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Westerbeke Diesel 90a Four Parts Manual



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 SERVICE MANUAL
       gOA FOUR
  MARINE DIESEL ENGINE
                          and
   32.0 KW·60 Hz BEDA
   25.0 KW·50 Hz BEDA
MARINE DIESEL GENERATORS .
     SINGLE AND THREE PHASE


           PUBLICATION NO. 43750
          15t Edition/September 2000




  ~r~ 'WESTERBEKE                                                 I




      ~   WESTERBEKE CORPORATION ·150 JOHN HANCOCK ROAD
          MYLES STANDISH INDUSTRIAL PARK· TAUNTON, MA 02780
          WEBSITE: www.WESTERBEKE.COM


       ---""'"
      ----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    WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness                   - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. " symptoms persist,
seek medical attention. Shut down the unit and do not restart
until 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 the
WARNING
&9-~~~
                        IIving/sleeping quarters of your vessel.
                        They are inexpensive and easily
    mmtJ._              obtainable at your local marine store.
                                              SAFETY INSTRUCTIONS
INTRODUCTION                                                          PREVENT BURNS - FIRE
Read these safety instructions carefuUy. Most accidents are
caused by failure to follow fundamental rules and precau-                 A WARNING: Fire can cause injury or death!
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personnel,            ·     Prevent flash fires. Do not smoke or permit flames or
and your machinery.                                                         sparks to occur near the carburetor, fuel line, filter, fuel
The following safety instructions are in compliance with the                pump, or other potential sources of spilled fuel or fuel
American Boat and Yacht Council (ABYC) standards.                           vapors. Use a suitable container to catch all fuel when
                                                                            removing the fuel line, carburetor, or fuel filters.
PREVENT 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 cleaner/silencer 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                       engine/generator 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 re-fueling safety instructions. Keep the vessel's
·    Do not connect utility shore power to vessel's AC                      hatches closed when fueling. Open and ventilate cabin
     circuits, except through a ship-to~shore double throw                  after fueling. Check below for fumes/vapor before run-
     transfer switch. Damage to vessel's 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 well-ven-
     with an insulated tool.                                                tilated area away from spark-producing equipment and
                                                                            out of the reach of children.
PREVENT BURNS - HOT ENGINE                                            ·     Do not fill the fuel tank(s) 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 INSTRUCTIONS
ACCIDENTAL 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 adequ~te 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 boat
BATTERY EXPLOSION                                                              builder or dealer for installation of approved detectors.
                                                                         ·     For additional infonnation refer to ABYC T-22 (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 nu-like 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 exhaust/water 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     Vomiting
BATTERY 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 belt's 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 21037
HAZARDOUS 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:
                                                                             U.S. Government Printing Office
    A WARNING: 00 not work on machinery when you are                         Washington, D.C. 20404
    mentally or physically incapaCitated by fatigue!

OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
        H-2 Ventilation
        P-l Exhaust systems
        P-4 Inboard engines
        E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                               Engines & Generators

                                                                     iii
                                   INSTALLATION

When installing WESTERBEKE engines and generators, it is important that strict attention be
paid to the following information:
CODES AND REGULATIONS
Federal regulations, ABYC guidelines and safety codes must be complied with when installing
engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water-injected exhaust elbow is close to or will be
below the vessel's waterline, provisions must be made to install a siphon-break in the raW water
supply hose to the exhaust elbow. This hose must be looped a minimum of20 in (51 em) above
the vessel's waterline. Failure to use a siphon-break when the exhaust manifold injection
port is at or below the load waterline will result in raw water damage to the engine and
possible flooding ofthe boat
If you have any doubt about the position of the water-injected exhaust elbow relative to the
vessel's waterline under any of the vessel's various operating conditions or when the vessel is not
underway, install a siphon-break. This precaution is necessary to protect your engine.
NOTE: A Siphon-break requires periodic inspection and cleaning to ensure proper operation.
Failure to properly maintain a siphon-break can result in catastrophic engine damage. Consult
the siphon-break manufacturer for a proper maintenance schedule.

EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to prevent
water from entering the exhaust under any sea conditions and at any angle of the vessel's 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 CONTENTS
Introduction ......................................................................... 2       32 KW BEDA Generator Parts Identification ................. 102
90A Four Propulsion Engine Specifications...................... .4                             Generator Information ..................................................... 103
90A Four Propulsion Engine Parts Identification ............... 5                              Generator Control Panel Switches .................................. 104
Testing for Overhaul. .......................................................... 6             Control Panel Troubleshooting ........................................ 105
Engine Troubleshooting...................................................... 7                 The BE Generator, Single and Three Phase.................... 106
Engine Disassembly.......................................................... 14                Generator AC Voltage Connections ................................ .l07
Engine Inspection and Repair........................................... 20                     Voltage Regulator Adjustments ....................................... 109
Engine Reassembly........................................................... 31                Internal Wiring Schematics ............................................. 110
Exhaust Manifold.............................................................. 47              BE Troubleshooting......................................................... 112
Engine Adjustments .......................................................... .48              Electronic Governor......................................................... 113
Lubrication System........................................................... 51               Troubleshooting the Electronic Governor....................... .114
Cooling System................................................................. 54             Shore Power Transfer Switch .......................................... 115
Fuel System ....................................................................... 59         32 KW BEDA Generator Wiring Diagram #040425
Starter Motor..................................................................... 64             (Single Relay) ............................................................. 116
Admiral Control Panel. ......................................................78                32 KW BEDA Generator Wiring Schematic #040425
                                                                                                  (Single Relay) ............................................................. .117
Captain Control Panel. .......................................................79
                                                                                               32 KW BEDA Generator Wiring Diagram #040425
Control Panel Troubleshooting......................................... 80                         (Two Relays) ............................................................... 118
DC Electrical System........................................................ 81                32 KW BEDA Generator Wiring Schematic #040425
Alternator........................................................................... 82          (Two Relays) .........................................................,...... 119
Dual Output Alternators .................................................... 84                32 KW BEDA Generator Wiring Diagram #44737
                                                                                                  (Two Relays) (plug-in Remote Start/Stop Panel) ....... 120
90A Four Propulsion Engine
   Wiring Diagram # 41343 ............................................. 86                     32 KW BEDA Generator Wiring Schematic #44737
                                                                                                  (Two Relays)(Plug-in Remote Start/Stop Panel) ....... 121
90A Four Propulsion Engine
   Wiring Schematic # 41343 .......................................... 87                      32 KW BEDA Generator Wiring Diagram #041128
                                                                                                  (Single Relay) 24 VDC Special Spec ......................... 122
Hurth HSW Transmissions ............................................... 88
                                                                                               32 KW BEDA Generator Wiring Schematic #041128
Hurth HBW 250 Transmission ......................................... 91                           (Single Relay) 24 VDC Special Spec ......................... 123
Borg Warner Velvet Drive Transmission .......................... 93                            32 KW BEDA Generator Wiring Diagram #44806
Transmission Troubleshooting .......................................... 96                        (Two Relays) (Plug-in Remote Start/Stop Panel) ....... 124
Standard Hardware / Sealants & Lubricants ..................... 98                             32 KW BEDA Generator Wiring Schematic #44806
90A Four Torque Specifications ....................................... 99                         (Two Relays) (Plug-in Remote Start/Stop Panel) ....... 125
32 KW BEDA Generator Specifications........................ .lOO                               Special Tools - Generator................................................ 126
                                                                                               Index ................................................................................ 128
                                                                                               Metric Conversions ......................................................... 130
                                                                                               Standard and Metric Conversion Data............................ 131




                                                                                 Engines & Generators

                                                                                           1
                                                    INTRODUCTION
ENGINE OVERHAUL                                                        CUSTOMER IDENTIFICATION CARD
This service manual contains detailed information relating to
the overhaul of the 90A Four Diesel Engine and the 32.0
KW/2S.0 KW BEDA Diesel Generators. For the major                          rWO/WESTERBEKE
engine overhaul procedure, refer to the ENGINE DISASSEM-
BLY, ENGINE INSPECTION AND REPAIR, and ENGINE                                        I
REASSEMBLY sections. Additional service information for                Customer Identification
the generators and other specific components and systems               MR. ENGINE OWNER
may be found by referring to the TABLE OF CONTENTS and
the INDEX. Refer also to your WESTERBEKE Parts                         MAIN STREET
Catalog.                                                               HOMETOWN, USA
These service procedures are intended for the guidance of              Model 90A FOUR                           Ser.#UOOOO-D906
suitably equipped and staffed marine engine service and                Expires 8/2/00
rebuilding facilities, and should only be undertaken by such-
facilities and their personnel.
                                                                       The WESTERBEKE engine serial number is an alphanu-
PRODUCT SOFTWARE                                                       meric number that can assist in determining the date of man-
Product software (tech data, parts lists, manuals, brochures           ufacture of your WESTERBEKE engine. The manufacturer's
and catalogs) provided from sources other than WESTER-                 date code is placed at the end of the engine serial number and
BEKE are not within WESTERBEKE'S control.                              consists of a character followed by three numbers. The char-
                                                                       acter indicates the decade (A=1960s, B=1970s, C=1980s,
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE                               D=1990s, £=2000s), the first number represents the year in
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-                                the decade, and the second and third numbers represent the
RANTIES OR REPRESENTATIONS WITH RESPECT                                month of manufacture.
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT                              ORDERING PARTS/SERIAL NUMBER LOCATION
BE LMBLE FOR ANY TYPE OF DAMAGE OR INJURY                              Whenever replacement parts are needed, always provide the
INCURRED IN CONNECTION WITH OR ARISING OUT                             engine model number and engine serial number as they
OF THE FURNISHING OR USE OF SUCH SOFTWARE.                             appear on the silver and black identification nameplate locat-
WESTERBEKE customers should also keep in mind the                      ed on the side of the engine's exhaust manifold. The engine
time span between printings of WESTERBEKE product soft-                serial number can also be found stamped into the engine
ware and the unavoidable existence of earlier WESTER-                  block just above the injection pump, and on generators, on
BEKE manuals. Product software provided with                           the decal located on the side of the generator. You must pro-
WESTERBEKE products, whether from WESTERBEKE or                        vide us with this information so we may properly identify
other suppliers, must not and cannot be relied upon exclu-             your engine. In addition, include a complete part description
sively as the definitive authority on the respective product. It       and part number for each part needed (see the separately fur-
not only makes good sense but is imperative that appropriate           nished Parts List). Also insist upon WESTERBEKE pack-
representatives of WESTERBEKE or the supplier in question              aged parts because will fit or generic parts are frequently not
be consulted to determine the accuracy and currentness of the          made to the same specifications as original equipment.
product software being consulted by the customer.                      NOTE: Component locations in this manual are referenced
NOTES, CAUTION AND WARNINGS                                            from the front of the engine which is the pulley/drive belt end.
                                                                       Left and right sides are determined as follows: imagine
As this manual takes you through the service procedures and            straddling the engine, facing in the same direction as the
troubleshooting of your marine engine, critical information            front of the engine: the left side is at your left, the right side.
will be highlighted by NOTES, CAUTIONS, and WARNINGS.                  is at your right.               .
p"~_explanation follows.
NOTE:   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 idelllification
nameplate 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.
                PF/PHASE ___ _                         I
                WIRES ________ _
                RATING _______ _
                INSUL CLASS __
                TEMP. RISE ___ _
                 BAITERY _____ _
                 C.I.D. _________ _

                                    GENERATOR DECAL




                            ENGINE. IDENTIFICATION .NAMEPLATE




                                  Engines & Generators

                                          3
                        gOA FOUR PROPULSION ENGINE SPECIFICATIONS
                         SPECIFICATIONS                                                                        FUEL SYSTEM
Engine Type                Diesel, four-cycle, four-cylinder, fresh water-          General                     Closed system with bleed points.
                           cooled, vertical in-line overhead valve
                           mechanism, (90 hp at 3600 rpm maximum).                  Fuel                        No.2 diesel oil (cetane rating of 45 or higher).
Aspiration                 Naturally aspirated.                                     Fuel Injection Pump         ZEXEL Model PE (In-Line).
Governor                  Integral with the injection pump; mechanical              Fuel Injection Timing       12° BTDC
                          flyweight type.                                           Nozzle                      Orifice type.
Bore & Stroke              3.94 x 4.33 inches (100.0 x 110.0 mm)                    Fuel filter (on engine)     Full flow replaceable, spin-on element.
Piston Displacement        210.8 cubic inches (3.5 liters)                          Air Intake Silencer         Metal screen type - cleanable. Tuned intake
                           1-3-4-2                                                                              (no filter).
Firing Order
Direction of Rotation      Clockwise, when viewed from the front                    AirFlow                     220 cfm (6.2 cmm)
                                                                                    (engine combustion)
Maximum Torque             168 Ib-ft (23 kg-m)
(at 3600 rpm)                                                                       Fuel consumption            2.0 U.S. gph (7.5 Iph) at 2500 rpm

Compression Ratio          18:1
                                                                                                            LUBRICATION SYSTEM
Dimensions                . Height: 36.0 inches (91.4 em)                           General                     Pressure fed system.
                            Width: 23.0 inches (58.4 cm)
                            Length: 39.3 inches (99.8 cm),                          Oil pump                    Trochoid type.
                                                                                    Oil filter                  Full flow, paper element, spin-on type.
Weight                     790 Ibs (358.3 kgs)                                                                  Water cooled.
                                                                                    Oil cooler
                                                                                    Sump Capacity               6.3 U.S. qts (6.0 liters)
                    TUNE-UP SPECIFICATIONS                                          (not including filter)      plus filter/cooler assembly.
Compression Pressure      427 psi (30 kg/cm') at 200 rpm                            Operating Oil Pressure      50 - 55 psi (3.5 - 3.9 kg/cm2)
(Limit of difference                                                                (engine hot)
between cylinders)         47.6 psi (3.0 kg/cm')                                    Oil Grade                   API Specification CF or CG-4,
                                                                                                                SAE 30, 10W-30, 15W-40
Valve 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 (CCA)
Engine Timing              Static timed - drop valve method
                           0.180 :t 0.005 inches BTDC.                              DC Charging Alternator      51 amp rated, belt-driven

Injector Pressure          2450:t 35 psi (172.2:t 2.5 kg/cm').                      Starting Aid                Air intake heater

Valve Seat Angle           Intake 45°                                               Starter                     12 Volt, 3 KW
                           Exhaust 30°                                              DC No-Load Current          :t 2% of rated amps
Valve Clearance            Intake 0.012 inches (0.3 mm)                             DC Cranking Current         250 - 300 amps (engine cold)
(engine cold) .            Exhaust 0.014 inches (0.35 mm)
Engine Speed               Idle: 700 - 900 rpm                                                         ENGINE AIR REQUIREMENTS
                           Cruise: 2500 - 3000 rpm
                          -Max: 3500 - 3600 rpm                                     Combustion Air              220 cfm (6.2 cmm)
                                                                                    Engine Cooling              100 cfm (2.8 cmm)
                        COOLING SYSTEM                                              Note: The pressure differential between the outside of the engine compart-
General                    Fresh water-cooled block, thermostatically-              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 manometer).
Operating Temperature      170 -190° F(77 - 88° C)
                                                                                                              TRANSMISSION
Coolant Pump               Centrifugal type, metal impeller, belt-driven.
Raw Water Pump             Positive displacement, rubber impeller,                  General                     (Hurth Standard Transmission) Case-
                                                                                                                hardened helical gears, with a servo-operated
                           belt-driven.                                                                         multiple disc clutch.
Raw Water Flow,            20.0 US gpm (75.5 Ipm) (measured                         Gear ratio (standard)       2.74 : 1 (HBW250 - 3R)
at 3600 rpm                before discharging into exhaust elbow).
                                                                                    Propeller Shaft             Right handed - standard transmission
Coolant (fresh water)      8.5 US qts (8.04 liters)
                                                                                    Propeller                   24 D x 12 P-2 blade or 22 D x 14 P-3
System Capacity                                                                     Recommendations             blade propeller should allow the engine
                                                                                    (using standard             to reach its full rated rpm (3600 + 000
                        EXHAUST SYSTEM                                              transmission                - 100) at'flill open throttle while under
                                                                                    2.74: 1 reduction)          way
                                                                                                                 ..
                                                                                                                     in forward gear.              .
Exhaust Elbow              70° elbow
                                                                                    Lubricating Fluid           ATF - type A or Dextran - /I or 11/
Exhaust Hose Size          3"I.D. hose                                              Transmission Sump
                                                                                    Capacity                    0.79 U.S. qts (0.75 liters) approximate




                                                                         Engines & Generators

                                                                              4
              gOA FOUR PROPULSION ENGINE PARTS IDENTIFICATION
                                   IDENTIFICATION                                                  TOP ENGINE
                                                                                                   OIL FILL




INSTRUMENT
CONNECTIONS




OUTPUT FLANGE
                                                                                   STARTER
                                                                                   WITH SOLENOID
                                   REAR                         RIGHT SIDE                FRONT
       COOLANT
       TEMPERATURE
       SWITCH




   OIL               OIL PREl;SUFlIEI                                        ENGINE OIL
   SENDER            SWITCH                                                  FILTER
                                   FRONT            LEFT SIDE                  REAR


                                                        Engines & Generators
                                                                :",5'
                                           TESTING FOR OVERHAUL
HOW TO DETERMINE WHEN                                                   Measuring Compression Pressure
TO OVERHAUL THE ENGINE                                                  To check the compression pressure, see ENGINE COMPRES-
Cause of Low Compression                                                SION TEST under ENGINE ADJUSTMENTS.
Generally, the time at which an engine should be overhauled             NOTE: Do not guess the conditions of other cylinders from a
is determined by various conditions such as lowered engine              result of testing one cylinder. Be sure to measure the com-
power output, decreased compression pressure, and increased             pression pressure for each cylinder. Lookfor cylinders with
fuel and oil consumption. The lowered engine power output,              dramatically (at least 20%) lower compression than the aver-
in the case of diesel engines, is not necessarily due to trouble        age of the other cylinders. If the weak cylinder is flanked by
with the engine itself, but is sometimes caused by injector             healthy cylinders, the problem is either valve- or head-gasket
nozzle wear or injection pump wear. It is most reasonable to            related. Very low compression in an adjacent cylinder indi-
judge by a decrease in compression pressure. The decrease in            cates gasket failure. Abnormally high readings on all cylin-
compression pressure is caused by many factors. It is, there-           ders indicate heavy carbon accumulations, a condition that
fore, necessary to determine a cause or causes on the basis of          might be accompanied by high pressures and noise.
data produced by periodic inspection and maintenance. Oil               NOTE: In case of severe vibrations and detonation noise,
analysis on a seasonal basis is a good means of monitoring              have the injectors overhauled by an authorized fuel injection
engine internal wear. When caused by worn cylinders or pis-             service center. Poor fuel quality, contaminants, and loss of
ton 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 parts.
These symptoms often appear together. Increased fuel con-
                                                                        When the decrease of compression pressure reaches its limit
sumption and hard engine starting can also result from exces-
                                                                        (see SERVICE STANDARDS), the engine must be over-
sive fuel injection, improper injection timing, and wear of the
                                                                        hauled. The engine also requires an overhaul when oil con-
injection pump and nozzles. They are also caused by defec-
                                                                        sumption is high, when blowby is evident, and when
tive electrical components such as the battery, alternator,
                                                                        compression values are at a minimum or below.
starter and air intake heater. Therefore it is desirable to judge
the optimum engine overhaul time by the lowered compres-                NOTE: Refer to the SERVICE STANDARDS chart during an
sion pressure caused by worn cylinders and pistons plus                 engine overhaul. It gives the measurements and values for
increased oil consumption. In diesel engines, satisfactory              the repair or replacement of the engine components.
combustion is obtained only under sufficient compression                NOTE: The ENGINE TROUBLESHOOTING section may be
pressure. If an engine lacks compression pressure, incomplete           helpful in determining the need for an engine overhaul.
combustion of fuel will take place even if other parts of the
engine are operating properly. To determine the period of
engine overhaul, it is important to measure the engine com-
pression pressure regularly. At the same time, the engine
speed at which the measurement of compression pressure is
made should be checked because the compression pressure
varies with engine rpm. The engine rpm can be measured at
the front end of the crankshaft.




                                                          Engines & Generators

                                                                    6
                                         ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems            NOTE: The engine:S- electrical system is protected by a 20
relating to engine service, the probable causes of these prob-            ampere manual reset circuit breaker located on a bracket.
lems, and the recommendations to overcome these problems.                 The preheat solenoid is mounted on the same bracket.

        PROBLEM                                 PROBABLE CAUSE                                      VERIFICATION/REMEDY

  HARD STARTING             LOW CRANKING SPEED
                            1. Engine oil viscosity too high.                           1. Replace engine oil wfth less viscous oil.
                            2. Run-down 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 and/or fuel shutoff.                a. Fill fuel tank. Open shutoff and bleed system.
                               b. Fuel filter/Water 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 and/or air in fuel system.                      6. Remove water and/or 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 TROUBLESHOOTING
    PROBLEM                          PROBABLE CAUSE                                         VERIFICATION/REMEDY

ENGINE IDLING   1. Idle speed too low.                                        1. Adjust idle stop as needed.
TOO 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 and/or 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 compartment.

ROUGH IDLING     MALFUNCTION OF ENGINE-RELATED 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 filter/water 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 pump.


ENGINE SLOWS     1. Fuel lift pump failure.                                   1. Check fuel pump operation.
AND STOPS
                 2. Switches and/or 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 tank(s); change filters
                                                                                 and bleed fuel system.

                                                                                                                            (continued)




                                                   Engines & Generators

                                                            8
                             ENGINE TROUBLESHOOTING
    PROBLEM                         PROBABLE CAUSE                                   VERIFICATION/REMEOY

LOW 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 V-belt.                                        2. Adjust or replace V-belt.
                 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 supply.

KNOCKING         ENGINE KNOCKS WITHOUT MUCH SMOKE
                 1. Main engine troubles.                                1. Check a. and b.
                    a. Overheated cylinder.                                 a. See ENGINE OVERHEATS/SHUTS
                                                                               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. After-injection drip.                                c. Repair or replace nozzle.
                    d. Nozzle needle valve seized.                           d. Replace needle valve.

ABNORMAL SOUND   CRANKSHAFT AND MAIN BEARING
OR 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 TROUBLESHOOTING
     PROBLEM                         PROBABLE CAUSE                                       VERIFICATION/REMEDY

ABNORMAL SOUND      CONNECTING ROD AND CONNECTING ROD BEARING
OR NOISE (Cont'd)   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 heat-damaged.       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 TIMING-RELATED 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 and/or incorrect fuel.                  1. Use No.2 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 drive-belt tension.                         2. Adjust.
                    3. Malfunction of alternator bearing.                   3. See Alternator Troubleshooting under
                                                                               DC ELECTRICAL SYSTEM.
                    4. Exhaust gas leakage.                                 4. Repair.

