1 379 10 3786 1 026 60 1566 2 757 20 7571 2 053 90 2377 3 1136 30 11357 5 132 120 3132 4 1514 40 15142 10 264 150 3962 5 1893 50 18928 20 528 180 4754 PINTS TO LITERS LITERS TO PINTS Pints Liters Pints Liters Liters Pints Liters Pints 1 047 6 284 1 211 6 1268 2 095 7 331 2 423 7 1479 3 142 8 379 3 634 8 1691 4 189 9 426 4 845 9 1902 5 237 10 473 5 1057 10 2113 TEMPERATURE 32 40 50 60 70 75 85 95 105 140 175 212 of I I I I I I I I I I I I I I I I I I I I I I I I 0 5 10 15 20 25 30 35 40 60 80 100 C Engines Generators 130STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches Feet tt x 305 Meters m x 3281 Feet Miles x 1609 Kilometers km x 0621 MilesVOLUME Cubic Inches in3 x 16387 Cubic Centimeters x 061 in3 Imperial Pints IMP pt x 568 Liters L x 176 IMP pt Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US pt x 473 LitersL x 2113 Pints US Quarts US qt x 946 Liters L x 1057 Quarts US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2205 PoundsPRESSURE Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2036 Hg Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13783 H20 Inches of Water H20 x 03613 psi x 27684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4026 H20TORQUE PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb PoundsForce Feet ttIb x 1356 Newton Meters Nm x 738 ftIbVELOCITY Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPHPOWER Horsepower Hp x 745 Kilowatts Kw x 134 MPHFUEL CONSUMPTION Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL Kilometers Per Liter KmL x 2352 IMP MPG Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL Kilometers Per Liter KmL x 2352 US MPGTEMPERATURE Degree Fahrenheit oF DC X 18 32 Degree Celsius DC OF 32 x 56 Engines Generators 131 Engines Generators1 0095C900

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