ROUGH OPERATION     INJECTION PUMP
(HUNTING)           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 TROUBLESHOOTING
    PROBLEM                        PROBABLE CAUSE                                          VERIFICATION/REMEDY

SMOKY EXHAUST   WHITISH OR PURPLISH
                1. Engine is running cold.                                     1. Warm-up 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 piston-to-cylinder 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 back-pressure in exhaust.                              5. Check for restrictions in exhaust system.
                6. Insufficient intake air.                                    6. Increa~e 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 no-load 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 setting.

EXCESSIVE
EXHAUST SMOKE
                1. Faulty injection timing.                                    1. Adjust timing.
                2. Water in injection pump, fuel filter or fuel filter/water   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 TROUBLESHOOTING
     PROBLEM                       PROBABLE CAUSE                                    VERIFICATION/REMEDY

INTERMITTENT
EXHAUST 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 fuel.

EXCESSIVE FUEL   ENGINE PROBLEMS
CONSUMPTION      1. Noisy knocking.                                     1. See KNOCKING.
                 2. Smoky exhaust.                                      2. See SMOKY EXHAUST.
                 3. Moving parts nearly seized or excessively worn.     3. Repair or replace.
                 4. Poor compression.                                   4. See Low Compression 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 rpm.

EXCESSIVE OIL    OIL LEAKAGE
CONSUMPTION
                 1. Defective oil seals.                                1. Replace oil seals.
                 2. Broken gear case gasket.                            2. Replace gasket.
                 3. Loose gear case attaching bolts.                    3. Retighten bolts.
                 4. Loose drain 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 TROUBLESHOOTING
      PROBLEM                         PROBABLE CAUSE                                    VERIFICATION/REMEDY

EXCESSIVE OIL       OIL LEVEL RISING
CONSUMPTION
(cDnt'd)            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 guide.

LOW 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 repair.

ENGINE OVERHEATS/   1. V-belt slackening or slippery with oil.              1. Adjust, replace or clean belt.
SHUTS 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 - tighten/replace.
                                                                               d. Air leak in system; run engine and open the
                                                                                  pressure cap to bleed air. Add coolant as
                                                                                  needed.




                                                     Engines & Generators

                                                           13
                                             ENGINE DISASSEMBLY
GENERAL DISASSEMBLY PROCEDURE                                          5. Drain the engine oil and the coolant from the engine.
NOTE: Before disassembly and cleaning, carefully check                 6. Carefully support and then unbolt the generator back
for defects which cannot be found after disassembly and                   end from the engine. See SPECIAL TOOLS-
cleaning.                                                                 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 engine's 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 dirt.
TRANSMISSION REMOVAL
1. Unplug the instrument panel wiring harness.
2. Drain the transmission fluid and the transmission oil
   cooler hoses.
3. Detach the oil cooler hoses.
4. Unbolt the transmission from the engine.
NOTE: For transmission service and maintenance, refer to
your transmission owners manual. To rebuild a transmis-
sion, contact your WESTERBEKE dealer or a qualified
marine transmission service facility.
If the transmission is not being rebuilt, it should be visually
inspected. Flush out and pressure-test the oil cooler, and
replace the coolant hoses. Inspect and lubricate the gear shift                             GENERATOR REMOVAL
linkage and the propeller shaft coupling. Clean and repaint
the transmission and change the transmission fluid. Refer to
the TRANSMISSIONS section in this manual.                              ENGINE mSASSEMBLY
GENERATOR REMOVAL                                                      With the transmission or generator separated from the
                                                                       engine, begin the following step-by-step procedure of the
1. Disconnect the AC wiring and unplug the engine's DC
                                                                       engine disassembly.
   wiring harness at the generator control panel.
                                                                       1. Clean the exterior of the engine of any deposits of dirt
2. Disconnect the battery cable connections and the
                                                                          and oil.
   engine ground cables.
                                                                       2. Mount the engine on a suitable engine stand for
3. Separate the exhaust hose at the water injected elbow.
                                                                          disassembly.
4. 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 washer.
3. 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 UP
4. Remove the engine wiring hamess in its entirety. Label
   the terminal connections to insure proper reattachment.
                                                                                                              FLYWHEEL
                                                                                                              WASHER




                                        LABEL THE TERMINAL
                                           CONNECTIONS


5. Remove the engine heat exchanger and the engine oil
   cooler/oil 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 GEAR
6. Remove the starter motor.                                               BREAK TOOL
7. 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 engine-mounted fuel fllter and fuel fllter
                   ENGINE DISASSEMBLY                                        bracket.


                                                             Engines & Generators

                                                                    15
                                               ENGINE DISASSEMBLY
20. 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 assembly.
21. Remove the air intake silencer.                                    30. Remove the push rods. Label each rod as to which valve
                                                                           it belongs.
22. Remove the two front lifting eyes and the rear lifting eye.
23. Remove the intake manifold.
24. Remove the alternator bracket.
25. Remove the crankcase breather hose.
26. Remove the rocker covers and gaskets.
27. Remove the fuel injectors, O-rings and gaskets from the
    cylinder head.



      ROCKER
      COVER
      COVER




    ROCKER
    COVER


                                                                                                                                    INNER
                                                                                                                                    SPRING

                                                                                       pu",'ODi                                     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 DISASSEMBLY
33. 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 section.


34. 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 DISASSEMBLY
35. 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



          g-_~.-·,w




               LUBRICATION SYSTEM
                  DISASSEMBLY




                                                    Engines & Generators

                                                         18
                                            ENGINE DISASSEMBLY
36. 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 PROCEDURE
1. 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 DISTORTION
2. 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 valve
3. 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 (standard):
Cylinder Head                                                               Intake: 1.892 in (48.05 mm)
1. Inspect the cylinder head for water leakage, fuel leakage,               Exhaust: 1.888 in (47.95 mm)
   damage and cracks. Replace it if necessary.
2. 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: 0.004 in (0.10 mm)                                                  C:


                                                                         a. When Dimension L is up to 0 - 0.020 in (0 - 0.5 mm)
                                                                               longer, the valve can be used as it is.
                                                                         b. When Dimension L is 0.020 - 0.059 in (0.5 -
                                                                            1.5 mm) longer, set a washer [inner dia.: 0.504 in
                                                                               (12.8 mm), outer dia.: 1.535 in (39 mm)] under the
                                                                               lower spring seat to adjust Dimension L to within the
                                                                               standard value.




                                  THICKNESS
                                  GAUGE
                                                                                                               WASHER
              MEASURING THE CYLINDER HEAD DISTORTION


3. If the cylinder head distortion exceeds the limit, replace
   it.


     A CAUTION: Do not attempt to repair the cylin-                      c. When Dimension Lis 0.059 in (1.5 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: 0.0303 - 0.0374 in                       cylinder head.
    (0.770 - 0.950 mm).                                               2. Check the valve seat for roughness or damage. If neces-
4. 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: 0.004 in (0.10 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: 4.512 in (114.6 rom)
   grinder to grind away the roughness and/or scars (to the                   Exhaust standard: 4.508 in (114.5 rom)
   minimum limit) of the seat surface, always checking the
   contact width and the contact position while grinding.                  Valve margin:
                                                                              Intake limit: 0.039 in (1.0 rom)
   Standard valve seat contact width:                                         Exhaust limit: 0.047 in (1.2 mm)
       0.0669 in (1.7 mm)
                                                                                  It~LVE 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: 0.353 -- 0.354 in (8.955 -- 8.980 mm)
3. To seat the valves, apply a thin coating of engine oil                         Exhaust: 0.352 -- 0.353 in (8.935 -- 8.960 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 CLEARANCE

Valve and Valve Guides                                                     b. Measure the inner diameters of each valve guide.
1. Inspection and repair of the valves.                                        Standard valve guide diameter:
   a. Inspect each valve and replace any that show damage,                        0.355 -- 0.356 in (9.018 -- 9.040 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:
             0.0015 - 0.0033 in (0.038 - 0.085 mm)
          Intake limit: 0.0050 in (0.127 mm)
          Exhaust standard:
            0.0023 - 0.0041 in (0.058 - 0.105 mm)
          Exhaust limit: 0.0050 in (0.127 mm)




                                                                       INDICATED
                                                                       SCALE



              MEASURING INNER DIAMETER OF VALVE GUIDE

4. 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 spring's free length and angle limit. Re-
                                                                      place if necessary.
                                                                      Free length:
                                                                          Inner spring:
                                                                             Standard: 1.83 in (46.6 mm)
                                                                             Limit:     1.76 in (44.7 mm)
                                                                          Outer spring:
                            REMOVING VALVE GUIDE                            Standard: 2.09 in (53.1 mm)
   b. Instalkltion                                                          Limit:      2.01 in (51.0 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 [0.65 in (16.5 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:
                                                                                 No.1: 2.044 - 2.045 in (51.910 -     51.940 mm)
                                                                                 No.2: 2.034 - 2.035 in (51.660 -     51.690 mm)
                                                                                 No.3: 2.024 - 2.025 in (51.410 -     51.440 mm)
                                                                                 No.4: 2.014 - 2.015 in (51.160 -     51.190 mm)


                         MEASURING SPRING'S FREE LENGTH

       Angle limit:
         Inner spring: 0.064 in (1.63 mm)
         Outer spring: 0.073 in (1.85 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:
                                                                                 No.1: 2.047 - 2.048 in (52.000 - 52.030 nun)
                                                                                 No.2: 2.037 - 2.038 in (51.750 - 51.780 nun)
                    SPRING ANGLE LIMIT                                           No.3: 2.028 - 2.029 in (51.500 - 51.530 mm)
Camshaft                                                                         No.4: 2.018 - 2.019 in (51.250 - 51.280 mm)
1. 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: 1.737 in (44.116 mm)
                                                                             the cylinder block.
          Limit:    1.717 in (43.616 mm)
                                                                              Standard oil clearance: 0.0024 - 0.0047 in
                                                                                 (0.060 - 0.120 mm)




                                                                             MEASURING INNER
                                                                             DIAMETER OF
        MEASURING THE CAM HEIGHT                                             CAMSHAFT BEARING

                                                                       Tappets
                                                                       1. Check the condition of the tappets.
2. Check the camshaft deflection.
    Limit: 0.003 in (0.08 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                                      0.559 - 0.560 in (14.218 -14.233 mm)
                                                      -.y'   WESTERBEKE
                                                             Eng/nes & 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
          0.563 - 0.564 in (14.288 - 14.319 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:
          0.0022 to 0.0040 in (0.055 - 0.101 mm)
                                                                   2. Check the oil clearance between the rocker arms and
       Oil clearance limit:
          0.0059 in (0.15 mm)                                         shafts.
                                                                      a. Measure the outer diameter of each rocker shaft.
Push Rods
                                                                          Standard rocker shaft diameter:
1. Check each push rod to see if either end is worn or dam-
                                                                             0.746 - 0.747 in (18.959 -18.980 mm)
   aged. Replace if necessary.                  "




     \~_--__====:::D!
       a======~--------
             CHECKING PUSH RODS

2. 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: 0.016 in (0.40 mm)



                                                         Engines & Generators

                                                              24
                                 ENGINE INSPECTION AND REPAIR
   b. Measure the inner diameter of each rocker arm
      bushing.
      Standard rocker arm bushing diameter:
         0.748 - 0.749 in (19.000 -19.021 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:
          0.0002 - 0.0024 in (0.020 - 0.062 mm)
       Oil clearance limit:
          0.0039 in (0.10 mm)
3. 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 piston's diameter at the skirt side of the
                                                                           piston 1.06 in (27 mm) above the bottom end of the
                                                                           piston.
                                                                            Standard piston outer diameter:
                                                                               Z: 3.9345 - 3.9350 in (99.937 - 99.950 mm)
                                       REPLACING ROCKER
                                       ARM BUSHING                             Y: 3.9350 - 3.9355 in (99.950 - 99.963 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 installed-oil must be
      able to flow through these openings.
   c. When the press-fitting 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.
                                                                                                                      1.06 in
       Standard clearance:                                                                                            (27mm)
          0.0008 - 0.0024 in (0.020 - 0.062 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 X-X and Y-Y
          Standard:                                                       directions (see illustration) for a total of six measurements.
              0.0020 - 0.0030 in (0.050 - 0.076 mm)
                                                                           a. Extent of wear.
          Limit:
              0.0017 and 0.0032 in (0.044 and 0.082 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: 3.9370 - 3.9375 in (100.000 -100.013 mm)
3. Checking the piston ring end gap.
                                                                                  Y: 3.9375 - 3.9380 in (100.013 - 100.026 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: 0.059 in (1.5 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 0.0079 in (0.20 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 liner.

4. 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: 0.0098 in (0.25 mm)                                   cylinders.
          Second ring: 0.0079 in (0.20 mm)
                                                                           a. Measure the outer diameter of each cylinder liner.
          Oil ring: 0.0079 in (0.20 mm)
                                                                               Standard outer diameter of cylinder liner:
                                                                                  A type: 4.0777 - 4.0782 in
                                                                                          (103.474 -103.487 mm)
                                                                                  B type: 4.0743 - 4.0748 in
                                                                                          (103.487 - 103.500 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:
                                                                           0.002 in (0.05 mm) per 1.97 in (50 mm)
          A type: 4.0748 - 4.0753 in
                  (103.500 - 103.513 mm)
          B type: 4.0753 - 4.0758 in
                  (103.513 - 103.525 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:
                                                                                1.3391 - 1.3399 in (34.012 - 34.033 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: 0.00051 in (0.013 mm)
          B type: 0.00154 in (0.039 mm)
                                                                                                     MEASURING CDNNECTING ROO
Connecting Rods                                                                                      BUSHING INNER DIAMETER

1. 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.                                                        1.3383 - 1.3386 in (33.993 - 34.000 mm)
2. 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
     0.002 in (0.05 mm) per 1.97 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 V-blocks.
       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
          0.0005 - 0.0016 in (0.012 - 0.040 mm)                               exceeds the specified limit, replace the crankshaft.
       Clearance limit:                                                       Deflection limit: 0.0020 in (0.05 mm)
          0.0024 in (0.06 mm)
4. Replacement of the connecting rod bushing.
   a. Use a press and a suitable pipe having a diameter of
       1.22 - 1.26 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                                  2.984 - 2.985 in (75.805 -75.825 mm)
                                          THE CONNECTING
                                          ROD BUSHING                            (2) Crankpin diameter
                                                                                     2.4060 - 2.4065 in (61.112 - 61.125 mm)
                                                                                 (3) Rear flange oil seal sliding surface
5. After pressing the bushing in, correct its inner diameter
                                                                                     3.9985 - 3.9995 in (101.562 - 101.587 mm)
   with a spiral expansion reamer so that the clearance will
                                                                                                       1
   be within the standard value.




                                                                                                        2
                                                                                           STANDARD JOURNAL DIAMETERS

                                                                              Journal wear limit: 0.0012 in (0.03 mm)
                                                                              Journal grinding limit: 0.0295 in (0.75 mm)
                                                                              Undersize bearings:
Crankshaft                                                                      0.010 in (0.25 mm), 0.020 in (0.50 mm),
1. Check the condition of the crankshaft.                                       0.0295 in (0.75 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:       0.146 - 0.157 in (3.7 - 4.0 mm)
                                                                                 Pin:           0.126 - 0.138 in (3.2 - 3.5 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: 0.0039 in (0.10 mm)
4. 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.


   J]1]) (rn) rn ffi
   jJ](~)mm
                       MAIN BEARINGS & THRUST WASHERS

Rear Oil Seal - Crankshaft
1. Inspecting the oil seal
    a. Check the oil seal lip for wear, fraying or other dam-
       age and, if necessary, replace it.
2. 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
       press-fit 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 0.1181 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 outer-facing 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 outer-facing side of the fly-
                                                                                wheel with a thickness gauge and a straightedge. If
                                                                                distortion exceeds the limit, replace the flywheel.
                                                                                 Limit: 0.008 in (0.20 mm)




                                                                                     MEASURING
                                                                                     FLYWHEEL
                                                     INSTALLATION
                                                                                     DISTORTION

                  REMOVAL
                        REAR OIL SEAL - CRANKSHAFT
                                                                    Engines & Generators

                                                                        29
                                 ENGINE INSPECTION AND REPAIR
Timing Gears                                                        4. Check the oil clearance between the idler gear and the
                                                                       idler gear hub.
1. 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:
                                                                              1.732 - 1.734 in (44.009 - 44.034 mm)




                      TIMING GEARS

2. 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: 0.0039 - 0.0079 in (0.10 - 0.20 mm)
      Limit:    0.0118 in (0.30 mm)
                                                                       b. Measure the outer diameter of the idler gear hub.
                                                                           Standard idler gear hub diameter:
                                                                              1.730 - 1.731 in (43.950 - 43.975 mm)




                MEASURING TIMING GEAR BACKLASH                                            MEASURING
3. Measure the end play of the idler gear with a dial guage.                              IDLER GEAR HUB
                                                                                          OUTER DIAMETER
    Standard end play:
      0.0020 - 0.0071 in (0.05 - 0.18 mm)                               c. Calculate the oil clearance by subtracting the outer
    End play limit: 0.0098 in (0.25 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: 0.0013 - 0.0033 in
                                                                                  (0.034 - 0.084 mm)
                                                                              Limit:      0.0059 in (0.15 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
GENERAL 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 No.2 or a high-tack 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 O-rings.
·   Be careful not to mix bolts and nuts. Both metric and
    S.A.E. bolts are used on various engine assemblies.
                                                                             INSTALLING
·   Replace plain bearings if they are peeling, burned or                    VALVE SEALS
    otherwise damaged.
·   Reassemble parts (e.g. 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 No.2 or equivalent.
    Don't 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, 2/3, and 111 torque.
    Exceptions are torque-to-yield 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 torque:
ENGINE REASSEMBLY                                                              8.1 - 13.0 ft-Ib (1.2 - 1.8 m-kg)

Valve Seals
NOTE: Always replace the valve seals during an engine
                                                                                    ~0
overhaul.
1. Apply engine oil to the valve guides.
2. Install the lower spring seats.
3. 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 REASSEMBLY
Tappets
Apply engine oil to the tappets and insert them into their
original 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 bearing.
Camshaft
                                                                         b. Position the plastigauge on top of the main journal
1. Apply engine oil to the camshaft and insert it into the
                                                                            (in the journal's 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 ft-Ib (10.0 - 10.7 m-kg)




                      INSTAUING CAMSHAFT

                                                                            4
2. Install the camshaft retaining plate with the flush side
   facing the cylinder block.
   Camshaft retaining plate tightening torque:
       14 - 19 ft-Ib (1.9 - 2.6 m-kg)


                                                                                      MAIN BEARING CAP TIGHTENING SEQUENCE

                                                                         d. Remove the main bearing cap and measure the oil
                                                                            clearance.
                                                                             Standard main bearing cap oil clearance:
                                                                                0.0023 - 0.0035 in (0.059 - 0.090 mm)
                                                                             Oil clearance limit: 0.0047 in (0.12 mm)
      INSTALLING CAMSHAFT
      RETAINING PLATE
                                                                                                                      \\ \!---...
Crankshaft
1. 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:                                                        0.0055 - 0.0150 in (0.14 - 0.39 mm)
                                                                        End play limit: 0.015 in (0.40 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:
                                                                            0.0896 - 0.0915 in (2.275 - 2.325 mm)
                     (@1
                MAIN BEARING CAP NUMBER & ARROW
                                                                         Oversize thrust washer width:
                                                                            0.0966 - 0.0985 in (2.453 - 2.503 mm)


3. 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 of
4. Apply engine oil to the thrust washers, then install them             the C~Ck~ .1J.-.-~
   to the center part of the main journal.                                         G                     ",-J~
                                                                              )s       ()      0        A    ()        O-","""A~
     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 REASSEMBLY
2. 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.
                                                                                                             ~~t-1"- COMBUSTION
                                                                                                                       CHAMBER
                                                                                                                       CUTOUT




              OILING THE CYLINDER LINERS

3. 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 won't
                                                                                  come out.




                  INSTALLING CYLINDER LINERS

Pistons and Connecting Rods
1. 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 ft-Ib (8.2 - 9.0 m-kg)
                       PISTON RING OPENINGS
                                                                            Standard oil clearance:
3. Install the pistons and connecting rods.                                    0.0014 - 0.0030 in (0.036 - 0.076 mm)
   a. Fit the connecting rod bearing to the connecting rod                  Oil clearance limit: 0.0020 in (0.05 mm)
      and apply engine oil.                                                 Undersize connecting rod bearings:
   b. After cleaning the inner surface of the cylinder liner,                 0.010 in (0.254 mm), 0.020 in (0.508 mm),
      apply engine oil.                                                       0.030 in (0.762 mm)
   c. Insert each piston and connecting rod assembly into
      the cylinder block using a piston insertion tool (com-
      merciallyavailable).




            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.
           0.0094 - 0.0130 in (0.239 - 0.379 mm)
                                                                                       Back plate tightening torque:
       End play limit: 0.0157 in (0.40 mm)
                                                                                          28 - 38 ft-Ib (3.8 - 5.3 m-kg)
       NOTE: Measure each connecting rod's 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 ft-Ib (8.2 - 9.0 m-kg)


          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 ft-Ib (18 - 20 m-kg)
Crankshaft Rear Oil Seal Flange
Install the crankshaft rear oil seal flange, with its gasket and
oil seal.
NOTE: Apply engine oil to the oil seal before assembly.




                                                                                                             SECURING THE FLYWHEEL




                                                                         Engines & Generators

                                                                              36
                                             ENGINE REASSEMBLY
Timing Gear Case                                                   4. Trim off the protruding parts of the gasket between the
                                                                      cylinder block and the timing gear case.
1. 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 silicon-based sealant to the areas where the
                                                                      gasket was trimmed off.
2.




                                                                                       APPLYING   SEALAN~
                                                                   Lower Block
                              INSTAUING TIMING                     1. Apply a silicon-based sealant to the ends of the block-to-
                              GEAR CASE GASKET
                                                                      lower-block front and rear gaskets, and install them.
                                                                      Apply the sealant to both ends of each gasket.
3. Install the timing gear case.
     Timing gear case tightening torque:                                                                BLOCK·TO-lOWER-BLOCK
                                                                                                        REAR GASKET
        14 - 19 ft-lb (1.9 - 2.6 m-kg)
                                    ~
                                                                         , /   ~~~EALANT          ~?                AREA

                                                                                                           ~




                                                                                                          AP:~: in (3 mm) ~~~
                                                                                                          SILICON-BASED
                                                                                                          SEALANT.
                                                                                                          BOTH ENDS
           INSTAWNG TIMING GEAR CASE

                                                                                INSTALLING BLOCK·TO·LOWER·BLOCK GASKET
                                                                                          (REAR GASKET SHOWN)



                                                        Engines & Generators

                                                              37
                                             ENGINE REASSEMBLY
2. Install the right and left block-to-Iower-block 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 ft-Ib (1.9 - 2.6 m-kg)                                   Oil Filter Housing
                                                                       Install the oil filter housing, gasket and oil filter.
                                                                            Oil filter housing tightening torque:
                                                                                14 - 19 ft-Ib (1.9 - 2.6 m-kg)




                                                                                                                                OIL
                                                                                                                                FILTER
                                                                                                                                HOUSING



Oil Pump
Remove the oil pipe from the oil pump and install the
oil pump. Re-install the oil pipe.
NOTE: Install the oil pipe after coating the O-ring with
engine oil.
                                                                                                            ~ ~.LL--_
    Oil pump tightening torque:                                                         INSTALLING OIL FILTER HOUSING
        Large bolts: 14 - 19 ft-Ib (1.9 - 2.6 m-kg)
    Oil pipe tightening torque:                                        Timing Gears
        Small bolts: 5.8 - 8.0 ft-Ib (0.8 - 1.1 m-kg)                  1.




                                                                                                     CRANKSHAFT
                                                                                                     GEAR
Set the rubber gasket between the lower block and the oil                                INSTALLING CRANKSHAFT GEAR
sump, 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 ft-Ib (1.9 - 2.6 m-kg)                                    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 REASSEMBLY
3. 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 ft-Ib (1.9 - 2.6 m-kg)
                                                                               B: 27 - 38 ft-Ib (3.8 - 5.3 m-kg)




                                                                                                                             A




                                         H~"   MARKS
                  INSTAWNG CAMSHAFT GEAR

                                                                                                           TIGHTENING FUEL
4. 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 Cover
5. 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 ft-Ib (1.9 - 2.6 m-kg)
       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 REASSEMBLY
Crankshaft Pulley                                                Cylinder. Head
Install 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 ft-lb (35 - 40 m-kg)                            block and the bottom of the cylinder head.


                                                                   A CAUTION: Use a new cylinder head gasket.




              INSTALLING CRANKSHAFT PULLEY
                                                                                     CYLINDER HEAD GASKET
Coolant Pump
Install the coolant pump and gasket.                             Push Rods
    Coolant pump tightening torque:                              Insert the push rods.
       14 - 19 ft-lb (1.9 - 2.6 m-kg)
                                                                   A CAUTION: Make sure the ends of the push rods
                                                                   are set in the hollowed portion of the tappets.




                                                                     ---:;;;=:~~--====~----
                 INSTALLING COOLANT PUMP

Alternator Bracket
Install the alternator bracket.
                                                                               ~~        INSERTING PUSH RODS
                                                                                                                           r
    Alternator bracket tightening torque:
       27 - 38 ft-Ib (3.8 - 5.3 m-kg)




                                                                          -           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: 5.93 - 5.96 in (150.7 - 151.3 mm)
                                                                                        Short size: 4.79 - 4.82 in (121.7 -122.3 mm)
                                                                                    Limit:
                                                                                        Long size: 5.98 in (152.0 mm)
                                                                                        Short size: 4.84 in (123.0 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 ft-Ib (1.9 - 2.6 m-kg)
  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 ft-Ib (6.0 m-kg) 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                 ~~~~I\~llIrt
                                          ,   SPRING        TAPER PIN

                                                    ~1n~RECESS
 #1 ROCKER


WAVE WASHER ~:~<..i..

                                     SHAFT~ S~A~~OP
     ~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 REASSEMBLY
3.




                                                                                        INSTALLING INTAKE MANIFOLD
                                                                                      ..
                 MARKING THE CYLINDER HEAD BOLTS                       Air Intake Silencer
4. Using these marks as reference points, tighten the cylin-
   der head bolts 90" (90" - 105°) in the same sequence.
5. 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 Filter
Fuel Injectors                                                         1. Install both front lifting eyes.
Install the fuel injectors, O-rings, gaskets, injector brackets           Front lifting eye tightening torque:
and fuel return line.                                                         Water pump side:
NOTE: Be sure the notch on the injector bracket is engaged                        Small bolt:       14 - 19 ft-Ib (1.9 - 2.6 m-kg)
in the hole in the cylinder head.                                                 Large bolt:       47 - 66 ft-Ib (6.5 - 9.1 m-kg)
     Fuel injector tightening torque:                                         Alternator side:
        34 - 40 ft-Ib (4.7 - 5.5 m-kg)                                            27 - 38 ft-Ib (3.8 - 5.3 m-kg)

                            ®




                  INSTALLING FUEL INJECTORS

Fuel Return Lines                                                                LEFT SIDE                                 RIGHT SIDE
Install the fuel injector's return lines.                                                  INSTALLING FRONT LIFTING EYES
Intake Manifold
Install the intake manifold and gasket.
     Intake manifold tightening torque:
         14 - 19 ft-Ib (1.9 - 2.6 m-kg)
                                                            Engines & Generators

                                                                  42
                                                  ENGINE REASSEMBLY
2. 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 ft-lb (1.9 - 2.6 m-kg)                               Joining bolts:
      Fuel filter bolts: 27 - 38 ft-Ib (3.8 - 5.3 m-kg)                                A: 17 - 26 ft-lb (2.4 - 3.6 m-kg)
                                                                                       B: 9 - 13 ft-lb (1.2 - 1.8 m-kg)
                  ~                      P\~II....-~                                Bracket bolts:
                                                                                       C: 14 - 19 ft-lb (1.9 - 2.6 m-kg)
                                                                                       D: 5.9 - 8.0 ft-lb (0.8 - 1.1 m-kg)


                                                              REAR
                                                              LIFTING
                                                              EYE


                                                                                                                                           D

         INSTALLING REAR LIFTING EYE & FUEL FILTER ASSEMBLY

Fuel Feed Line
1. Install the fuel feed line from the fuel lift pump to the                                                ~NSTALLING   INJECTION
                                                                                                                   PUMP OIL LINE
   engine-mounted fuel filter.
    Fuel feed line tightening torque:                                        6. Install the fuel injection lines, and their clamps, from
       Joining bolts: 22 - 25 ft-lb (3.0 - 3.5 m-kg)                            the injection pump to the injectors.
       Bracket bolts:
           Small:      5.8 - 8.0 ft-lb (0.8 - 1.1 m-kg)
           Large:      14 - 19 ft-lb (1.9 - 2.6 m-kg)                              A CAUTION: Be careful not to damage the fuel
                                                                                   injection lines when installing them.

                                                                                 Injection line tightening torque:
                                                                                     Joining nuts: 18 - 22 ft-lb (2.5 - 3.0 m-kg)




   FEED LINE



                     INSTALLING FUEL FEED LINE

2. Install the fuel line from the fuel filter to the injection
   pump.
                                                                                           INSTALLING FUEL INJECTION LINES
3. Install the injection pump return line.
4. 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: 21.7 - 25.3 ft-lb (3.0 - 3.5 m-kg)                          Oil level dipstick tightening torque:
       Bracket bolt: 5.8 - 8.0 ft-lb (0.8 to 1.1 m-kg)                               14 - 19 ft-lb (1.9 - 2.6 m-kg)
                                                                             NOTE: Apply engine oil to the O-ring before installation.




                                                                                                                          INSTALLING OIL
                                                                                                                         LEVEL DIPSTICK
                     INSTALLING FUEL SUPPLY
                     LINE TO FUEL LIFT PUMP                         Engines & Generators

                                                                        43
                                               ENGINE REASSEMBLY
Raw Water Pump                                                           1. Install the alternator cap screw through the alternator leg
                                                                            (underside) and spacer into the alternator bracket.
Install the raw water pump and drive belt. Make sure the raw
water pump's pulley is in proper alignment with the crank-               2. Swing the alternator into position on the adjusting strap
shaft pulley. Check the belt tension. See the RAW WATER                     and fasten. Lightly tighten.
PUMP 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 TROUBLESHOOTING for testing
                                                                         information.
                                                                            Alternato~  strap tightening torque:
                                                                               14 - 19 ft-Ib (1.9 - 2.6 m-kg)
                                                                            Alternator tightening torque:
                                                                               Strap bolt: 14 - 19 ft-Ib (1.9 - 2.6 m-kg)
                                                                               Long bolt and nut:
                                                                                   27 - 38 ft-Ib (3.8 - 5.3 m-kg)




                      RAW WATER PUMP


Coolant Pump Connector and Hose




                                                                                              INSTALLING ALTERNATOR

                                                                         Thermostat
                                                                         If the thermostat was removed, reinstall the thermostat, gas-
                                                                         ket and housing.
                                                                             Thermostat tightening torque:
                                                                                5.8 - 8.0 ft-Ib (0.8 - 1.1 m-kg)



        COOLANT PUMP
        CONNECTOR 11< HOSE


Alternator
Install the alternator, alternator adjusting strap and drive belt
as 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 REASSEMBLY
Rocker Cover and Crankcase Breather Hose                                 Bellhousing (propulsion engines only)
1. Apply Three Bond (1382) to the rocker cover gasket at                 Install the bellhousing.
   the locations shown in the illustration.
                                                                         Heat Exchanger
2. Install the rocker cover and its gasket.
                                                                         Mount the engine heat exchanger. The heat exchanger should
3. 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
             ~::n=(-r-()~=n=(-)=n=()-:3
                   ,                      ,                              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 torque:
4. Put the rocker cover outer gasket on the rocker cover's                       9 - 13 ft-Ib (1.2 - 1.8 m-kg).
   cover and install.
                                                                         Engine Wiring Harness
    Rocker cover's cover tightening torque:
       1.4 - 2.5 ft-Ib (0.2 - 0.35 m-kg)                                 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 COVER'S COVER                            14 - 20 ft-Ib (1.7 - 2.7 m-kg)
                                                                         2. Reinstall the marine transmission and fill with the
Exhaust Manifold                                                            proper lubricant.
Install the exhaust manifold (see EXHAUST MANIFOW                           NOTE: Some transmissions, such as the Borg Warner
page).                                                                      Velvet Drive, require oil coolers. Oil coolers should be
    Exhaust manifold tightening torque:                                     cleaned, pressure tested and repainted at engine over-
       17 - 20 ft-Ib (2.3 - 2.7 m-kg)                                       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 COOLER
Back Plate
Attach the back plate.                                                   3. Fill the engine cooling system with pre-mixed coolant
    Back plate tightening torque (9/16" socket):                            (50/50 good quality antifreeze and distilled water). Fill
       27 - 38 ft-Ib (3.8 - 5.3 m-kg)                                       the engine oil sump to the mark on the dipstick with
                                                                            lube oil (A.P.1. spec. CF or CG-4).
Fuel filter Assembly                                                        The engine should be test run under load prior to rein-
Mount the fuel filter assembly.                                             installing. At this time readjust the valve clearances on
    Fuel r.Jter tightening torque:                                          the hot engine.
       33 - 49 ft-Ib (4.6 - 6.8m-kg)                                        Allow the engine to cool to room temperature and re-
                                                                            torque the cylinder head bolts and re-check the valve
Transmission Damper Plate (propulsion engines only)                         clearances (see ENGINE ADJUSTMENTS).
Install the transmission darnper plate.
    Damper plate tightening torque:
      14 - 20 ft-Ib (1.7 - 2.7 m-kg)                      Engines & Generators

                                                                    45
                                             ENGINE REASSEMBLY
GENERATORS
1. 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 schematics.

2. Fill the engine cooling system with pre-mixed coolant
   (50/50 good quality antifreeze and distilled water). Fill
   the engine oil sump to the mark on the dipstick with lube
   oil (A.P.I. spec. CF or CG-4).
   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 re-check the valve
   clearances (see ENGINE ADJUSTMENTS).

EXHAUST MANIFOLD
See the EXHAUST MANIFOW page for inspection and
assembly information.




                                                         Engines & Generators

                                                                 46
                                             EXHAUST MANIFOLD
INSPECTION                                                               ASSEMBLY
The exhaust manifold, which was disassembled from the                    1. If the manifold was removed as an assembly and left
cylinder head, should be inspected before reassembly.                       intact, it can be replaced on the cylinder head in the
1. Remove the exhaust nipples, elbows and plugs from the                    reverse order of removal.
   manifold.                                                                Do not reuse the gaskets; install new ones.
2. 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 seal-
3. Flush out the manifold's interior with a liquid cleaner and                 ant on these gaskets.
   rinse thoroughly with fresh water.                                       b. Gradually tighten each fitting to ensure proper
4. 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 steps.

S. Flush out the coolant recovery tank and its connecting                       Manifold mounting bolts torque:
   tube.                                                                          12 -17 ft-lb (1.6 - 2.4 m-kg)
                                                                         2. Reinstall the exhaust connections. Use new gaskets and
                                                                            check the exhaust elbow-to-manifold clamp's 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~   PRESS.URE 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 mechanic.
VALVE CLEARANCE ADJUSTMENT                                                   DRIVE BELT ADJUSTMENT
1. Remove the cylinder head cover.                                           Proper inspection, service and maintenance of the drive belts
2. 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 SCHEDULE).
3. 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 and/or cause the alternator to
    Intake: No.1 and No.2 cylinders
                                                                             wear out prematurely. Excessive drive belt tension can also
    Exhaust: No.1 and No.3 cylinders
                                                                             cause rapid wear of the belt and reduce the service life of the
    Valve clearance (engine cold):
                                                                             coolant pump's bearing. A slack belt or the presence of oil on
      Intake: 0.012 in (0.30 mm)                                             the belt can cause belt slipping, resulting in high operating
      Exhaust: 0.014 in (0.3S mm)
                                                                             temperatures and tachometer variations.
                                                                             The drive belt is properly adjusted if the belt can be deflected
                                                                             no less than 3/8 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 belt's 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 and
4. Turn the crankshaft one turn so that the piston of No.4
                                                                                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: No.3 and No.4 cylinders
   Exhaust: No.2 and No.4 cylinders
          Check these valve clearances when the piston"of
          No.1 Cylinder is at the TOC of its compression stroke.
            I       i         I                           I
           1 IN   1 EX       2 IN "                     3 EX
            1-1--

                                                                                               3/8" TO 1/2" DEFLECTION"




                                                                                            ADJUSTING BELT TENSION


    - /-iFRONT
     ~OFENGINE



S. 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 mechanic.

TORQUING 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 photoelectric-type tachometer to check the idle speed.
                                                                        NOTE: In a new installation having new instrument panels,
ENGINE COMPRESSION TEST                                                 the tachometer may not always be correctly calibrated to the
                                                                        engine's rpm This calibration should be checked in all new
To check the engine's compression pressure, warm up the                 installations.
engine, shut off the raw water through-hull, remove all the
fuel injectors, disconnect the fuel shut-off solenoid wire, and         1. Warm up the engine to normal operating temperature.
install a compression adapter in the injector hole. Connect a              Remove any specks on the crankshaft pulley with a clean
compression tester on the adapter and crank the engine with                cloth and place a piece of suitable reflecting tape on the
the starter motor until the pressure reaches a maximum value.              pulley to facilitate the use of the tachometer.
Repeat this process for each cylinder. Look for cylinders               2. Start and idle the engine.
with dramatically (at least 20%) lower compression than the             3. Aim the light of the tachometer onto the reflecting tape to
average of the others.                                                     confirm the engine speed. Check the instrument panel
    Compression pressure:                                                  tachometer reading. Adjust the tachometer in the panel
      Standard: 4261b/in2(30 kglcm2) @ 290 rpm                             by using the instrument calibration pod as needed to bring
      Limit:     384 Ib/in2(27 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 rpm




If a weak cylinder is flanked by healthy cylinders, the prob-
lem is either valve- or piston-related. Check the valve clear-
ances for the weak cylinder, adjust as needed, and test again.                             CHECKING THE IDLE SPEED
If the cylinder is still low, apply a small amount of oil into .
the cylinder to seal the rings, and repeat the test. If the com-
pression comes up, the rings are faulty.
Abnormally high readings on all cylinders indicate heavy
carbon accumulation, a condition that might be accompanied
by high pressures and noise.
NOTE: In case of severe vibrations and detonation noise, have
the injectors checked and overhauled by an authorizedfuel
injection service center. Poor fuel quality, contaminants and
loss of positive fuel pressure to the injection pump will result
in 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 mechanic.

Adjusting the Idle Speed
1. Loosen the locknut on the idle adjustment bolt on the
   fuel injection pump.
2. 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 counterclockwise.
3. Tighten the locknut.
4. Race the engine several times to ensure the idle speed
   remains as set.
NOTE: Should the engine rpm be in question, verify the
tachometer readings as shown at the instrument panel
with a mechanical or strobe-type tachometer at the
engine crankshaft.




  FUEL INJECTION
  PUMP




              IDLE SPEED ADJUSTMENT




                                                         Engines & Generators

                                                              50
                                             LUBRICATION SYSTEM
DESCRIPTION                                                                           +
The lubricating system is a pressure feeding system using an
oil pump. The engine oil is drawn from the oil sump by the                                             DlL PRESSURE SWITCH
oil pump, which drives the oil, under pressure, through the                                             PROPULSION ENGINE
oil filter, oil cooler and various lubricating points in the
engine. The oil then returns to the oil sump to repeat the con-
tinuous cycle. When the oil pressure exceeds the specified
pressure, the oil pushes open the relief valve in the oil pump                                             .         .~YOPEN
                                                                                      +
and returns to the oil sump, keeping the oil pressure within
its specified range.
                                                                                                         FUEL SOLENOIO       .   1
TESTING THE OIL PRESSURE                                                                               OIL PRESSURE SWITCH
                                                                                                                                 ~
                                                                                          ~..JUL""""        GENERATOR
To test the oil pressure, remove the oil pressure sender, then
install a mechanical oil pressure gauge in its place. After
warming up the engine, set the engine speed at 1800 rpm                OIL PUMP
(generators) or 3600 rpm (propulsion engines) and read the
oil pressure gauge. If the pressure is not within the specified        Removing the Oil Pump
range, check each part and repair if necessary.                        Remove the following components from the engine in the
   Oil pressure:                                                       numbered sequence (see illustration):
       30 - 35 Ib/in2 (2.1 - 2.5 kg/cm') at 1800 rpm                      1.   Stiffeners
       50 - 55 lb/in' (3.5 - 3.9 kg/cm') at 3600 rpm                      2.   Oil pan
                                                                          3.   Oil pan gasket
                                                                          4.   Oil pipe attatching bolts.
                                                                          5.   Oil pipe.
                                                                          6.   Oil pump




                         TESTING THE
                         OIL PRESSURE



Low Oil Pressure
The specified safe minimum oil pressure is 4.3-1.4 psi
(0.3--0.1 kg/cm». A gradual loss of oil pressure usually indi-
cates worn bearings. For additional information on low oil pres-
sure readings, see the ENGINE TROUBLESHOOTING section.
OIL PRESSURE SWITCH/SENDER
When performing an engine overhaul, replace the oil pressure
switch and the oil pressure sender.
When installing the new parts, apply teflon sealant to the thread-
ed ends, being careful not to close off the oil hole in the sender.
    Oil pressure switch and sender torque:
        9 - 13 ft-Ib (1.2 - 1.8 m-kg)


      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 Snap-On, Proto, New Britain and
      others. Damage to the switch will cause oil leaks
      and/or switch failure.


                                                                                               REMOVING THE
                                                                                                 OIL PUMP
                                                          Engines & Generators

                                                                  51
                                            LUBRICATION SYSTEM
Disassembly                                                             b. Check the relief valve for wear or damage.
Disassemble the oil pump components in the following                    c. Check for a weak or broken relief valve spring.
numbered sequence (see illustration).                                      Measure the spring's free length.
   1. Oil strainer                                                          Standard relief valve spring free length:
   2.   Oil strainer gasket                                                    1.69 - 1.76 in (42.8 - 44.8 mm)
   3.   Pump cover                                                                        RELIEF VALVE       RELIEF VALVE




                                                                            ~~
   4.   Outer rotor
   5.   Drive gear (use a press and a suitable mandrel)
   6.   Pumpbody
   7.   Innerrotor~5
   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:
                                                                           0.0015 - 0.0030 in (0.04 - 0.08 mm)
                                                                        Clearance limit: 0.0039 in (0.10 mm)




               OIL PUMP                    4


                                     ___-3
   2


                                  .~
                                 1     ~~.
                                 (j--,10
                                                                     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:
                                                                            0.0016 - 0.0079 in (0.04 - 0.20 mm)
Inspection                                                               Clearance limit: 0.0098 in (0.25 mm)

1. 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 SYSTEM
4. 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:
       0.0039 - 0.0083 in (0.10 - 0.21 mm)
    Clearance limit: 0.0098 in (0.25 mm)




                                                                            Reassembly
                                                                            Reassemble the oil pump in the reverse of the order of disas-
                                                                            sembly.
5. 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                    5.8 - 8.7 ft-lb (0.8 - 1.2 m-kg)
   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.
       0.0012 - 0.0039 in (0.03 - 0.10 mm)                                  NOTE: When installing the oil pump set screw, apply sealing
    Clearance limit: 0.0059 in (0.15 mm)                                    compound on the set screw threads.

LUBRICATION SYSTEM SPECIFICATIONS
  Lubrication system type                                                     Pressure-fed
                            Type                                              Trochoid
  Oil pump
                            Relief valve opening pressure                     92.4 Ib/in2 (6.5 kg/cm2)
                            Type                                              Full flow, paper element, spin-on type
   Oil filter
                            Oil filter relief valve opening pressure          14.2 Ib/in2 (1.0 kg/cm2)
   Oil cooler               Type                                              Water cooled
   Oil filter body          Relief valve opening pressure                     56.9 Ib/in2 (4.0 kg/cm2)
  Oil sump capacity (not including oil filter/cooler assembly)                6.3 U.S. Quarts (6.0 liters)
  Oil filter capacity                                                         1.1 U.S. Quarts (1.0 liters)
  Oil Grade                                                                   API Specification CF or CG-4, SAE 30, 10W-30, 15W-40




                                                                 Engines & Generators

                                                                       53
                                                COOLING SYSTEM
DESCRIPTION                                                            The raw water pump is a self-priming, rotary pump with a
                                                                       non-ferrous housing and a neoprene impeller. The impeller
Westerbeke marine diesel engines are designed and equipped
                                                                       has flexible vanes which wipe against a curved cam plate
for fresh water cooling. Heat produced in the engine by com-
                                                                       within the impeller housing, producing the pumping action.
bustion and friction is transferred to fresh water coolant
                                                                       This pump must not be run dry as water acts as a lubricant
which circulates throughout the engine. This circulating fresh
                                                                       for the impeller.
water coolant cools the engine block, its internal moving
parts, and the engine oil. The coolant is, in tum, cooled by           Heat Exchanger
raw water, and the raw water carries the transferred heat over-
                                                                       The engine heat is transferred externally from the fresh water
board through the exhaust system. The fresh water coolant
                                                                       coolant to the raw water in the heat exchanger. The raw
and raw water circuits are independent of each other. Using            water flows through tubes in the heat exchanger while the
only fresh water coolant within the engine allows the cooling
                                                                       fresh water coolant flows around the tubes. The engine heat
water passages to stay clean and free from harmful deposits.           is conducted from the fresh water coolant through the tube
Coolant Pump                                                           walls to the raw water.
The fresh water coolant is pumped through the engine by a              Thermostat
circulating pump. The coolant passes through the thermostat            A thermostat, located near the manifold at the front of the
into the manifold, to the heat exchanger where it is cooled,
                                                                       engine, controls the coolant temperature as the coolant contin-
and returned to the engine block via the suction side of the           uously flows through the closed cooling circuit. When the
circulating pump.
                                                                       engine is first started, the closed thermostat prevents coolant
Raw Water Pump                                                         from flowing (some coolant is by-passed through a hole in
                                                                       the thermostat to prevent the exhaust manifold from over-
The raw water flow is created by a positive displacement               heating).As the engine warms up, the thermostat graduallY
impeller pump. This pump draws water directly from the
                                                                       opens.
raw water source (ocean, lake, or river) through a hose to the
water strainer. The raw water passes from the strainer                 When the engine is started cold, external coolant flow is pre-
through the raw water pump to the heat exchanger, then to the          vented by the closed thermostat (although some coolant flow
transmission oil cooler (propulsion engines only). The raw             is bypassed around the thermostat to prevent the exhaust
water is then discharged into the water-injected exhaust el-           manifold from overheating). As the engine warms up, the
bow, mixing with and cooling the exhaust gasses. This mix-             thermostat gradually opens, allowing the engine's coolant to
ture of exhaust gas and raw water is discharged overboard by           flow unrestricted to the external portion of the cooling system.
the engine's exhaust gas discharge pressure.
                                                                   COOLANT
                                                                   TEMPERATURE
                                                                   SWITCH
                                                                                                                     ¢   COOLANT

                                                                                                                     ·. RAW WATER

                                                                                                                     NOTE: Anti·slphon
                                                                                                                     valve is not shown




           TO TRANSMISSION                                                    COOLING SYSTEM
           OIL COOLER (PROPULSION
           ENGINES ONLY)
                                                         WESTERBEKE                                           COOLANT DRAIN
                                                                                                              Located under
                                                         Engines & Generators                                 heat exchanger
                                                                                                              near engine's
                                                                                                              back plate
                                                                  54
                                                COOLING SYSTEM
HEAT EXCHANGER                                                        Replacing The Thermostat
The heat exchanger should be inspected and serviced during            Remove the cap screws and disassemble the thermostat
an engine overhaul.                                                   housing as shown. When installing the new thermostat and
1. 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 over-tighten the cap
   covers and gaskets.                                                screws.
2. 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 housing.
3. Clean out any zinc debris, and pressure test the coolant
   and raw water passages.
4. When reassembling, install new gaskets and O-rings.
   Apply some lubricant to the new gaskets and to the
   petcocks and fittings as you install them.
S. Install a new zinc anode.
NOTE: All of the above can be accomplished by sending the
heat exchanger to a heat exchangerlradiator service shop.                                                          GASKET
They will also service the transmission and engine oil                                                             PUT A THIN COAT OF
                                                                                                                   SEALANT ON GASKET
coolers.                                                                   THERMOSTAT                              BEFORE ASSEMBLY
                                                                           HOUSING
6. Repaint the assembled heat exchanger with Westerbeke
   heat-resistant spray enamel.
7. Reconnect all hoses, replacing them as needed.
8. Refill the system with coolant.
9. Pressure test the system and check for leaks.
           Dro---ZINC
                   ANODE
                                                                                         THERMOSTAT ASSEMBLY

                                                                      COOLANT PUMP
                                                                      The coolant (fresh water) pump is a centrifugal-type pump,
                                                                      and is belt-driven.
                                                                      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 gasket




THERMOSTAT
Visually check the thermostat for damage. Then put it in
water and raise the water temperature gradually to test its
valve opening temperature. Replace if defective.


  A CAUTION: The wax pellet-type thermostat remains
  closed if its heat-sensing part is defective. Leaving                                    REMOVING COOLANT PUMP
  this uncorrected would cause the engine to overheat.




                                                         Engines & Generators

                                                                 55
                                               COOLING SYSTEM
Disassembly                                                         3. Tap out the seal using a pipe of the specified size.
Disassemble the coolant pump in the following sequence:                NOTE: The outer diameter of the pipe should be below
   1. Pulley flange
                                                                       1.1 in (28 mm) and the inner diameter of the pipe
   2.   Shaftlbearing                               IMPELLER
                                                                       should be above 0.55 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 body.
1. 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.




                                                                    Reassembly
2. 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 1.0 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 SYSTEM
2. 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 size.
3. Apply coolant to the seal.
4. 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
                                                                            0.75 in (19 mm) and an outer diameter of less
     A CAUTION:                                                             than 1.18 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-
         seal's sliding surface.                                            truding portion is about 0.413 in (10.5 mm).
      b) Using a pipe with an inner diameter of 1.1 in
         (27 mm) or more, press in the seal making
         sure it goes in straight.

5. Dry off both the seal and the impeller's sliding surface
   with compressed air.




                                                                   Installation
                                                                   The coolant pump installation sequence is the reverse of the
                                                                   removal sequence.




6. 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 SYSTEM
RAW WATER PUMP                                                             NOTE: It may be necessary to use a drift and arbor press
                                                                           to press the bearing and seal assembly from the shaft.
NOTE: Since completely rebuilding a damaged or worn pump
from individually purchased parts would almost match the                6. Inspect all parts and replace those showing wear or
price of a new pump, Westerbeke recommends that a new                      erosion.
pump be purchased.
Before disassembling the raw water pump, inspect the pump
by 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 prevent
have excessive play, a major overhaul may be needed.
                                                                              blockage in the cooling circuit. They often can be
Disassembly                                                                   found in the heat exchanger.
The pump, as removed from the engine, will have hose
attachment nipples threaded into its inlet and outlet ports.            7. Use the illustration to assist in reassembling the raw water
The nipples may be left in place or removed if they interfere              pump.
with the pump disassembly. Note the port location and posi-                a. Apply a small amount of petroleum jelly to the seat's
tioning if removed.                                                           surface and to the impeller shaft at reassembly.
1. 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 impeller
2. 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 on
3. Pull out the impeller with long-nose pliers or a pair of                the nipple thread. Assemble the pump to the engine and
   screwdrivers.                                                           attach the hoses and the belt.
4. Remove the cam screw and cam.
5. 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 -"""1-~lA




                                                                                       RAW WATER PUMP




                                                           Engines & Generators

                                                                   58
                                                 FUEL SYSTEM
INTRODUCTION
1. The fuel system uses 5-hole type injection nozzles and              combustion chamber, improving combustion and
   an in-line injection pump (Bosch type). The injection               increasing power.
   pump generates a high injection pressure of 2417 lb/in'          2. The fuel, which is drawn up through the fuel filter/water
   (170 kg/cm'), 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 SYSTEM




CHANGING THE FUEL FILTER
1. Shut off the fuel supply.
2. 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 fuel.
3. Close the drain and unscrew the bolt that secures the
   bowl. The bowl and the filter will drop down.
4. Clean the base. Install a new sealing ring in the base
   making certain that it lies squarely on the base recess.
5. Replace the upper sealing ring and the o-ring in the filter
   head. Install the new filter element and re-install the
   retaining bolt.
   NOTE: Apply fuel to the seal rings and o-ring before
   installing.
6. Bleed the air from the filter assembly.

                                                                                          FUEL FILTER




                                                       Engines & Generators

                                                               59
                                                      FUEL SYSTEM
FUEL FEED PUMP STRAINER                                                 Bleeding air from the fuel line between the engine-mount-
                                                                        ed fuel filter and the injection pump.
An additional fuel screen is located in the feed pump. This
screen (strainer) is removed for cleaning by releasing the              1. Confirm that the plugs on the fuel filter/water separator
banjo bolt at the bottom. This screen should be cleaned every              are closed and that the fuel lines are connected.
250 operating hours. Use compressed air and/or clean with               2. Tum the fuel lift pump primer counterclockwise to re-
kerosene.                                                                  lease it.
                                                                        3. Disconnect the fuel return hose.



TO FUEL ~--.,~'~"".A\
SCREEN
       ----..-l




                                                      FUEL IN



            FUEL FEED
            PUMP STRAINER


                                                                        4. Repeatedly depress and release the primer until only fuel
BLEEDING THE FUEL SYSTEM                                                   (no air bubbles) flows out of the air bleeding plug hole.
If air is present in the fuel lines, the engine may be difficult        5. Connect the fuel return hose.
to start, there may be insufficient power, or hunting may oc-           6. Depress the primer and tum it clockwise, to lock it.
cur when idling.
Air bleeding must be performed after the injection pump
has been installed, and after checking or adjusting the injec-            A CAUTION: If hunting occurs when idling or
tion timing.                                                              there is less engine power after air bleeding, then
Bleeding air from the fuel line between the fuel tank and                 loosen the injector ends of all fuel lines, and bleed
the engine-mounted fuel filter.                                           air by using the engine starter to crank the engine
                                                                          until only fuel comes out.
1. Confirm that the plugs on the fuel filter/water separator
   are closed and that the fuel lines are connected.                      After bleeding the air, start the engine and check
                                                                          for fuel leaks.
2. Tum the primer on the fuel lift pump counterclockwise
   to release it.
3. Loosen the air bleeding plug on the fuel filter.
4. Repeatedly depress and release the primer until only
   fuel (no air bubbles) flows out of the air bleeding plug
   hole.
5. Retighten the air bleeding plug.
6. Depress the primer and tum it clockwise to lock it.




                                                                                    LOOSEN THE INJECTOR ENDS OF AU FUEL LINES




                                                          Engines & Generators

                                                                   60
                                                       FUEL SYSTEM
TESTING THE FUEL INJECTORS                                              Fuel Injector Components
NOTE: The fuel injectors must be serviced in a clean room               The fuel injector consists of the following parts:
environment.
Removing the Fuel Injectors
1. 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 ____




                                                                                      GUm"M~l
   Avoid bending the lines.
2. 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 PIN--@

4. Remove the fuel injectors.                                                    PRESSURE SPRING---B
   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 build-up or the like, work the injector side-to-                                                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 Pressure
5. Remove the gaskets.                                                  1. Set the nozzle tester in a clean place where there is no
                                                                           dust or dirt.
6. Remove the O-rings.            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                                            68°F (20°C).
                           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 - 24891b/in2 (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 TEST

6. 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
   0.002 in (0.05mm), from 0.0197 in (0.50mm) to 0.059 in                     NORMAL                   FAULTY                 FAULTY
   (1.50 mm). If the thickness of a shim is increased 0.002 in                PAmRN                   PATTERN                PAmRN
   (0.05 mm), the injection pressure increases approximately
                                                                                              FUEL INJECTOR SPRAY PATIERNS
   71.1lb/in2 (5.0 kg/cm2   ).

 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 valve
Tightness of the Valve Seat                                                 and check for damage to other parts.
Apply a pressure of 2133 lb/in2 (150 kg/cm2) and check if                2. Check for damage to the nozzle body. Hold the nozzle
fuel leaks from the injection nozzle holes. If fuel leaks, disas-           body upright and insert four-fifths of the needle valve.
semble, 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 SYSTEM
Reassembly                                                            FUEL INJECTION PUMP
Be sure to do the following when reassembling the fuel injector:     NOTE: The fuel injection pump is a very important compo-
1. 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 bench-tested, and the
    Nozzle torque: 29 - 36 ft-lb (4.0 - 5.0 kg-m)                    owner/operator 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 HOLDER



2. After assembling the fuel injector, check the injection
   starting pressure and the spray pattern.

Injector Installation
The fuel injector installation sequence is the reverse of the
removal sequence. Make sure to include the following:
1. Use new gaskets - do not reuse the old gaskets.
2. Replace the copper sealing washer for each injector.
3. Tighten the fuel injector holder bracket mounting nuts to
   the specified torque.
   Bracket mounting nuts torque:
            34.0 - 40.0 ft-lb (4.7 - 5.5 kg-m)                                                      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 1/2002
                                                  STARTER MOTOR

                                                                                        START
                                                                                       SWITCH


                                BATIERY



                                                                                                                   CONTROL
                                                                                                                    SWITCH



                  -

                                                             -
                                           FIGURE 1. STARTER WIRING CIRCUIT

TROUBLESHOOTING                                                         Continuity Check
To independently test the starter it is necessary to remove             Disconnect the field lead on the starter from the solenoid M
it from the engine. However, before doing this, checks                  terminal and insulate it carefully to prevent accidental contact.
should be made to ensure that the problem is with the starter           Set the transmission in neutral. Use a voltmeter to check for
and not with the engine, battery, wiring or switches. When              voltage at the solenoid S terminal while the start switch is
the other possible problem sources have been eliminated,                held in the START position. If voltage is not present at the S
then remove and test the starter. Comparison of test results            terminal, use the voltmeter and the wiring diagram to trace
with the Troubleshooting chart will aid in isolating the prob-          the control circuit and locate the point of voltage loss and cor-
lem within the starter to specific components. This will                rect it as necessary.
determine the repair or repairs needed to restore the starter to        Starter Removal
serviceability.
                                                                        If the battery, wiring and switches are in satisfactory condi-
Battery Test                                                            tion and the engine is known to be functioning properly,
Realistic testing, as well as successful operation, requires a          remove the starter for further testing.
fully charged battery capable of supplying the current needs            Starter No-Load Test
of the starting system. Step one in troubleshooting the start-
ing system is to test the battery. Follow the battery manufac-          With the starter removed from the engine, the no-load test
turer's instructions.                                                   can reveal damage that can be corrected by repair or it may
                                                                        indicate the need for component testing after the starter is dis-
Wiring and Switches                                                     assembled. Repair and component test procedures are
VISual Inspection                                                       described in the UNIT REPAIR section. The no-load test is
                                                                        also used to test units for normal operation after repair or
Visually inspect all wiring and switches in the starting cir-           overhaul. Comparison of test results with the Trouble-
cuit for damage and loose or corroded connections. This                 shooting chart will indicate what corrective action, if any, is
includes all ground connections. Clean and tighten the con-             required.
nections as required. Replace damaged wiring or compo-
nents.




                                                          Engines & Generators

                                                                   64
                                                  STARTER MOTOR
Test Hook-Up (Figure 2)                                                 NOTE: During the no-load test, close the switch and operate
Connect the starter for the no-load test as shown in the                the starter for cycles of 30 seconds maximum. Between
illustration using suitable instruments, battery cables and con-        cycles, allow the starter to cool for at least two minutes, oth-
necting wiring. Do the following:                                       erwise overheating and damage to the starter may result.
1. 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 to
2. 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 TROUBLESHOOTING.
3. 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 and
4. If sparking or current flow in the battery circuit is                       refer to TROUBLESHOOTING.
   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,
   TROUBLESHOOTING).                                                           release the switch and proceed with the next step of
                                                                               the no-load test.
5. 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
                                                                           24-volt starter). Observe and record the ammeter and rpm
6. 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 to
Test Procedure                                                             TROUBLESHOOTING 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 D.E. (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 NO-LOAD TEST HOOK-UP



                                                              Engines & Generators

                                                                   65
                                                           STARTER MOTOR
Troubleshooting                                                                   ble cause and its remedy. The problems listed in the chart
If the results of the no-load test are outside the limits, refer                  apply specifically to the no-load test and do not necessarily
to the following TROUBLESHOOTING chart for the proba-                             apply to operation under other circumstances.

                    PROBLEM                                         PROBABLE CAUSE                                   VERIFICATION/REMEDY*
 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 coil(s) or high insulation          c. Inspect armature.
                                                        between commutator bars.
                                                     d. Broken brush spring(s) 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 bearing(s) 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 instructions.

STARTER REPAIR                                                                    This section provides instructions for complete disassembly
                                                                                  of the starter as would be the case for overhaul. If the starter
NOTE: Always install fasteners at their original locations.                       is not due for an overhaul, and repair affecting specific parts
If it is necessary to replace fasteners, use only the correct                     only is required, the starter may be disassembled only to the
part numbers or equivalent. If the correct part number is not                     extent necessary to gain access to these parts. Parts removed
available, use only afastener of equal size and strength. Use                     from the starter as subassemblies or groups need not be dis-
a torque wrench to tighten fasteners when a torque value is                       assembled for such limited repair unless they contain the
specified. Torques specified are for dry, unlubricated fasten-                    affected parts. Total disassembly is recommended however,
ers unless otherwise specified.                                                   to ensure that all parts can be thoroughly cleaned and
Introduction                                                                      inspected.
(Figure 3)                                                                        In this section the starter is broken down by main groups.
Figure 3 shows the starter broken down into its component                         These groups are then disassembled into individual parts and
parts and assemblies. Do not attempt to disassemble the fol-                      assemblies. Illustrations accompany the text to show specific
lowing 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


                                                            6)l    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. D.E. HOUSING                                                        18
    BUSHING                 21.   SHIFT LEVER SCREW
 7. BRUSH SPRING            22.   SHIFT LEVER WASHER                            34
 8. D.E. ARMATURE           23.   SHIFT LEVER NUT
    BEARING                 25.   SOLENOID SCREW
 9. C.E. ARMATURE           26.   PLATE (IF USED)
    BEARING                 27.   DRIVE HOUSING PLUG
10. CENTER SUPPORT          28.   DOWEL PIN
    BEARING                 29.   INSULATED BRUSH SCREW
11. SHIFT LEVER             30.   WASHER (FIBER)
12. PINION STOP             31.   WASHER (THIN; ONE OR
13. ARMATURE                      TWO MAY BE USED)
14. C.E. FRAME              32.   WASHER (THICK)
15. DRIVE SHAFT             33.   FRAME SEAL
16. ARMATURE SUPPORT        34.   BUSHING PLUG (IF USED)
    BRACKET                 35.   STOP RING
17. DRIVE SHAFT             36.   DRIVE HOUSING BOLT (LONG)
    SUPPORT                 37.   DRIVE HOUSING BOLT
18. DRIVE HOUSING                 (SHORTER ON SOME MODELS)
19. FRAME & FIELD           39.   GROUNDED BRUSH SCREW
    ASSEMBLY                41.   THRU BOLT
20. C.E. FRAME O-RING       42.   BRUSH PLATE SCREW


                             FIGURE 3. STARTER ASSEMBLY




                                     Engines & Generators

                                          67
                                              STARTER MOTOR
General Disassembly                                                5. Frame, field and brush holder group (A), dowel pin (28)
(Figure 4)                                                            and frame seal (33).
Remove or Disconnect:                                                   a. The armature assembly (13) may come off with the
                                                                           frame, field and brush holder group (A) or may be
1. 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 REPAIR).
2. Thru bolts (41).
                                                                   7. Solenoid screws (25).
3. Brush plate screws (42).
                                                                   8. Solenoid assembly (1).
4. C.E. frame (14) and O-ring (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
      (0.079 in.) dia. x 10 mm (0.394 in.) long pin pro-
      cured or manufactured locally.

        42    ---4~                                                                 25

         14




                41


         1. SOLENOID ASSEMBLY
         8.   D.E. ARMATURE BEARING                                 9
         9.   C.E. ARMATURE BEARING
        13.   ARMATURE ASSEMBLY
        14.   C.E. FRAME'
        20.   C.E. FRAME O-RING
        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

                                                              68
Disassembly of Frame, Field and Brush Holder Group
(Figure 5)
Remove or disconnect:
                                                                                                             19
1. 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 (29).
2. Frame and field assembly (19).
3. Grounded brush screws (39).
                                                                                                19. FRAME & FIELD
4. 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'
                                                                                                    SCREW
5. 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
   REPAIR.
Disassembly of Gear Reduction and Drive Group
(Figure 6)
Remove or disconnect:




                                                                      I
1. Housing bolts (36 and 37).                                                                               18
2. Armature support bracket (16).                               Gr:f?'
    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.
                                                                                                6
3. Washers (30 through 32).                                                            21
    a. Save the washers; they are to be installed in the same
                                                                     6. D.E. HOUSING BUSHING
       position and number at assembly.                             11. SHIFT LEVER
4. 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 (IF
5. Shift lever nut (23), washer (22) and screw (21).                22. SHIFT LEVER WASHER         USED)
                                                                    23. SHIFT LEVER NUT        36. DRIVE HOUSING BOLT
6. 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 MOTOR
Disassembly of Drive Shaft and Clutch Group
(Figures 7 and 8)
Disassembly of the drive shaft and clutch group is not
required unless it is necessary to clean, inspect or replace
one or more parts of the group separately. Then proceed as
follows:
Remove or disconnect:
1. 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 assembly.
2. Clutch drive assembly (2) from drive shaft (15).
3. 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).
                                                                         14.2 MM
                                                                         (0.56 IN.) DIA-fa               22 MM
                                                                                                         (0.87 IN.) DIA




                                                                                                            OPEN
                                                                                                            TUBE




                                                                                             tti::::ZZ:::~LPINION   STOP (12)

                                                                       DRIVE SHAFT (15)


                                                                                    FIGURE 8. REMOVING PINION STOP




                                                        Engines & Generators

                                                                 70
                                                    STARTER MOTOR
CLEANING, INSPECTION, TESTING AND REPAIR                                6. Brushes (4 and 5) for excessive wear.
Cleaning                                                                   a. The minimum allowable brush length is 12 mm
                                                                              (0.472 in.). Replace excessively worn brushes in
NOTE: Do not clean or immerse starter parts in grease dis-                    sets.
solving solvents. Solvents will dissolve grease packed in the
drive assembly and may damage the armature or field coil                7. The D.E. housing bushing (6) for scoring or other dam-
insulation.                                                                age. Replace a damaged bushing (refer to REPAIR
                                                                           PROCEDURES).
Clean:
                                                                        8. Ball bearings (8, 9 and 10) as follows:
1. All starter parts with a soft cloth prior to testing.
                                                                           a. Hold the armature (13) or drive shaft (15) and slowly
Inspection                                                                    rotate the outer bearing race by hand.
(Figure 3)
                                                                           b. Check that the bearing turns freely without binding or
Inspection in the following steps refers to visual inspection
                                                                               the feel of flat spots.
of the starter parts and assemblies to determine their servicea-
bility. Electrical tests for certain assemblies are described in           c. Replace damaged bearings (refer to REPAIR
COMPONENT ELECTRICAL TESTING.                                                 PROCEDURES).
Inspect:                                                                9. Armature assembly (13) for the following:
1. 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. 400
2. 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 lathe.
3. 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 (1.378 in.) or
4. The clutch drive assembly (2) for the following.
                                                                              if the undercut depth at any point is less than 0.2 mm
   Replace the clutch drive assembly if damaged:                              (0.008 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 (6).
5. 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 MOTOR
Component Electrical Testing                                                             BATIERY
(Figures 9 and 10)                                                                       TERMINAL
Perform the following electrical tests on the solenoid assem-
bly (1), armature assembly (13) and frame and field assem-
bly (19) to determine their serviceability.
1. Using a suitable ohmmeter, check the windings of the
   solenoid assembly (1) for continuity as follows:
   a. Check the resistance of the solenoid pull-in and
      hold-in 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 0.95 ohms for 12-volt starters and approxi-
      mately1.75 ohms for 24-volt 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 assembly.
2. 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 opens.
3. 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 MOTOR
Repair Procedures                                                    Remove or disconnect:
(Figures 3 and 11)                                                      a. The center support bearing (10) from the drive shaft
1. 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 the
Remove or disconnect:                                                       tool bolt ends through the access holes in the wide
                                                                            end of the drive shaft and squarely press the bearing
   a. C.E. and/or D.E. bearings (8 and/or 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 the
Install or Connect:
                                                                        drive housing (18) as follows:
   b. New C.E. and/or D.E. bearings (8 and/or 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 bearing's 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 (6).
2. 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 3/16 IN.)                        CENTER
                                                                                  SUPPORT
          THICK, AND 55 MM (OR 2 1/4 IN.) SQUARE OR ROUND.
                                                                                  BEARING
        · THREE 6 MM OR 3/16 IN. BOLTS OF EQUAL LENGTH,
          LONG ENOUGH TO EXTEND AT LEAST 35 MM (1 3/8 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 3'2 MM
              (1.26 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 MOTOR
ASSEMBLY                                                              1. Lubricate the D.E. housing bushing, shift lever, and
                                                                         drive shaft as described under LUBRICATION DURING
Lubrication During Assembly                                               ASSEMBLY.
1. 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.   D.E. 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 bearing
Drive Shaft and Clutch Group                                                  (10, Figure 7) remains fully seated in the drive shaft
(Figures 7 and 12)                                                            support.
1. 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 4.5 Nm (40 lb-in.).
   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 disassembly.
Install or Connect:                                                   7. The armature support bracket (16) to the drive housing
                                                                         (18), aligning the mark made prior to disassembly with
1. 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 37).
2. The clutch drive assembly (2) to the drive shaft (15).
3. 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 (3/16 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 U-shaped 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 1/2 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 (15).
Assembly of Gear Reduction and Drive Group
(Figure 6)
   Important:
   If the D.E. 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 MOTOR
Assembly of Frame, Field and Brush Holder Group                       NOTE: The brush leads may be damaged by excessive
(Figures 5, 13 and 14)                                                handling. Do not over-jlex 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 (39).
Install or Connect:                                                       a. Position the terminals of the grounded brush leads
                                                                             behind the terminal tabs on the brush holder (3) (see
1. 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 1.5 Nm (13 lb-in.).
      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
                                                                         Important:
4. The frame and field assembly (19) to the brush holder
   assembly.                                                             a. The O-ring can easily be damaged during installa-
                                                                             tion of the C.E. frame (14). To prevent such dam-
   a. Position the brush holder assembly (3) (with                           age, install the O-ring as described in the following
       installed brushes) over the terminal end of the frame                 steps.
       and field assembly (19).
                                                                         h. Install the O-ring 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 C.E. frame when
       the insulated brush screws (29).                                      installed. This is the normal installed position for
Tighten:                                                                     the O-ring.
   c. The insulated brush screws to 1.5 Nm (13Ib-in.).                   c. Carefully roll the O-ring out of its normal installed
                                                                             position up onto the major O.D. of the field frame.
Starter Assembly                                                             Allow the O-ring to remain in this position until the
(Figures 4 and 15)                                                           C.E. frame is partially installed.
Support the gear reduction and drive group (B) with the               6. C.E. frame (14)
pinion gear end down and proceed as follows:
                                                                         a. Align the marks on the C.E. frame and frame and
Important:                                                                   field assembly (19, Figure 5) made prior to disas-
If the armature bearings (8 and 9) are being replaced, install               sembly.
them on the armature (13) as specified in REPAIR PROCE-                  h. Start the C.E. frame onto the frame and field assem-
DURES, step 1 before proceeding with assembly.                               bly, leaving a gap just slightly larger than the thick-
Install or Connect:                                                          ness of the O-ring (20).
1. 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 C.E. frame (14).
     h. Position the solenoid assembly mounting flange and            Tighten:
         install the solenoid mounting screws (25).                      h. Brush plate screws to 2.8 Nm (25 lb-in.).
Tighten:                                                              8. Thru bolts (41).
     c. Solenoid screws to 2.8 Nm (25Ib-in.).                            a. Install the thru bolts and tighten them by hand but do
2. Frame seal (33).                                                          not close the gap between the C.E. frame and the
                                                                             frame and field assembly where the O-ring (20) goes.
3. The armature assembly (13) with bearings (8 and 9) into
   the gear reduction and drive group (B).                               h. Roll the O-ring (20) back down into its installed
                                                                             position between the C.E. 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 C.E. frame
                                                                             (14) with the timing spots on the frame and field
4. 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 8.5 Nm (75 lb-in.).
       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 lb-in.).
S. O-ring (20).




                                                         Engines & Generators

                                                                 76
                                                STARTER MOTOR
STARTER INSTALLATION                                                                                   C.E. FRAME
Testing After Repair or Overhaul
After repair or overhaul, the starter can be tested as speci-
fied in the Starter No-Load Test found in the TROU-
BLESHOOTING section.
After repair, overhaul, testing or replacement of the starter,
reinstall it using the following torques when making the elec-                                               TIMING
trical 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 burn.

Tighten:
   a. Solenoid battery (B) terminal nut to 18 Nm (13 lb-ft.)~
   b. Solenoid switch (S) terminal nut to 1.8 Nm
       (16Ib-in.).                                                          FIGURE 15. ALIGNING TIMING MARKS
STARTER SPECIFICATIONS
A1l12 Volt models have these No-Load Test Specifications:
                                                             AMPS                                      RPM
               VOLTS
                                                 Minimum              Maximum              Minimum             Maximum
                 10                                125                     190               3000               5600
A1l24 Volt models have these No-Load Test Specifications:
                                                             AMPS                                      RPM
               VOLTS
                                                 Minimum              Maximum              Minimum             Maximum
                 20                                 75                      90               3600               5400
Starter Solenoid current consumption:
                                                         PULL IN WINDING                          HOLD IN WINDING
           RATED VOLTAGE
                                              AMPS           VOLTS            OHMS        AMPS        VOLTS            OHMS
                 12                          52-59               10        0.17 - 0.19   12 -14         10          0.76 - 0.81
                 24                         100 -125             20        0.16 - 0.20   12 -14         20          1.15 -1.65




                                                         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 manually-operated 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 engine's 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 engine's 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
 engine's 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-
 tem's voltage. All gauges are illuminated when the key                                 necting the buzzer to the four-pin connection on the engine's
 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 rubber-booted                             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
                                                                                        engine's oil pressure rises above 15 psi (1.1 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 ENGINE'S NORMAL OPERATING OIL
                                 ILLUMINATED WHILE THE KEY SWITCH IS                                                PRESSURE RANGES BETWEEN 30 - 60 psi
                                 TURNED ON. THE ENGINE'S NORMAL OPERATING                                           (2.1 - 4.2 kg/em').
                                 TEMPERATURE IS 170· -190· F(77· - 88·C).

RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OF THE PANEL.



HOURMETER:
REGISTERS ELAPSED                                                                                                                               KEY SWITCH: PROVIDES
TIME, AND SHOULD BE                                                                                                                             POWER ONLY TO THE
USED AS A GUIDE FOR                                                                                                                             INSTRUMENT PANEL
THE MAINTENANCE                                                                                                                                 CLUSTER.
SCHEDULE.




                                                                                                                                                DC VOLTMETER:
                                                                                                                                                INDICATES THE AMOUNT THE
                                                                                                                                                BATTERY IS BEING CHARGED.
                                                                                                  /
                                                                                             /                                                  SHOULD SHOW 13V TO 14V.
PREHEAT BUTTON: WHEN PRESSED, ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL                                      /        AUTOMATIC ALARM SYSTEM
SOLENOID ON THE INJECTION PUMP, AND THE ENGINE'S
AIR INTAKE HEATER. IT BYPASSES THE ENGINE'S OIL                                                  COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
PRESSURE ALARM SWITCH. IN ADDITION, THIS BUTTON                                                  SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
ENERGIZES THE START BUTTON.                                                                      REACHES 210° F (99°C), THIS SWITCH WILL CLOSE SOUNDING THE
                                                                                                 ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.

START BUTTON: WHEN PRESSED, ENERGIZES THE            ~                                           OIL PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.
THIS BUTTON WILL NOT OPERATE ELECTRICALLY
                                                       ._./~.
                                                       -/~
                                                                . .... _    "I'"                 LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
                                                                                                 THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD                                                    FALL TO 5 -10 psi (0.4 - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND-
AT THE SAME TIME.                                                                                ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
                                                                                                 SIGNAL.




                                                                           Engines & Generators

                                                                                   78
                                              CAPTAIN CONTROL PANEL
DESCRIPTION                                                             on... PRESSURE or high COOLANT lEMPERATURE. The
                                                                        RPM gauge is illuminated when the KEY switch is turned on
This manually-operated control panel is equipped with a
                                                                        and remains illuminated while the engine is in operation.
KEY switch, an RPM gauge, PREHEAT and START but-
tons, an INSTRUMENT lEST button and three indicator
lamps, one for ALlERNATOR DISCHARGE, one for low
On... PRESSURE, and one for high ENGINE COOLANT
lEMPERATURE. It also includes an alarm buzzer for low




                                                                        ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE FALLS
                                                                        BELOW 5 -10 psi (0.4 - 0.7 kg/em'). 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 TO
RPM GAUGE: REGISTERS REVOLUTIONS                                        210°F (99"C). IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAl.
PER MINUTE OF THE ENGINE AND CAN BE                                     NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
RECALIBRATED FOR ACCURACY FROM                                          SOUNDING IS NORMAl. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
THE REAR OF THE PANEl.                                                  PRESSURE REACHES 15 psi (1.1 kg/em'), 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
                     STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS                       PREHEAT BUTTON: WHEN PRESSED, ENERGIZES THE
                     BUTTON WILL NOT OPERATE ELECTRICAlLY UNLESS THE                        ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL
                     PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME                         SOLENOID ON THE INJECTION PUMP, AND THE ENGINE'S
                     TIME.                                                                  AIR INTAKE HEATER, AND BYPASSES THE ENGINE'S OIL
                                                                                            PRESSURE ALARM SWITCH. IN ADDITION, THIS BUTTON
                                                                                            ENERGIZES THE START BUTTON.                      .




                                                             Eng/nes & Generators

                                                                  79
                               CONTROL PANEL TROUBLESHOOTING
TACHOMETER/HOURMETER                                                   Tachometer Inaccurate
The tachometerlhourmeter used in propulsion engine instru-             a. With a hand-held tach on the front of the crankshaft
ment panels contains two separate electrical circuits with a              pulley retaining nut or with a strobe-type tach, read the
common ground. One circuit operates the hourmeter and the                 front crankshaft pulley rpm at idle.
other the tachometer. The hourmeter circuit operates on 12             h. Adjust the tachometer with a small Phillips type screw-
volts alternator charging voltage supplied to the (+) terminal            driver through the calibration access hole in the rear of
on the back of the instrument.                                            the tachometer. Zero the tach and bring it to the rpm
The tachometer circuit operates on AC voltage 6-8 volts, fed              indicated by the strobe or hand tach. (Verify the rpm at
from one of the diodes in the alternator and supplied to the              idle and at high speed 3000-3600 rpm). (Adjust the tach
tachometer input terminal while the engine is running, and                as needed.)
the alternator producing battery charging voltage 13.0-14.8
volts DC.
                                                                       NOTE: Current model tachometers use a coarse adjustment
                                                                       dial to set the tachometer to the crankshaft pulley rpms. The
The following are procedures to follow when troubleshooting            calibrating screw is then used for fine tuning.
a fault in either of the two circuits in a tachometerlhour-
meter.

Hourmeter Inoperative
Check for the proper DC voltage between (+) and (-)                  COARSE
terminals.                                                           ADJUSTMENT
1. Voltage present - meter is defective - repair or replace.
2. Voltage not present - trace (+) and (-) electrical con-
   nections for fault. (Jump 12 volts DC to meter (+)
                                                                                                            ~~-(+)        TERMINAL
   terminal to verify the operation.)

                                                                                                                 ..... Tj~CHltlMETER INPUT
Tachometer Inoperative                                                                 CURRENT TACHOMETER              (AC VOLTAGE)
Check for the proper AC voltage between tachometer input
terminal and (-) terminal with the engine running.
1. Voltage present - attempt adjusting meter through calibra-
   tion access hole. No results, repair or replace meter.
2. AC voltage not present - check for proper alternator DC
   output voltage.
3. Check for AC voltage at tach terminal on alternator to
   ground.
4. Check electrical connections from tachometer input ter-
   rpinal to alternator connection.

Tachometer Sticking
1. Check for proper AC voltage between ''tach inp." terminal                           EARLY MODEL TACHOMETER
   and (-) terminal.                                                                                                         (-) GROUND
                                                                                                                             TERMINAL
2. Check for good ground connection between meter (-) ter-
   minal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt.

                                                                                                                      (-) GROUND
                                                                                                        ~~~~~TERMINAL


                                                                         (-) GROUND"l!
                                                                         TERMINAL      LIGHT       h!                   TACHOMETER INPUT
                                                                                                                        (AC VOLTAGE)
                                                                                    (+) TERMINAL

                                                                                          EARLY MODEL TACHOMETER




                                                             Engines & Generators

                                                                   80
                                           DC ELECTRICAL SYSTEM
12 VOLT DC CONTROL CIRCUIT                                            AIR INTAKE HEATER
The engine has a 12 volt DC electrical control circuit that is        The air heater consists of a small heating coil located just
shown on the wiring diagrams that follow. Refer to these dia-         inboard of the air intake silencer housing. The coil heats the
grams when troubleshooting or when servicing the DC elec-             engine intake air. It is wired through the preheat solenoid.
trical 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.
 engine's electrical circuit.

BATTERY
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 - 900 Cold
Cranking Amps (CCA).

Battery Care
Review the manufacturer's recommendations and then estab-
lish a systematic maintenance schedule for your engine's
starting batteries and house batteries.
o   Monitor your voltmeter for proper charging during
    engine operation.
o   Check the electrolyte level and specific gravity with a
    hydrometer.
o Use only distilled water to bring electrolytes to a proper
  level.                                                                            TO WIRING
o Make certain that battery cable connections are clean and                         HARNESS

  tight to the battery posts (and to your engine).
                                                                                           AIR INTAKE
o 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
                                                             ALTERNATOR
DESCRIPTION
The charging system consists of a DC belt driven alternator
with a voltage regulator, an engine DC wiring harness, a
                                                                           A    WARNING: When testing with a multimeter:
mounted DC circuit breaker and a battery with connecting                   DC and AC circuits are often mixed together in marine
cables. Because of the use of integrated circuits (IC's), the              applications. Always disconnect a shore power cord,
electronic voltage regulator is very compact and is mounted                isolate DC and AC converters, and shut down the engine
internally or on the back of the alternator.                               before performing DC testing. No AC tests should be
                                                                           made without a proper knowledge of AC circuits.
#14 GREY

#14 BLUE
                                                                          1. Start the engine.
                                         #14 BROWN
                                          10 Tachometer                   2. After the engine has run for a few minutes, measure the
#14 PINK                                                                     starting battery voltage at the battery terminals using a
                                                                             multimeter set on DC volts ..
51 AMP                                    1#10 RED                           a.1f the voltage is increasing toward 14 volts, the alterna-
ALTERNATOR                                11+ OUTPUT                            tor is working; omit Steps 3 through 8 and go directly
(ENGINE)                                  to Starter Motor
                                                                                to Checking the Service Battery on the next page.
                                                                             h.1f 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 PURPLE:=,ft,~~~~                                                       MULTIMETER
                                                                                                             COM
               to Fuel Solenoid
               & Fuel Lift Pump

             51 AMP
             ALTERNATOR
             (GENERATOR)




ALTERNATOR TROUBLESHOOTING                                                     TESTING THE STARTING
                                                                               BATTERY/ALTERNATOR
                                                                                 (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 connections.
Use this troubleshooting section to determine if a problem
exists with the charging circuit or with the alternator. If it is            Ensure that the battery terminals and the engine ground
determined that the alternator or voltage regulator is faulty,               connections are tight and clean.
have a qualified technician check it.
The alternator charging circuit charges the starting battery                   A CAUTION: To avoid damage to the battery
and the service battery. An isolator with a diode, a solenoid                  charging circuit, never shut off the engine battery
or a battery selector switch is usually mounted in the circuit                 switch when the engine is running!
to iselate the batteries so the starting battery is not discharged
along with the service battery. If the alternator is charging the         4. If a battery selector switch is in the charging circuit,
starting battery but not the service battery, the problem is in              ensure that it is on the correct setting.
the service battery's charging circuit and not with the alterna-          5. Tum on the ignition switch, but do not start the engine.
tor.
                                                                          6. Check the battery voltage. If the battery is in good condi-
Testing 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 13-14 volts, the alternator is o.k. 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                                     MULTIMETER

7. 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
           BATTERY/ALTERNATOR
                                                                             A CAUTION: To avoid damaging the altemator diodes,
             (ENGINE RUNNING)
                                                              ENGINE         do not use a high voltage tester (i.e. a megger) when
                                              ..l..::-C==>--I GROUND
                                                                             perfonning tests on the altemator charging circuit.

8. 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 13.5 and 14.5 volts. If your alternator                and inspected. The housing can be wiped off with a solvent
   is over- or under-charging, 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
                                                                                                     BRACKET

DESCRIPTION
Dual output and high output alternators are available as
optional equipment on most WESTERBEKE engines. These
alternators can be installed during factory assembly or as
add-on equipment at anytime.
Dual alternators can be configured to charge two banks of
batteries at the same time or, using a battery selector switch,
charge each set of batteries separately.

INSTALLATION
If an optional dual alternator has already been factory installed,
simply follow the WESTERBEKE wiring diagram and the
engine installation instructions.
If the new dual alternator is being added to an existing "in-
the-boat" engine, carefully follow the alternator installation
instructions below:
1. Disconnect the alternators negative cable from the battery.
2. Remove the alternator and disconnect or tape off the
   output [positive] cable. Do not reuse.
3. Install the new alternator.
4, Attach a new heavy gauge output cable[s] from the
   alternator's output terminal [s]. Using the cable sizes
   indicated.

                                                                                        DUAL OUTPUT ALTERNATOR
                                                                                        [CHARGING ONE BATTERY]

5. Make certain that the batteries negative post ground cable
    to the engine block is the same heavy gauge as the
   -positive cable.
6. 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 2-pin 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 ALTERNATORS
TROUBLESHOOTING                                                       Alternator Testing
NOTE: Before troubleshooting, make certain that the drive             The regulator is functioning properly and the batteries
belts are tight and the batteries are in good condition.              are in good condition.
Regulator Testing                                                     1. Test the voltage at the alternator plug with the engine
                                                                          off-key on. The voltage at the alternator tenninal F and
The red "battery sensing" wire A connects to the battery, it              the voltage in the plug [blue wire F] from the regulator
must always read battery voltage. If battery voltage is not               should read the same.
present, trace the wire for a bad connection.
                                                                      2. Hold a screw driver close [1/2"] to the alternator pulley.
The orange wire S should read 0 volts with the key off, 12               If voltage is present you should feel the magnetic field. If
volts [approximately] with the key on. If the readings are               not, the problem may be the brushes [worn] or the rotor
incorrect, trace the wire for a bad connection.                          [open circuit].
The blue wire F supplies current to the alternator fields, its        3. Start the engine, at fast idle the output tenninals should
voltage will vary depending on the battery charge or ~ctual              indicate 14.2 volts [no load]. A reading of 12.6 would
load/rpm. The readings can vary from 4 to 12 volts WIth the              indicate the alternator is not perfonning properly.
key on, 0 volts with the key off.
                                                                         Apply a load such as an electric bilge pump, the voltage
KEY ON - NO VOLTAGE     REGULATOR IS DEFECTIVE                           should maintain at least 13.8 volts. 13 volts or less
KEY OFF - BATTERY VOLTAGE   REGULATOR IS DEFECTIVE                       indicates the alternator is faulty.
REGULATOR TEST POINTS AND PROPER VOLTAGE
                                                                      NOTES:
Terminal/Color Ignition Off Ignition On    Engine Running
 I Brown       ovolts       2 -12 volts    14.2 volts                 ·   When the engine is first started, it takes a few moments
 A Red         12.6 volts   12 volts       14.2 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   12.6 volts   12 volts       14.2 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 ON-OFF 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 Vl)C             START

+-----;1-; 1--7
              1
                          r-,
                           SOL.

               -----"""~~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 transmission.

OIL COOLER                                                                NOTE: When the boat is being sailed (engine stopped), the
                                                                          gear shift must be in the neutral position. The propeller is at
The oil cooler, mounted above the transmission, provides
                                                                          idle and can free-wheel.
continuous cooling for the transmission fluid. Raw water
passes through the tubes of the cooler and discharges over-               DAILY OPERATION
board. The transmission fluid is cooled as it flows around the
tubes 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 not
TRANSMISSION FLUID                                                        exceed 176°F (80°C). A connection for a temperature probe
Fill the transmission with Dextron III ATF. The fluid level               is provided. At maximum output of the engine, the fluid may
should be up to the mark on the dipstick. After checking the              reach 220°F (104°C).
level, press the dipstick into the case and tum it to tighten.
During the first 25 operating hours, inspect the bell housing,
output shaft and transmission cooler for leakage. The fluid                A    CAUTION: If the transmission fluid temperature is
should be changed after the first 25 hours and every 300                   too high, stop the engine immediately and check the
hours thereafter.                                                          transmission fluid.
NEUTRAL SWITCH
These transmissions are equipped with a neutral safety
switch. This is to prevent the engine from starting in gear.
Unless the transmission selector lever is perfectly aligned in
neutral, the engine starter will not activate.




                                                               Engines & Generators

                                                                     88
                                          HURTH HSW TRANSMISSIONS
CHANGING 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 - 2.12 quarts (2.0 Liters)
                                                                                     HSW630 - 3.2 quarts (3.0 Liters)
                                                                                     HSW630V - 4.2 quarts (4.0 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.


                        O-RINGS
                                                                        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).

                                                                        Lay-up/Winterize
Filter Element                                                          Storage requires special care. Follow these procedures:
The Hurth HSW transmission has a filter element located                 D Drain water from the transmission oil cooler and replace
opposite the dipstick. 1bis filter must be replaced whenever                with a proper mixture of antifreeze. coolant.
the fluid is changed.                                                       NOTE: This operation will normally occur when the
Remove the filter by loosening the screw on the cover using a               engine raw water cooling system is properly winterized.
6mm Allen wrench.
                                                                        D Clean up the transmission and touch up unpainted areas
Twist and pull out the filter and remove the element. Place                 (use heat resistant paint).
the new filter onto the cover and lock it into place by turning
it clockwise. Check the O-rings for damage and replace if               D Fill the transmission with Dext~n III ATF fluid to the
                                                                            full mark on the dipstick.
necessary. Replacement filters can be obtained from your
local WESTERBEKE dealer or ZF (Hurth dealer).                           D Loosen attaching hardware from the transmission output
                                                                            flange and propeller shaft coupling flange before remov-
Removing the Fluid                                                          ing the boat from the water. Separate the flanges and
Push a suction pump hose down through the pipe hole (under                  spray with lubricant.
the filter) to the bottom of the housing and suck out the fluid.        D   Inspect the gear shift cable, linkage, and attachments.
Remove the oil return line from the cooler and allow the oil                Look for corrosion of the end fittings, cracks or cuts in
to drain into a container, then reconnect the oil return line.              the conduit, and bending of the actuator rods. Lubricate
                                                                            all moving parts.
Wipe down the transmission and properly dispose of the used
fluid.                                                                      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 TRANSMISSIONS
CABLE CONNECTIONS                                                           SHAFT COUPLINGS
The transmission is suitable for a single lever gear shift.                 WESTERBEKE recommends a flexible connection between
Upon loosening the retaining screw, the actuating lever (see                the transmission and the propelIer shaft if the engine is flexi-
illustration) can be moved to any position required for the                 bly mounted, in order to compensate for angular deflections.
control elements (cable or rod linkage). Make certain that the              The instalIation of a special propelIer thrust bearing is not
actuating lever does not contact the lever hub: the minimum                 required, since the propelIer thrust will be absorbed by the
distance between the lever and hub should be 0.02in(0.5mm).                 transmission bearing, provided the value specified under
The control cable or rod should be arranged at a right angle                SPECIFICATIONS is not exceeded. However, the output
to the actuating lever when in the neutral position. The neu-               shaft should be protected from additional loads. Special care
tral position of the gear shift lever on the control console                should be taken to prevent torsional vibration. When using a
should coincide with the neutral position of the lever on the               universal joint shaft, make certain to observe the manufac-
transmission.                                                               turer's instructions.
Shifting 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 800mm.
NOTE: When shifting to "A" or "B" positions, make sure the
shift 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
        A=RH
        N = NEUTRAL                                                                          GEAR SHIFT LEVER
        B =LH
                                      B
                                                           ACTUATING
                                                           LEVER



                                                           LEVER HUB




                                                     1- O.02in
                                ACTUATING            r{O.5mm)
                                 LEVER                                                                            TYPICAL STEERING STATION
A greater amount of actuating lever travel is in no way
detrimental and is recommended. However, if the lever travel
is shorter, proper clutch engagement might be impeded                       For additional information contact:
which, in turn, would mean premature wear, excessive heat                         HURTH MARINE GEAR
generation and clutch plate failure. This would be indicated                      ZF Industries
by slowc1utch engagement or no engagement at all (see                             Marine US Headquarters
CONTROL CABLES under TRANSMISSION                                                 3131 SW 42nd Street
TROUBLESHOOTING)                                                                  Fort Lauderdale, FL 33312
                                                                                  Tel.: (954) 581-4040
NOTE: Check for proper actuating lever travel at least each
                                                                                  Fax: (954) 581-4077
season.

 A CAUTION: The position of the mechanism behind
  the actuating lever is factory-adjusted 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 TRANSMISSION
DESCRIPTION                                                                 NOTE: When installing the gearbox, make certain that shifting
The 90A Four engine is also being equipped with the HBW                     is not impeded by restricted movability of the Bowden cable
250 transmission. The information below is specific to the                  or rod linkage, by unsuitably positioned guide sheaves, too
HBW 250, the TRANSMISSION TROUBLESHOOTING                                   small a bending radius, etc. In order to mount a support for
SECTION applies to all models.                                              shift control cable connections, use the two threaded holes
                                                                            located above the shift cover on top of the gear housing.
CONNECTION OF GEAR BOX WITH PROPELLER                                       Refer to the WESTERBEKE parts list.
HBW recommend a flexible connection between the gearbox
                                                                            CONTROL CABLES
and the propeller shaft if the engine is flexibly mounted, in
order to compensate for angular deflections. The installation               The gearbox is suitable for single lever remote control. Upon
of a special propeller thrust bearing is not required, since the            loosening the retaining screw, the actuating lever can be
propeller thrust will be taken by the transmission bearing,                 moved to any position required for the control elements
provided the value specified under SPECIFICATIONS is not                    (cable or rod linkage). Make certain that the shift lever does
exceeded. However, the output shaft should be protected                     not contact the actuating lever cover plate: the minimum dis-
from additional loads. Special care should be taken to pre-                 tance between lever and cover should be 0.5mm.
vent torsional vibration. When using a universal joint shaft,               The control cable or rod should be arranged at right angle to
make certain to observe the manufacturer's instructions.                    the actuating shift lever when in the neutral position. The
Even with the engine solidly mounted, the use of flexible                   neutral position of the operating lever on the control console
coupling reduces stresses in gearbox bearings caused by hull                should coincide with the neutral position of this lever.
distortions, especially in wooden boats or where the distance               The shifting travel, as measured at the pivot point of the actu-
between gearbox output flange and stem gland is less than                   ating lever, between the neutral position and end positions A
about 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 factory-adjusted 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 TRANSMISSION
INITIAL OPERATION                                                       OPERATING TEMPERATURE
All HBW marine transmissions are test-run on a test stand               The maximum permissible ATF temperature should not
with the engine at the factory prior to delivery. For safety            exceed 230°F (1lO°C). This temperature can only be reached
reasons the fluid is drained before shipment.                           for a short time.
Fill the gearbox with Automatic Transmission Fluid
(DEXRON II or DEXTRON ill). The fluid level should be
up to the index mark on the dipstick. To check the fluid level,
just 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 the
into the case after the fluid level is checked and tighten. Do
not forget the sealing ring under the hexhead of the dipstick.
                                                                            transmission fluid.
Check for leaks and change the fluid after the first 25 hours,
also make a visual inspection of the coupling, oil cooler and
hoses, 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 fluid.
FLUID CHANGE                                                            o    Shift into gear.
Change the fluid for the first time after about 25 hours of
operation, then every 250 operating hours or at least once a            NOTE: Too Iowan idle speed will produce a chattering noise
year or when you change engine oil.                                     from the transmission gear and damper plate. In such cases the
Removing the fluid                                                      idle speed should be increased
Push a suction pump hose down through the dipstick hole to              For additional information refer to the following text in this
the bottom of the housing and suck out the fluid. (If space             Transmission Section: SHAFT COUPUNGS, MAINTENANCE
allows, use the transmission drain). Remove the drain plug              AND TRANSMISSION TROUBLESHOOTING.
from the bottom of the transmission and allow the fluid to
drain into a container, then reinstall the plug with its sealing
washer. Wipe down the transmission and properly dispose of                    HBW 250 TRANSMISSION SPECIFICATIONS
the used fluid. After running the engine, shut down and
recheck the fluid level.                                                  General                 (Hurth Standard Transmission) Case-
                                                                                                  hardened helical gears, with a servo-
Drain plug torque:   20 - 25 Mbs                                                                  operated multiple disc clutch.
                                                                          Gear ratio (standard)   2.74: 1 (HBW250 - 3R)
NOTE: When changing the fluid, take care not to lose the
                                                                          Propeller Shaft         Right handed - standard transmission
drain plug sealing washer. The drain plug will leak without
                                                                          Direction of Rotation
this sealing washer.
                                                                          Propeller               240 X 12 P-2 blade or 220 x 14 P-3
                                                                          Recommendations         blade propeller should allow the engine
                                                                          (using standard         to reach its full rated rpm (3600 + 000
    A WARNING: Never pullout the dipstick while                           transmission
                                                                          2.74:1 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       0.79 U.S. qts (0.75 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 minutes.
SHIPMENT
For safety reasons, the transmission is not filled with trans-         Neutral
mission fluid during shipment and the selector lever is tem-         Move the gear shift lever to the middle position. You should
porarily attached to the actuating shaft.                            feel the detent. This centers the actuating lever on the trans-
Before leaving the WES1ERBEKE plant, each transmission               mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission fluid.       completely interrupted and the output shaft of the transmis-
The residual fluid remaining in the transmission after drain-        sion does not turn.
ing acts as a preservative and provides protection against
                                                                     NOTE: Some transmissions are equipped with a neutral safety
corrosion for at least one year if properly stored.
                                                                     switch. Unless the transmission actuating lever is perfectly
TRANSMISSION FLUID                                                   aligned in neutral, the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextron III and            Forward
continue to use this fluid. During the first 25 hours of opera-      Move the gear shift lever to the forward position. You should
tion, keep a lookout for any leakage at the bell housing, out-       feel the detent. The actuating lever on the transmission is in
put shaft and transmission cooler. This fluid should be              the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300         move the boat in a forward direction.
operating hours thereafter and/or at winter lay-up.
                                                                     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 finger-tight.)
                                                                       o   Run the engine, shutdown and recheck the fluid level.

FORWARD                   NEUTRAL
          TRANSMISSION ACTUATING LEVER POSITIONS
                                                   REVERSE
                                                                        A WARNING: Never pull out the dipstick while the
                                                                        engine is running. Hot fluid will splash from the dipstick
DAILY OPERATION                                                         hole. This could cause severe bums.
o   Check the transmission fluid.
o   Visually check the gear shift linkage and transmission.            Oil Capacity
o   Start the engine in neutral. Allow a few minutes at idle           Approximately 2.5 quarts (2.36 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 transmission.
o   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 plate.

INSPECTION                                                                    ==
o   Visually check for oil leaks at the hydraulic connections.
    Check for wear on the hydraulic lines and replace if
    worn.
o   Lubricate the detent ball and shift cable attaclunents.
o   Inspect the shift linkage.
o   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 190°F (88°C) is recom-
                                                                       mended. Discontinue operation anytime sump oil tempera-
CHANGING THE TRANSMISSION FLUID                                        ture exceeds 230°F (110°C).
After the initial 50 hour change, the transmission fluid should        PRESSURE GAUGE
be changed at every 300 operating hours thereafter or at win-
ter haul-out. However, the fluid must be changed whenever it           An optional mechanical pressure gauge can be installed at
becomes 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 forward
o   Remove the oil filler cap and dipstick.                            gear should indicate 95 - 120 Ib-in 2 (6.7 - 8.4 kg-cm 2) and be
o   Remove the oil cooler return line and allow the oil to             constant.
    drain into a container.
o   Reconnect the oil cooler return line.
o   Use a suction pump to remove the transmission oil
    through the filler cap/dipstick hole.



                                                             Engines & Generators

                                                                  94
                        BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                            WARRANTY NOTES
Transmission maintenance is minimal. Keep the exterior                 Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular           dealer.
routine, and change the fluid every 300 operating hours.               For assistance, contact:
Periodically inspect the transmission and the cooler for leaks                BORG WARNER
and corrosion. Make certain the air vent is clear and when                    200 Theodory Rice Blvd.
checking the fluid level look for signs of water contamination                New Bedford, MA 02745
(fluid will appear as strawberry cream).                                      Tel.: (508) 979-4881
Lay-up/Winterize                                                       BORG WARNER is aware of the shock loads that can be
                                                                       placed on its gears as the result of mechanical propeller oper-
Storage requires special care. Follow these procedures:                ation or fully reversing of the propeller blades while shifting.
o   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 winterized.
o   Clean up the transmission and touch-up unpainted areas              A CAUTION: System-related noises or vibrations can
    (use heat resistant paint).                                         occur at low engine speeds which can cause gear rattle
o   Fill the transmission with Dextron 1II ATF fluid to the             resulting in damage to the engine and/or transmission.
    full mark on the dipstick.                                          BORG WARNER is not responsible for total system-
o   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 TROUBLESHOOTING in this manual.
o   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 TROUBLESHOOTING
CONTROL CABLES                                                                        OIL COOLERS
The majority of transmission difficulties arise as a result of                        The continued flow of raw water through the cooler will, in
improper clutch adjustments (manual transmissions) or prob-                           time, erode the inside of the cooler causing cross leaks to
lems with control cables (hydraulic transmissions) rather than                        occur. These internal cooler leaks will cause one of the fol-
from problems with the transmission itself.                                           lowing two problems:
HURTH clutches, in particular, are very sensitive to improper                         1. Transmission fluid will leak into the flow of raw water
cable adjustments.                                                                       and be discharged overboard through the engine exhaust.
If you experience operating problems with the transmission,                              A loss of transmission fluid will cause the transmission to
shut the engine down. First check the transmission-oil level,                            fail.
then have a helper move the cockpit shift lever through the                           2. The raw water will leak into the transmission fluid caus-
full range - from neutral to full forward, back to neutral,                              ing an increase in transmission fluid. This contaminated
into full reverse, and back to neutral - while you observe                               fluid will appear as strawberry cream. The transmission
the actuating lever on the transmission. If the remote is stiff                          will eventually fail.
to operate, break the cable loose at the transmission and try                     Either case requires an immediate response:
again. If it is still stiff, check the cable for kinks or exces-
sively tight bends, and check any linkage for binding. A new                      1. Install a new oil cooler.
cable and perhaps a new linkage mechanism may be needed.                          2. Refill the transmission with DEXTRON III ATF.
While the cable is loose, shift the transmission in and out of                    If water has contaminated the fluid, the transmission fluid
gear using the lever on the side of the transmission to make                      needs to be cleaned out and replaced with fresh fluid. It will
sure there's no binding inside the case.                                          take several fluid changes to get rid of the contamination.
If the transmission passes these tests, crank the engine and                      Check your dipstick each time until it appears as pure trans-
have a helper put it in forward and reverse while you observe                     mission fluid. Change the transmission filter and clean out
the propeller shaft; if the shaft isn't turning, the transmission                 the fluid lines that connect to the cooler.
needs professional attention. If it does tum but there's no                       If the transmission fails to shift properly, it will most likely
thrust, check to see you still have a propeller on the end of                     need the attention of a qualified transmission service facility.
the shaft or, if you have a folding or feathering propeller, that                 A transmission cooler may last ten years or more but, in
it isn't 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                                             Verification/Remedy
 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 paint/dirt 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 TROUBLESHOOTING
               Problem                           Probable Cause                                        Verification/Remedy
 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" position.

NOTE: If you suspect a major problem in your transmission,
immediately contact your WESTERBEKE dealer or an
authorized marine transmission facility.




                                                                Engines & Generators

                                                                          97
                                                             STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt.                        Metric bolt class numbers identity bolts by their strength with 10.9 the
Customary (inch) bolts are identifed by markings two to grade eight                 strongest.
(strongest). The marks correspond to two marks less than the actual grade,
Le.; a grade seven bolt will display five embossed marks.




NOTES: 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 6·7         SAE GradeS
 Capsrew Body Size         Torque               Torque               Torque             Bolt                 Grade 4.6     Grade4.S     Grade 8.8 - 9.S Grade 10.9
 (Inches) - (Thread)      A-Lb(Nm)            A-Lb(Nm)              A-Lb(Nm)            Dia.   Wrench Size   A-Lb(Nm)      Ft-Lb (Nm)     Ft-Lb(Nm)     Ft-Lb (Nm)
      1/4 - 20                8 (11)              10 (14)              12 (16)
          - 28               10 (14)                                   14 (19)          M3       5.5mm       0.3 (0.5)      0.5 (0.7)       1 (1.3)       1.5 (2)
                                                                                        M4        7mm        0.8 (1.1)       1 (1.5)         2 (3)        3 (4.5)
     5116 -18                17 (23)              19 (26)              24 (33)          M5        8mm        1.5 (2.5         2 (3)         4.5 (6)       6.5 (9)
          - 24               19(26)                                    27 (37)
      3/8-16                 31 (42)              34 (46)              44 (60)          M8       10mm          3 (4)         4(5.5)         7.5 (10)      11 (15)
         - 24                35 (47)                                   49 (66)          M9       13mm         7 (9.5)        10 (13)        18 (25)       35 (26)
     7/16 -14                49(66)               55 (75)              70(95)           Ml0      16mm         14 (19)        18 (25)        37 (50)       55 (75)
          - 20               55 (75)                                   78 (106)
      1/2 -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)
     9/16 -12              110(149)              120 (163)            155 (210)
          -18              120 (163)                                  170 (231)
                                                                                        M18      27mm        81 (110)      118 (160)       225 (305)     321 (435)
      518-11               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)
      3/4 -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)
      7/8 - 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 (3720)

NOTE: Formula to convert Ft-Lbs to Nm (Newton Meters) multiply Ft-Lb x 1.356.

                                                      SEALANTS &LUBRICANTS
GASKETSJSEALANTS
Oil based PERMATEX #2 and it's HIGH TACK equivalent are excellent all               Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolant
purpose sealers. They are effective in just about any joint in contact with         passages. Do not use tape sealants!
coolant, raw water, oil or fuel.
A light coating of Ollar LIQUID TEFLON can be used on rubber gaskets                BOLTS & FASTENERS/ASSEMBUES
and O-rings.                                                                        Lightly oil head bolts and other fasteners as you assemble them. Bolts and
lOCTITE 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 or
filter assembly.                                                                    HIGH TACK
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer.        When assembling the flywheel, coat the bolt threads with lOCTITE blue.
When installing gaskets that seal around water (coolant) passages, coat both        Anti-seize compounds and thread locking adhesives such as lOCTITE protect
sides with WHITE SILICONE grease.                                                   threaded components yet allows them to came apart when necessary.
                                                                                    lOCTITE offers levels of locking according to the job.
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position dur-
ing assembly.                                                                       LITHIUM based grease is waterproof, ideal for water pump bearings and stuff-
                                                                                    ing boxes.
Specialized gasket sealers such as HYlOMAR work well in applications requir-
ing non-hardening properties. HYlOMAR is particlariy effective on                   Heavily oil all sliding and reciprocating components when assembling. Always
copper cylinder-head gaskets as it resists fuel, oil and water.                     use clean engine oil!

                                                                           Engines & Generators

                                                                                   98
                                               gOA FOUR TORQUE SPECIFICATIONS
  Component                                      ft -Ib            kg-m                       Component                                      ft -Ib            kg-m
  Alternator bracket ............................27 - 38 ........3.8 - 5.3                    Injection pipe flare nut ....................18 - 22 ........ 2.5 - 3.0
  Back plate ........................................27 - 38 ........3.8 - 5.3                Injector to head ................................12 -17 ........ 1.6 - 2.4
  Camshaft thrust plate ......................14 - 19 ........ 1.9 - 2.6                      Intake manifold ................................14 -19 ........1.9 - 2.6
  Connecting rod cap ........................59 - 65 ........ 8.2 - 9.0                       Main bearing cap ............................72 - 77 ...... 10.0 -10.7
  Coolant temperature sender ............ 18 - 29 ........ 2.5 - 4.0                          Oil filter ..........................................8.0-9.4 ........ 1.1-1.3
  Coolant temperature switch ............ 18 - 29 ........ 2.5 - 4.0                          (or tighten firmly by hand)
  Crankshaft pulley nut ....................253 - 289 ....35.0 - 40.0                         Oil pan bolts ....................................14 -19 ........ 1.9 - 2.6
  Cylinder head bolts ..............................00 NOT TORQUE                             Oil pan drain plug ........................36.2 - 43.4 ......5.0 - 6.0
  Cylinder head cover ........................1.4 - 2.5 ...... 0.2 - 0.35                     Oil pump pipe ................................5.8 - 8.0 ........ 0.8 - 1.1
  Damper ............................................16 - 24 ........2.2 - 3.4                Oil pressure sender ..........................9 -13 .......... 1.2 -1.8
  Engine mounts ................................23 - 34 ........ 3.2 - 4.7                    Oil pressure switch ..........................9 - 13 .......... 1.2 - 1.8
  Exhaust manifold ............................17 - 20 ........2.3 - 2.7                      Rear oil seal cap ..............................14 -19 ........ 1.9 - 2.6
  Flywheel ........................................130 -145 ........18 - 20                   Rocker arm assembly ......................14 - 19 ........1.9 - 2.6
  Coolant pump bolts ..........................9 -13 ..........1.2 -1.8                       Thermostat housing ......................5.8 - 8.0 ........ 0.8 - 1.1
  Idler gear. .........................................14 -19 ........ 1.9 - 2.6              TIming gear case ............................12 -17 ........ 1.6 - 2.4
  Injection pump drive gear .............. 29 - 52 ....... .4.0 - 9.0                         Timing gear cover. ...........................14 -19 ........ 1.9 - 2.6



Conversion factor to get Nm:
   FHb x 1.356 = Nm




                                                                                   Engines & Generators


                                                                                       99
                              32 KW BEDA GENERATOR SPECIFICATIONS
                        SPECIFICATIONS                                                                         FUEL SYSTEM
Engine Type                 Diesel, four-cycle, four-cylinder, fresh               General                      Open flow, self priming - 1 bleed point
                            water-cooled, Vertical, in-line overhead valve
                            mechanism (46 hp at 1800 rpm maximum).                 Fuel                         No.2 diesel oil (cetane rating of 45 or higher)

Aspiration                  Naturally aspirated.                                   Fuel Injection Pump          ZEXEL Model PE (In-Line)

Governor                    Electronic Governing                                   Fuel Injection Timing        12° BTDC

Combustion Chamber          Swirl type                                             Nozzle                       Orifice type

Bore & Stroke               3.94 x 4.33 inches (100.1 x 110.0 mm)                  Fuel Riter                   Full Row Replaceable
                                                                                   (on engine)
Piston Displacement         210.8 cubic inches (3.5 liters)
                                                                                   Air cleaner                  Metal screen type - cleanable
Firing Order                1-3-4-2
                                                                                   Air Row                      110 cfm (3.1 cmm)
Direction of Rotation       Clockwise, when viewed from the front                  (engine combustion)
Maximum Torque              166 Ib-ft (23 kg-m)
(at 1800 rpm)                                                                                                COOLING SYSTEM
Compression Ratio           18:1                                                   General                      Fresh water-cooled block, thermostatically-
                                                                                                                controlled with heat exchanger.
Dimensions                  Height:      30.0 inches    (762.0mm)
                            Width:       22.0 inches    (558.8 mm)                 Operating Temperature        170 -190° F (n - 88° C)
                            Length:      44.6 inches    (113.3 mm)
                                                                                   Fresh Water Pump             Centrifugal type, metal impeller, belt-driven
Weight                      10381bs (471.8 kgs)
                                                                                   Raw Water Pump               Positive displacement, rubber impeller,
                                                                                                                belt driven.
                   TUNE-UP SPECIFICATIONS
                                                                                   Raw Water Flow,              15.0 gpm (56.7lpm) (measured
Compression Pressure         427 psi (30 kg/cm') at 200 rpm                        at 1800 rpm                  before discharging into exhaust elbow).
(Limit of difference between
 cylinders)                  47.2 psi (3.0 kg/cm'})                                System Capacity              8.5 qts (8.04 liters)
                                                                                   (fresh water)
Valve 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, spin-on type
Engine Timing               Static timed - drop valve method
                            0.180 ± .005 inches BlDC                               Sump Capacity                6.3 U.S. qts (6.0 liters)
                                                                                   (not including filter)       plus filter/cooler assembly
Injector Pressure           2450 ± 35 psi (1 + 5-0 kg/cm')
                                                                                   Operating Oil Pressure       30 - 35 psi (2.1 - 2.5 kg/cm')
Valve Seat Angle            Intake 45°                                             (engine hot)
                            Exhaust 30°
                                                                                   Oil Grade                    API Specification of CF or CG-4,
Valve Clearance             Intake 0.012 inches (0.3 mm)                                                        SAE 30, 10W-30, 15W-40
(engine cold)               Exhaust 0.014 inches (0.35 mm)
Engine Speed                1800 RPM 60 Hertz
                            1500 RPM 50 Hertz


                                                                                                                                                    (continued)




                                                                       Engines & Generators _

                                                                             100
                            32 KW BEDA GENERATOR SPECIFICATIONS

                      ELECTRICAL SYSTEM                                                        AC GENERATOR (3 Phase)
Starting Battery          12-Volt (-) negative ground                          General - 3 Phase           Brushless six pole, revolving field.
                                                                               20.0 KW - 60 Hertz          Sealed lubricated single bearing
Battery Capacity          600 - 900 Cold Cranking Amps (CCA)                   16.0 KW - 50 Hertz          design. 12 Lead reconnectable for low voltage
DC Charging Altemator     51 Amp rated, belt-driven                                                        WYE and for Delta. Solid State voltage regula-
                                                                                                           tor with protection circuitry.
Starter                   12-Volt 3 KW
                                                                               Voltage - 3 Phase           Low voltage WYE              208 volts
Starting Aid              Glow plugs, sheathed type                            (60 Hertz)                  High voltage WYE             480 volts
                          .1-.2 ohm                                                                        DELTA                        240 volts
DC No-Load Cu rrent       ± 2% of rated Amps                                   Voltage - 3 Phase           High voltage WYE             380 volts
                                                                               (50 Hertz)                  DELTA                        230 volts
DC Cranking Current       250 - 300 Amps (engine cold)
                                                                               Amperage - 3 Phase          Low voltage WYE              111.0 Amps
                                                                               (60 Hertz)                  High voltage WYE             48.1 Amps
               AC GENERATOR (SINGLE PHASE)                                     .8 power factor             DELTA                        96.2 Amps
General - Single Phase    Brushless, four-pole, revolving field Sealed         Amperage - 3 Phase          High voltage WYE             47.5 Amps
                          lubricated single bearing design.                    (50 Hertz)                                               82.0 Amps
                                                                                                           DELTA
                          Reconnectable single phase for 1201240 volts         .8 power factor
                          with solid state voltage regulator.
Voltage - Single Phase    120 or 1201240 Volts - 60 Hertz                                           GENERATOR COOLING
                          230 Volts - 50 Hertz
                                                                               Air Requirements            1.0 power factor 500 cfm (15.0 cmm)
Voltage regulation:       ± 2% no load to full load.                           (60 Hertz at 1800 RPM)
Frequency regulation:     .3 Hertz no load to full load.                       Note: Increase air supply 15% for 50 Hertz operation 1500 rpm
Rating (Volts AC)         32 KW - 60 Hertz (1800 rpm)                          Engine Combustion Air       110 cfm (3.1 cmm)
                          120 Volts 266 Amps                                   Requirements
                          1201240 Volts 2661133 Amps                           (60 Hertz at 1800 RPM)
                          25 KW - 50 Hertz (1500 rpm)
                          230 Volts 108.7 Amps




                                                                   Engines & Generators       _

                                                                         101
                           32 KW BEDA GENERATOR PARTS IDENTIFICATION

                                         AIR INTAKE SILENCER              ACTUATOR


                                                                                                    EXHAUST TEMPERATURE SWITCH




20 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 ~X[;HANIt;~HI ~



                                                                                                                                   RAW WATER PUMP



                                                                                                                             LUBE OIL DRAIN HOSE




                                                                                       BLOCK DRAIN PLUG                    STARTER WITH SOLENOID
                                  REAR                                    RIGHT SIDE                              FRONT


                                                               Engines & Generators

                                                                   102
                                           GENERATOR INFORMATION
USE OF ELECTRIC MOTORS                                                    Generator Frequency Adjustment
The power required to start an electric motor is considerably             Frequency is a direct result of engine/generator speed, as
more than is required to keep it running after it is started.             indicated by the following:
Some motors require much more current to start them than                  · When the generator is run at 1800 rpm, the AC voltage
others. Split-phase (AC) motors require more current to start,              output frequency is 60 Hertz.
under similar circumstances, than other types. They are
                                                                          · When the generator is run at 1500 rpm, the AC voltage
commonly used on easy-starting loads, such as washing
                                                                            output frequency is 50 Hertz.
machines, or where loads are applied after the motor is
started, such as small power tools. Because they require 5 to             Therefore, to change the generator's frequency, the genera-
7 times as much current to start as to run, their use should be           tor's drive engine's speed must be changed. Along with a
avoided, whenever possible, if the electric motor is to be dri-           reconfiguring of the AC output connections at the generator,
ven by a small generator. Capacitor and repulsion-induction               a regulator board voltage output adjustment must also be
motors require from 2 to 4 times as much current to start as              made. See ELECTRONIC GOVERNOR in this manual.
to run. The current required to start any motor varies with the
load connected to it. An electric motor connected to an air               Generator Maintenance
compressor, for example, will require more current than a                 · Maintaining reasonable cleanliness is important.
motor to which no l<;>ad is connected.                                      Connections of terminal boards and rectifiers may become
In general, the current required to start 115-Volt motors con-              corroded, and insulation surfaces may start conducting if
nected to medium starting loads will be approximately as                    salts, dust, engine exhaust, carbon, etc. are allowed to
follows:                                                                    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 rust-inhibiting
                          (AMPERES)             (AMPERES)
        1/6                   3.2              6.4 to 22.4*                 petroleum-base coatings, should be sprayed or brushed
        1/4                   4.6               9.2 to 32.2*                over all surfaces to reduce rusting and corrosion.
        1/3                   5.2              10.4 to 72.8*              · In addition to periodic cleaning, the generator should be
        1/2                   7.2              14.4 to 29.2*                 inspected for tightness of all connections, evidence of
        3/4                  10.2              20.4 to 40.8 *                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 screws
*NOTE: In the above table the maximum Amps for Starting is                  and for any evidence of incipient cracking failure. Discs
more for some small motors than for larger ones. The reason
                                                                            should not be allowed to become rusty because rust may
for this is that the hardest starting types (split-phase) are not
                                                                            accelerate cracking. The bolts which fasten the drive disc
made in larger sizes.
                                                                            to the generator shaft must be hardened steel SAE grade
Because the heavy surge of current needed for starting                      8, identified by 6 radial marks, one at each of the 6 cor-
motors is required for only an instant, the generator will not              ners of the head.
be damaged if it can bring the motor up to speed in a few                 · The rear armature bearing is lubricated and sealed; no
seconds. If difficulty is experienced in starting motors, turn              maintenance is required. However, if the bearing becomes
off all other electrical loads and, if possible, reduce the load            noisy or rough-sounding, have it replaced.
on the electric motor.
                                                                          · Examine bearing at periodic intervals. No side movement
                                                                            of shaft should be detected when force is applied. if side
Required Operating Speed                                                    motion is detectable, bearings are wearing or wear on
Run the generator first with no load applied, then at half the              shaft of bearing socket outside bearing has occurred.
generator's capacity, and finally loaded to its full capacity as            Repair must be made quickly or major components will
indicted on the generator's data plate. The output voltage                  rub and cause major damage to generator.
should be checked periodically to ensure proper operation of
the generating plant and the appliances it supplies. If an AC                Carbon Monoxide Oetector----------,
voltmeter or ampmeter is not installed to monitor voltage and
                                                                             WESTERBEKE recommends mounting a carbon
load, check it with a portable meter and ampprobe.
                                                                             monoxide detector in the vessels living quarters. Carbon
NOTE: When the vessel in which the generator is installed                    monoxide, even in small amounts is deadly.
contains AC equipment of 120 volts only, it is recommended                   The presence of carbon monoxide indicates an exhaust
that the generator's AC terminal block be configured to pro-                 leak from the engine or generator, from the exhaust
vide one 120 volt AC hot leg for the vessel's distribution                   elbow/exhaust hose, or that fumes from a nearby vessel
panel. This will ensure good motor starting response from the                are entering your boat.
generator.
                                                                             If carbon monoxide is present ventilate the area with clean
                                                                             air and correct the problem immediately!




                                                                Engines & Generators

                                                                    103
                            GENERATOR CONTROL PANEL SWITCHES
DESCRIPTION                                                           3. START: The START toggle switch is a double pole, single
This manually controlled series ofWESTERBEKE marine                        throw switch. The switch serves two purposes: starting
diesel generators is equipped with toggle switches on the                  the engine and defeating of bypassing the engine oil pres-
engine control panel and, optionally, at remote panels. The                sure switch. The defeat function turns on the fuel sole-
following instructions and methods of correcting minor prob-               noid, instrument power and alternator excitation.
lems apply only to such toggle switch controls.                            While the PREHEAT switch is still depressed, depressing
                                                                           the START switch engages the start solenoid. Panel
All three switches are momentary contact type and serve the                power and the fuel solenoid will be activated. When the
following functions:                                                       engine begins to fire, the START switch should be
1. 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. When
2. 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 panel's 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 panel's 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 TROUBLESHOOTING
                                 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                                        Verification/Remedy
 PREHEAT depressed, no panel indications   1. Oil Pressure switch.                        1. Check switches and/or 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 terminal.(Exc. 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 (0-.25 amp) meter in battery
                                                                                             lines (Do NOT start engine). Remove connections and replace
                                                                                             after short is located.



                         TROUBLESHOOTING WATER TEMPERATURE AND OIL PRESSURE GAUGES

If the gauge reading is other than what is normally indicated                     If both of the above gauge tests are positive, the gauge is
by the gauge when the instrument panel is energized, the first                    undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition (B+)                        conductor from the sender to the gauge or with the sender.
and the Negative (B-) terminals of the gauge.                                     If either of the above gauge tests are negative, the gauge is
Assuming that there is 12 volts as required, leave the                            probably defective and should be replaced.
instrument panel energized and perform the following steps:                       Assuming the gauge is OK, check the conductor from the
1. 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 bat-
2. 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 PHASE
DESCRIPTION                                                         CIRCUIT BREAKER
'This generator is a four-pole, brushless, self-excited generator   A circuit breaker is installed on all WES1ERBEKE genera-
which requires only the driving force of the engine to pro-         tors. 'This circuit breaker will automatically disconnect gener-
duce AC output. The copper and laminated iron in the exciter        ator power in case of an electrical overload. The circuit
stator are responsible for the self-exciting feature of this gen-   breaker can be manually shut off when servicing the genera-
erator. The magnetic field produced causes an AC voltage to         tor to ensure that no power is coming into the boat.
be induced into the related excitor rotor windings during
rotation. Diodes located in the exciter rotor rectify this volt-    NOTE: This circuit breaker is available as a WESTERBEKE
age to DC; and supply it to the windings of the rotating field.     add-on kitfor earlier model generations; contact your
'This creates an electromagnetic field which rotates through        WESTERBEKE dealer.
the windings of the main stator, inducing an AC voltage                                 PART # CIRCUIT BREAKERS
which is supplied to a load. An AC voltage is produced in the                           42703 32 Kw 60 Hz
auxiliary windings of the main stator and is, in turn, supplied                         43271 25 Kw 50 Hz
to a voltage regulator. The regulator produces a DC voltage
to further excite the exciter stator windings, enabling the gen-
erator to produce a rated AC output. The voltage regulator
senses AC voltage output and adjusts DC excitation to the
exciter stator winding according to amperage load the gener-
ator is furnishing. To maintain a constant voltage output.




                                                           Engines & Generators


                                                                106
                                   GENERATOR AC VOLTAGE CONNECTIONS                       .   -- .                 .

DESCRIPTION
The regulator is equipped with seven numbered terminals (0
to 6) and their related brass jumpers. The illustrations show
connection points and jumpers for the 3 phase configuration
of the generator. The sensing leads connect between pin #1
and pin #2 on the AC terminal block and connection #2 and
#0 on the voltage regulator board.
NOTE: Series Delta requires the installation of a jumper on
the regulator board between tenninal B and 1.                                                   170 - 270 V                                    80 -160 V


                                                         N'GND



  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
                               2+3
                                                                 L1
                                                                         1+3    2+4
                                                                                                        L1
                                                                                                                 1+12
                                                                                                                          o
                                                                                                                          2+3



             L2
                         5
                                o
                               6+7
                                                                 L2
                                                                         5+7
                                                                                0
                                                                                6+8
                                                                                                        L2
                                                                                                                 4+5
                                                                                                                          0
                                                                                                                          6+7
                                             N
             L3                 o ..~.",+"                       L3                       N ()          L3                0        ()
                         9    10 + 11                                                                            8+9     10+11    ~

                   "SERIES Y"                                         "PARALLEL Y"                            "SERIES DELTA" -
                        480V/60 Hz.                                   208V-120V 160 Hz.                         240V/60 Hz.
                        380V/50 Hz. .                                                                           230V/50 Hz.
                                                               6 STUD 3 PHASE AC WIRING

                  PARALLEL WYE (STAR)                             SERIES WYE (STAR)                                     SERIES DELTA



                  ~
                  (!U0
                                                  N

        L - L - 208 VAG 3,8             60   Hz                  L - L - 450 VAG 311   60Hz                        L - L - 240 VAG      2,0'     60Hz
        L - N -120 VAG 1,9'             60   Hz                  L - N - 265 VAG t8    60 Hz                   L2, L3-N -120 VAG        1,0'     60Hz
        L - L - 190 VAG 3,9'            50   Hz                  L - L- 380 VAG 3,9'   50Hz                        L - L - 230 VAG      3,9'     50Hz
        L - N -110 VAG 1,9'             50   Hz                  L - N - 230 VAG 1~    50Hz                    L2, L3-N -115 VAG        1,9'     50Hz

                                                        BE THREE PHASE (TWELVE WIRE)                            A. SERIES DELTA-Note the
                                                                                                                   repOSitioning of the ground
                                                                                                                   lead from neutral to
                                                                                                                   generator housing.
                                                                                                                J. Jumper using #10 AWG
                                                                      Engines & Generators _

                                                                          107
                               GENERATOR AC VOLTAGE CONNECTIONS
AC VOLTAGE CONNECTIONS                                                  Generator Frequency
NOTE: The frame ground wire (white/green) must be prop-                 1. Frequency is a direct result of engine/generator speed:
erly positioned when changing the AC output configuration                  1800 rpm = 60 hertz; 1500 rmp = 50 hertz.
of the AC terminal block. For making connections to the AC              2. To change generator frequency, follow the step's below:
terminal block, use terminal ends for 114 inch studs that will
                                                                           Configure the AC tenninal block for the desired voltage
accept multi strand copper wire sized for the amperage rating
                                                                            frequency as shown. Ensure that the case ground wire is
from the hot lead connection. The frame ground wire is white
                                                                            connected to the correct terminal block neutral ground
or white with a green strip. It connects between the neutral
                                                                           stud.
stud and the generator frame.
                                                                        NOTE: The white/green 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.
          120/240V 60Hz                120V60Hz                        230V50Hz                  115V 50Hz

              o     o                   o       0                             o                       o     0
   L1                                                                        f®l
                                                                             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 ADJUSTMENTS
Description                                                           Amp-Hertz
The voltage regulator is an advanced design which ensures'            These two adjustments are used in conjunction with the two
optimum AC alternator performance. It is equipped with                protection circuits in the voltage regulator that are indicated
complete protection circuitry to guard against operating              by the illumination of a colored LED lights.
conditions 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 start-up 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 generator.
This potentiometer is used to adjust output voltage. At proper
engine operating speed the output voltage should be held at           Setting the Overload Protection
±1 % from a no-load condition to a full rated generator output        In order to set the AMP overload protection, the alternator
and from power factor 1.0 - 0.8 with engine drive speed vari-         must be loaded to its full output rating.
ations up to -6%.                                                     1. Load the alternator to its rating, then decrease the speed of
Prior to starting the engine, turn the VOLT and STAB trim-               the engine by 10.10% (54 Hertz on 60 hertz units, 45
mers (using a mini phillips screwdriver) fully in a counter              hertz on 50 hertz units).
clockwise (Minimum) direction until you feel them hit their           2. Rotate the AMP adjustment counterclockwise until it hits
stops.                                                                   its stop. Wait about 15-20 seconds after which the AC out-
Turn the AMP and HERTZ trimmers completely clockwise                     put of the alternator should drop and the yellow LED light
(Maximum) in the same manner.                                            should come on.
With the alternator running at no-load, at normal speed, and          3. Slowly rotate the AMP adjustment clockwise until the
with VOLT adjust at minimum, it is possible that output volt-            output voltage increases to approximately 97% of the volt-
age will oscillate. Slowly rotate the VOLT adjust clockwise.             age output at the start of the adjustment. At this point the
The v.oltage output of the alternator will increase and stabi-           yellow LED light should come on.
lize. Increase the voltage to the desired value. In this situa-       4. Return to nominal speed, the yellow LED will turn off
tion, only the green LED will stay lit.                                  and the alternator voltage will rise to its normal value.
                                                                         Should this not happen, repeat the adjustment.
Stability
This potentiometer permits variation of the regulator's               NOTE: When changing from 60 hertz to 50 hertz operation,
response to generator load changes so as to limit overcom-            remove the 60 hertz jumper bar from the regulator board.
pensation and obtain a minimum recovery time to the normal
voltage output.                                                       Setting the Underspeed Protection
In order to adjust the regulator stability the alternator must be     NOTE: lfthe unit is operating at 60 Hertz ensure that the
running at no-load and the output must be monitored.                  jumper strap is in place on the regulator board between the
Turn the STAB adjust slowly clockwise until.the voltage               two 60 Hertz terminals. In order to adjust the underspeed
starts to fluctuate. At this point rotate the STAB adjust coun-       setting, the alternator should be running at no-load.
terclockwise until the voltage is stable within 1 or 2 tenths of
                                                                      1. To adjust the underspeed (low frequency) protection circuit,
a 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 counterclockwise slowly until
                                                                         the alternator's 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 PHASE
r------------,
        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
                                                                                                                                 6.3 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 ........!B~LA~CK~I· · · ·I-i-_~BL~AC~K_ _ _ 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
                                                                                                         rREi)~I
                                                                                                           RED  I
                                                                                                                 · · · ·~_---,:!R~EO_--7WI

                                         :                 b   I                               : : rII--1-,
                                         I                                                     I                  I                   I
                                         I                                                     I                  I   _. _ _ _       J
                                         I                                                     I                      AUX
                                         L. _ _ _ _ _          ~    __________                 ~                      WINDINGS
                       _         ________ J
         L._


                                                                   REGULATOR
                                                                                                                                      FUSE
                                                                                                                                      6.3 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

                                                                            I~T;o;-l
r--------,
I EXCITER STATOR,.. - - _ +
                          ' - _ - _ - - -..,                                !      2
                                                                              _ _1IIi
                                                                         I.....j-
                                                                                           I
                                                                                      _...t-!      : 12
                                                                                             - - -... 11

I            '.                                                                 -..J-:____
                                                                         L-j:r.-1iI
                                                                                 3         : 1~
                                                                         r-+-r-~-"":-------:
I                 EXCITER
                  ROTOR
                               I.         ROTOR FIELD           I
                                                                I                                                       8 AC
I        +   I                                                  I        4 ....      4
                                                                                      . . . . . . .- - - - - -          7 TERMINAL
                                                                         C:!::_.5_~:===::: ~                                BLOCK
I                                                               :
I
I
                                                                I
                                                                I
                                                                            :        6:
                                                                         ~~~~~~~~~::::::::
                                                                                                                    :   ~
                                                                                                                        2
                                                                              7                                         1
I                                                               I                    8    .   I
I
L.      _____               ...J
                                                                    AUX    ...                ,
                                                                                              I

                                                                    WINDINGS
                                                                                                  FUSE       NOTE: This fuse
                                                                                                  6.3 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                                                              18.06                      18.20
     EXCITER ROTOR _ a - b                                                        0.68                       0.72
                      b-c                                                         0.68                       0.72
     ROTATING FIELD                                                               1.75                      2.01
     MAIN STATOR                    1-2                                           0.05                      0.05
                                    3-4                                           0.05                      0.05
     AUXILLARY WINDING                                                            1.19                      0.98
                       THREE PHASE                                     20, 25, & 32 BE

     EXCITER STATOR                                                              18.20
     EXCITER ROTOR _                a-b                                           0.7
                                    b-c                                           0.7
     ROTATING FIELD                                                               2.01
     MAIN STATOR                                                                  0.06 (each winding)
     AUXILLARY WINDING                                                            0.98


                                                Engines & Generators             -

                                                        111
                                                    BE TROUBLESHOOTING
                                                   NOTE: AC GENERATOR TROUBLESHOOTING MUST
                                                BE PERFORMED WITH ENGINE OPERATING AT 60 HERTZ.


              PROBLEM                                                                             PROBABLE CAUSE
No 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 pozi-resistor                          5. Short or open in rotating
                                                                      on exciter rotor.                                 field winding.

                                                                   3. Four or more shorted or
                                                                      open diodes on exciter rotor.

Residual voltage produced at no load                               1. Blown 6 AMP buse fuse                          3. Shorted or open main
15 - 20 volts AC.                                                     auxiliary circuit feed to AVR.                    stator auxiliary winding.

                                                                   2. Faulty voltage regulator

Low AC voltage output at no load                                   1. Open or shorted diodes in                      3. Faulty voltage regulator.
60 - 100 VAC.                                                         exciter rotor 1 to 3 diodes.

                                                                   2. Open or shorted exciter
                                                                      rotor winding

High AC output voltage                                             1. Faulty voltage regulator.
150 VAC or higher.

Unstable voltage output.                                           1. STB pod on regulator                           2. Faulty voltage regulator.
                                                                      needs adjustment.

AC voltage drop under load                                         1. Diode(s) on exciter rotor
60 - 100 volts AC.                                                    breaking down when load is
                                                                      applied (inductive) 1-3 diodes.

      r--·----------,
                          EXCITER
                          STATOR
                                                                                                       RED
                                  r-----~----------~
                    I                           I                           I                                                RED
                    I                           I                           I
                    I                 EXCITER   I    ROTOR FIELD            I                     1-------1
                    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
Electronic Governor System
The system is composed of three basic components:
1. ControUer. Mounted in the instrument panel.
2. Sensor. Installed on the bellhousing over the flywheel
   ring gear.
3. Actuator. Mounted at the front of the engine and
   attached with linkage to the throttle arm of the injection
   pump.

Controller Adjustment
1. Speed. This adjustment is used to raise or lower the
   engine's speed to the desired hertz.
2. Gain. This adjustment affects the reaction time of the
   actuator to the generator/engine 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 GOVERNOR
Calibration
                                                                                                              LINEAR ACTUATOR
1. With no power to the governor, adjust the GAIN to 9:00
   o'clock.
2. 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 exist.
3. At no-load, turn the GAIN potentiometer clockwise until
   the engine begins to hunt. if the engine does not hunt,
   physically upset the governor linkage.                                                                  LINEAR ACTUATOR
4. Turn the GAIN potentiometer counterclockwise
   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-===.!:~~_ _ O.030in


        FLYWHEEL ~ ~          r-\-r===:;:
                                              t
        TEETH     7 v


                      ----         v      \




                                                         Engines & Generators _

                                                                113
                         TROUBLESHOOTING THE ELECTRONIC GOVERNOR
              Problem                          Probable Cause                                          VerificationJRemedy
System appears dead                   1. Low battery voltage at controller.           1. Check wiring for cause. Check battery state of charge.
(Engine 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 1.5 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 (1.20-2.0 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 other.
Actuator fully extends when PREHEAT   1. Check controller. Lift one of the purple
is 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 lead.
Actuator hunts (oscillates) and       1. Linkage between actuator and throttle        1. Lubricate/free-up.
engine 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 - 9.6 VDC or higher
                                                                                         24 VDC System -19.2 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 SWITCH

SHORE POWER CONNECTIONS (60 HERn)                                                                     120 VOLT/60 HZ THREE WIRE CONFIGURATION
                                                                                                      Notice the repositioning of the white wire ground load on the
Gen&rator              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. 120-Volt system from the generator,
                                                                                                                          with three-wir ·· 120-Volt boat system.

     r-----\~
     I
                 ~I
            , __ ,
                                          "II
     I                                      I
     I                                      I
     I                                      I
     j                /"'---',              I
                                 \          I




            r~:~ l_~}
                                                                      Ship-ta-Shore Switch (3 Pole)
                                                                          PH 32008
                                                                          (40Ampa/Pole)
                                                                          PH 32009
                                                                          (SO Amps' Pole)
                                                                          PH 32010
                               \        Neutral                           (125 Amps' POle)
                  I                                     N   Sh;p', Load   PH 32133


            ii'~;;;:::
                                                                          (200Ampa'Pole)

                                                  It.                                                                      __ . .                       L2}
     T
   l52
             ~
         Sl T N
                  r-
                   )
                                                                                                                     .~_/~:..;..:-I---'===--~' ~~~~,LO'd
                                                                                                                     -I   '-                                  No 240-Volt
    Shore POwer                                                                                                      ~I     Ground                II.         EqUipment
                                                                                                                     Z.        (GRN)

If the installer connects shore power to the vessel's AC cir-
                                                                                                           ~
cuit, this must be done by means of the Shore Power Transfer                                                Shore Power

Switch. Set the transfer switch shown in the diagrams to the
OFF position. This switch prevents simultaneous connection
of 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                                                vice-versa because voltage surges induced by switching
 covered under the warranty; it is the installer's 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 RED/PUR
                                                              aLliJ:l
                                                                                                                              WATER TEMPERATURE
                                                                                                                                                .llJ:!ll..E..B.
                                                                                                                                                ...-R..

                                                                                                                                                r
  .14 PUR


                                                                                                                                                                                         [
                                                              fUEL SOLENOID
                                                                                                       AIR INTAKE
                                                                                                         .!!tAll.B.                                                              01 L PRESSURE



                                                                                               ~
                                                                     114 RED




                                                                                                                                   :
                                                                                Ie RED
                                                                                                                       IIII
            BATTERY      SWITCH             ~~/
              r V~--                 - - - --- - -      ~~---...,
                L:I~ ~~C                        ~t..t=-~
                                                                                         114 PUR/WHT


              :                                                                                                                                                                     OIL PRESS
              '- ~                               llAlli.B.                                                                                                                            .llJ:!ll..E..B.
                                --                      Il.QIQ..B.
                                 -                  0                                                 _____~-...,
                                                                           ~~_ _ _ _ _ _ _~'~"~"~L~/'~"~

                      GROUND                   ~
                                TO B L O C K , , r---'-~-"r-------HI----"'-::....:;:.::...---------------------+--t---'
                                                 =                         114BLU

                                                                      114 TA"
             rHIELDED

            "Ill 0 .
                   ~
                                                                                         112R£00                          112 RED

              ~
                  .e..ws.J!f.                                                                20A CIRCUIT
                                                                                                ~
                                                                                                                                 EMERGENCY~
                                                                                                                              STOP SWITCH
                                                                                              114 BRN



                                                                                                   REMOVE TH IS-.,.
                                                                                                   JUMPER WHEN ,.,.,
                                                                                                                                     ~
                                                                                                                                   =.4-=,   . ..,.,.)             I
                                                                                                                              1"',..==-··..
                                                                                                                                          ""·,,,·,
                                                                                                                                                                                             __=------'
                                                                                                   CONNECT I KG A
                                                                                                                                     [i~~:t;:===~~---------:

                                                                                               a
                                                                                                   REMOTE  PANEL
                                                                                                       114 REO                       Ii
                                                                                                                        I!.!.!!:!SI'---                                                   .14 GftN

                                                                                                                                       ~""
                                              114 RED
                                                                                                ''''U'
                                                                           ~                                                                                                                                          -
                                                                           ~
                                                                                    r-                                                 ::-;-:
                                                                                                         ~.'                           ~           (D


                                                                           ~             114 RED                                         I         ;:       ;:        III   10
                                                                           t:::::                                                       ~
                           r---..----.-I-.-.E-.----~~~~-------+~----------~~~-+~~~;
                                                                                                                     .1 .. SlK
                                                                                                                                                                      ;:
                                LT83
                            ~/RED
                                            "'RE.
                                                                                           '14 YEL


                                                                                           .14 PUR
                           _~ BlK                                                        110 RED/WHT

            L-__-,~~~~~~TI                                                                                                    rti'i"""6RII


         "'=......,)r---
                  61 ·
        L........_ _ _ _ WHT

  L-----------~~~J
                 r---~.
L........________________PUR
                                     '---
                                                         1--- --- --- ------ --- ---- -- --- --- ---
                                                                                                          b                                                                                             --I

                                                                                                                                                10RtO

                                                                                                     14 YEL                      10 ItEO/WHT




                                                                           .....
                                                                       PRESSURE
                                                                                              WATER
                                                                                               "fEY'                                                                                                          illl!.IlA.B.J).
                                                                                                                                                                                                               INSTRUMENT
                                                                          o                        o                                                                                                          .P.All.E.l..




                                                                                                               10 liED/WIlT




                                                                                               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
                               SWITCH
1    I BREAKER


                                                             D

r    I EMERGENCY
     I STOP
     I SWI TCH r          I PREHEAT
                            SWITCH
                    I     I                           K
    __---------+--------------~3~0                        r8~1______~

r    1
        STOP
      I SWITCH                                                                                FUEL SOLENOID
      I
                              OIL PRESS.         EXHAUST TEMP           WATER TEMP.
                                SWITCH              SWITCH                SWITCH
                                                                                                   K
                                      ~--------~l/}~--------~/~+_~~+_--~8~6                            ~8~5____~




                                                                     TEMP.            VOLTMETER
      HOURMETER




                    OIL                      WATER
                    PRESS.                   TEMP.
                    SENDER                   SENDER




                                                      Engines & Generators

                                                            117
                                              32 KW BEDA GENERATOR
                                            WIRING DIAGRAM #040425 (TWO RELAYS)
                                                                                            110 ORN
                                                                                                                                                                                            ALTfRNATOR    51A




IU PUR




~l                                                   FUfl SOl fNOI P                             AIR INTAKf
                                                                                                                                                             OIL PRfSSURf



     U                                                                                     ~
                                                                                                                                                                m.IQ!
                                                           1141[0




                                                                                                                            :
                                    -- ~                 /.,--.....;.:
                                                                    .....;.""'.C----i!.I!IIJ!I!III.l                1111
          8A HERr SW 1 T C H " " ' J '                                                                 :r

            (£o!------ J:ij-                                                      114 PUR/WMT

            I    12 VDC
                                                                                                                                                                OIL PRfSS
            L~                                ~ijamRO                                                                                                             .s..El!.P.E..B.

                  GROU.' TO B'OC'           J""--                   L4-+____________
                                                                                       114 BlU
                                                                                                                 ~.~"~'~EL~/.~'.~     ______        ~




                                                             1.4 TAN




                                                                                   ' " RE'    U· '"                         REO

                                                                                        ZOA CIRCUIT                         fMfRGfNCV=lY
                                                                                            ~                              STOP SWITCH
                                                                                          I'" 6.M



    '-t-t-----------'!20                                     ~iJ.,..
                        I !,..!.!!PU!!..-j---j-j--H--:;i:-":-;j.
                                                                                               REMOVE
                                                                                        JUMPER( S) WHEN
                                                                                                                 TH~I1;!!!
                                                                                                                        ~~I
                                                  r-         :::; =;:                   RE~~~N~~~i~~s~                      ~E-:;-;'~===;--'
                                              '-I-I-I-_=-~.~ ~g                                        ." .ED               'Ii~'-;~"""-----+++--------------l
                                        ~".!.J'·~'·~+=~./~I~J~:;-l---~l"c!"'·m~pu,                          IZ                  I~                      ~
                                                     i              ~           ~--=:=:;t''F':.~.;··'Y'Y11        II. eL'~                  i :1 ~ ~
                  1.4 !IlK
                                                     _              ==             II. RED                  " ' Be<             ~           ~   ;   ~   ::
                                                                                                                                                                        .,. BLK
                                  '14 RED


                l\~AED
                                     '141 D



            ~~               ".                                                      114 PUR

                                                                                  '10 RED/WMT                          f
                                                                                                                                IU WNT




                                                                                                                                      "-"-"-"-1
                                                                                                                                                                                        1
                                                                                                                                    101[0




                                                                                                                                                -fit
                                                                                               I'''[L                      101[D/WNT

                                                                                                                                                                          _T
                                                                                                                                                                           IMTCH        1
                              '\ f/                                                                                    .
                                                                                                                       :
                                                                                                                                                                   /'                   1
                                                                                                                                                                                            ~
                                                                                                                                                                                             INSTRUMfNT
                                                                                                                                                                                            fA1!EJ..

I                                                                                                                                                       ~;                 Sf......
                                                                                                                                                                           IMTCH

                                                                                                                                         . .
                                                                                                            10lEO/UT


                                                                                                                                                                            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 .., EME.RGENCY                                                     ~-      -,                     AIR INTAKE
  I
  ~~
         I   ~~?~CH                                                                                      HEATER




                                                                                                      AL TERNATOR

                                  87
                                       KI-START
                                  30                                                                        R

                                                   K2-RUH                                                               FUEL SOL.
        ~---~--~~---~30 r8~7~_ _ _ _ _ _ _ _ _ _._--~---_;




                                  OIL PRESS.            EXH. TEMP.             WATER TEMP.
                                         SW.                   SW.                 SW.




                                                                             I N4002                               K2-RUN RELAY
                      L -_ _   ~r_--~~------~~--~-_r----~8~6                                                               r8~5_-.


   ~~                                                                                                             KI-START RELAY
                                                        ~~---_r-------~--~8~6                                              ~8~5_-.


                                                                                                                OIL PRESS. SENDER


                                                                                                                WATER TEMP. SENDER
T81-2      T81-3 T81-4                     T82-2       T81-S           T82-1           T82-4       T82-S                      T81-10
        ~--~~--~                                                                                       ~---L2=r--~




                                                            VOL TMETER
                                 HOURMETER




                                                               Engines & Generators -

                                                                       119
                                                                                               32 KW BEDA GENERATOR
                                                                                         WIRING DIAGRAM #44737 (TWO RELAYS)
                                                                                          (PLUG-IN REMOTE START/STOP PANEL)



         ."".,
          ALTERNATOR




          114 BRN
                     ~


                     'Ljj

          .....:l", :"
                             "QA~?"ypC




                            [XC.        A.




                                                                                               ~
                                                                                                     ~
                                                                                                                                 WATER li:lJHATURE




                                                                                                                                                 U-~
                                                                                                                                                                                          WATER iif:fflATURE



                                                                                                                                                                                               ~~~
                                                                                                                                                                                                                                   ....  ,.,
                                                                                                                                                                                                                                       , T · · · nn.




                                                                                                                                                                                                                                    110 OftG
                                                                                                                                                                                                                                                E~'}
                                                                                                                                                                                                                                               ,~
                                                                                                                                                                                                                                                 S   J
                                                                                                                                                                                                                                                   OGND(E)

                                                                                                                                                                                                                                                       0
                                                                                                                                                                                                                                                           ,n&_I,ynr




                                                                                                                       ~
                                                                                                                       =                                                                                                             '''''11


                                                                                                                                                                                                      I" IIED/YIO


                                                                                                          ~
                                                                                 ....,                                                                                                                                             ~
                                                                                                     ""R
                                                                                                                                                                                                                                    P -=-
                                                                                                                                                                                                                                    FUEL SOb ENOl




                                                                                                                                                                                                          .?J.. "
                                                  0
                                                  0                                                       "1l:rT
                                                                                                     .{                        !E OOIE ,
                                                                                                                                                                               TEU4=:
                                   _;Q
                                                                                                                                                                                                              .w.lilI
                                                                                                                                                                                                      0
                                                                                                                                                                                                                               0



                                                                                                                  a~~M!~~~~~,                                                                                                  .
                                                                                         '"    ".                                                               I.ID
00"'''
    I
    L~
       ,.. ".
 r£o!--------- k'"
        I Z-Z' YDC

                                                                    0             I      IU flLlIU         . IO~lr
                                                                                                           ~
                                                                                                           -     RRfAulf-        04    YDC


                                                                                                                                                                         IIIIlIm1
                                                                                                                                                                                                  0



                                                                                                                                                                                                  .
                                                                                                                                                                                                  0



                                                                                                                                                                                                  .
                                                                                                                                                                                                          AUX. 0 It PRESSURE
                                                                                                                                                                                                                SIITCH             111-11
                                                                                                                                                                                                                                      QII~UR£
                                                                                                                                                                                                                                               D--                     ~
                                                                                                                                                                                                                                                                       ;
                                        -=-      STARTER MOTQR                                                        "'lIrb,nT




                                                                                                                                                                             ~-      ~~~~R~'N'~H                    .
                                                                                                                                      I " TAli
                lilliE.!!2R
                ~
                                                                                                                                      .1411111                                                                      .
I                                                         I                                                                           I'. VIO



                                                                                                                     l~                 I.t                            III
                                                                                                                                                                               tI4'~~
                A~
                                                                                                                                              REO/.NT


                                                                                                                                                                 ~"E""'1'
                                                                                                                      ~If-
                                                                                                                                                                                                                                                    GROUND TO
                                                                                                                '-                                                 ':_"" f!'                                                                rill      ENGINE

                                                                                                                      ~                                                  f!'
                                                                                                                                                                         li';i I - -
                                                                                                                                                                                                                                                       BLOCK




                             ~0
                                                                                                                                                                               II · ·T


                                                                                                                          ~                                .".'.~~
                                                                                                                          ~                                      ~                    ;


                                  RED                 ,.!!:!.
                                                      ~I
                                                                  1101 RED
                                                                                  114 RED
                                                                                                                          ~
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                                                                                                                                                                                                                                                           ruSE 811.
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                                                                                                                                                                                                                                                    p=!}
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                                                                -.:L
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                                                                 VIO
                                                                                                                                                    l.rUL
                                                                                                                                                                              .IIIIRIl

                                                                                                                                                                              III"[D


                                                 YIO~~
                                                                                                                                                    1'1 OIlG




                                                                                                    --1---··_· __ ··_··_· __ ·· __ ·_·
                                                                                                               !!Ai.lli!.t
                                                                                              .r~IELDED         lli!.U!                                                       ' " WMT

                                                                                                                                                   ~                           lit ILl


                                                                                                                                                               (ill@J
NOTE:
I. REMOVE JUIIPER IHEN CONNECTING A 5£COIO REMOTE PANEL.                                                                                                                            ... WHT

2. GROUND -,- TERMINAL      or    PREHEAT SOLENOID ON 2.cv SYSTEM ONLY.


                                                                                                                                      " ' ORG
              ,.------'.'""'-"".!!!I!.!.I-~ T82.1
                                   ..
                                              ....0,..'                                                                                                                                                     PREHEAT
                                                                                                                                                                                                             swrrcH
                 ,.-_+_.....!J!!"!!!L-_"""",,,,                         IBH
                       r-I--..!.!.!..!W!l.L_-"'J IBH
                                  r--!.!JL!!!!illL--:~ la I . j


                                                                                                                                                                                                              START
                                                                                                                                                                                                              swrrcH
                                               ;)+..!.!.!......""""";iI)IBI-IO




                                                                                                                                                                                                               STOP
                                                                                                                                                                                                              swrrcH
                                                                                                               HOUR                               VOLT
               L---,-!,!.!..J!,J!!!!!!~-~TBZ·8                                                             . ~. ____
                                                                                                                   ~_ .. _                                                   .. _         .. ____ .. ---1


                                                                                                                             Engines & Generators

                                                                                                                                         120
                                 32 KW BEDA GENERATOR
                         WIRING SCHEMATIC #44737 (TWO RELAYS)
                          (PLUG-IN REMOTE START/STOP PANEL)



                       C I RCU IT
                       BREAKER                                                           STARTER

      .--_ _ _.;cJr       ~o;--------o--....L.-lI--I-----l
                        L _...J


                                                                     '- -   _.I
                                                                                                       AIR INTAKE
                                                                                                          HEATER

 r .., EMERGENCY
 I      I~~?b                                                                       I PREHEAT I
                                                                                    ISOlENOI ~


                                                                                    '-   - _..         AL TERNATOR


                      KI·START


                                                                   Kl·RUN
     ~T=B~I.~I----------~---4----------~3D~~B~T-------------.__--~~----~




                                                             WATER TEMP.
                                             EXH. TEMP.           SWITCH       Oil PRESS.
                                               SWI TeH                            SWITCH




                                                                   IUDDl                                         Kl·RUN RELAY
                                                                                                                 86       85


               PREHEAT                           START
               SWITCH

               r -"                             r-,
                                                SWI TCH
                                                                                                                 86
               [_ .J                            L_J
                                                                                                              AUX. O.P. SWITCH




                                                                                                             OIL PRESS. SENDER




TBH           T81-3    T61· ..       TBl·2                TBI·5        TB2·1        TB2·8                      WATER TEMP. SENDER
                                                                                               TB2·'

                                                                                                                            TBI-IO




                                                                                                             WA TER TEMP. GAUGE




 .... -STOP
        '
       SWI TCH
                           PREHEAT                START
                          5_1 reH                sw. reH                                                     OIL PRESS. GAUGE
                                                                                  IND. LIGHT
                          r-"o;..-.._~....!o--l:"""
                          [_ .J
                                     · TTP ICAl REMOTE START/STOP 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
                                                                                                        1.4 PUR                                                                        11.4 PUR
                                                                                                                                                                                                                                                            1111f1"'r6TPUT



                                                                                        WAIER TEMeERATuRE
                                                                                             aill..I:f.                          I.AF                                             I.' R(D/PUR
                                                                                                                                                                                                                                                 I          \~
                                                                                                                                                                                                                                                            ~~
                                                                                                                                          "l..)'


                                                                                                                                                                           W~TEB        IEMPEBATUBE
                                                             0                                                                                                                         ~

                                                             -
                                                                             ~                                                                                                         ~
               .. "";-
                                                                                                                                          $'''10''\
                                                                                                                 I" IED/WHT

                                                                                             r-- ~                                                                                                                       --11'
                                                                                                                                                                         (~
                                                                                                                                                                                                                                   GROUND TO
                                                                                                     ~ '0
                                                                                             L.-                                                                                                                              I          ENGINE
                                                                                                                                             ',.'"'1
                                                                                                                                                                         ~                                                               BLOCK
                                                                                                     t::-;":                                                             ~-
                                                                                                     E7- ;I-
                                                                                                                                                           .. oinT




                         ~K@
                                          y.               ·                                         ~
                                                                                                     S
                                                                                                                                  "   .... ~~ -,                         ~
                                                                                                     ~
                                                                                                                                                                ·· tIL
                           RED            TB3
                                                                                                                                                                                                                 .ueu
                                          ~        II"R£O                                            -                                                                                                                                    FUSE 86




                                          --.
                                                                IU REO
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                                    VIO~~
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                                                                                                                              "'ORG

                                    YIO~~

                                                                                   --
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                                                                                                                            ~                             .IIIU


                                                                                                                                        (~~ a(~
                                                                               ~




                                              p
                                                                                        1"-"-"-"-"-"-"-"-'
NOTE:
I. REMOVE JUMPER OEM CONNECT IIG A S[CONO REMOTE PANEl.




                                                                                                                                                                                          PRa£AT
                                                                                                                                                                                           SWITCH

                 .---+--"'..!!!...--0 ,,,.,
                    r+-....!!1JWl!"--0 TIU-S
                        .--.1!L!!"""'"~eTBI·)


                                                                                                                                                                                           START
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                                                                                                      Engines & Generators

                                                                                                                   124
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                              WIRING SCHEMATIC #44806 (TWO RELAYS)
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                                                                                             BATTERY      12-2~VDC




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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.