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53017 Rev2 20.0 33.0ede eder 65a Technical Man



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SERVICE MANUAL
       65A-FOUR
       MARINE ENGINE

.,,--.,26.0 AND 20.0KW EDER
        -NET MOBILE/INDUSTRIAL
     .GENERATORS '

       3,28.5 and 25.5KW EDE D-NET
       ARINE GENERATORS
            PUBLICATION #053017
              SECOND EDITION
                 APRIL 2009



~        WESTERBEKE
 .,F
,:IL
         WESTERBEKE CORPORATION. 150 JOHN HANCOCK ROAD
        MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
        WEBSITE: WWW.WESTERBEKE.COM
     CALIFORNIA PROPOSITION 65
               WARNING
   Exhaust gas from diesel and
   gasoline engines (and some of
   its constituents) are known to
   the State of California to cause
   cancer, birth defects, and other
   reproductive harm.




                  AWARNING:
Exhaust gasses contain carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms ofCarbon Monoxide
exposure can include:
-Dizziness                   - Throbbing in Temple{;
-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 IMMEOIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.




A 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 living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.




                          Engines & Generators
                                              SAFETY INSTRUCTIONS
ImOOUCTION                                                            PREVENT BURNS - FIRE
Read this safety numual carefuily. Most accidents are
caused by failure to follow fundamental rules and precau-                 A WARNING: FiltJ can caUBB injury 01 deathl
tWns. Know when dangerous condiJions exist and take the
necessary precautitJns 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 instructWns are in compliance with                 pump, or other potential sources of spilled fuel or fuel
the 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: lID not touch AC eltN:tricaJ COIIIIIIetIons             Do not operate with the air cleanerlsilencer removed.
    willie tJIJfIiOtlIs mnning, 01 wilen connected to sholtJ            Backfire can cause severe injury or death.
    "... LetIIaI milage Is PItJSBIIt at tIrtJstJ 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 f~m fuel vapors can couse
                                                                          Injury 01 d.atIr!
 Remove wristwatch and all jewelry when working on
  electrical equipment.                                                    Follow re-fueling safety instructions. Keep the vessel's
 Do not COMect 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-
  tIansfer 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-
                                                                            tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE                                                  out of the reach of children.
                                                                           Do not fill the fuel tank(s) while the engine is running.
    A WARNING: lID not touch hot BOgin. palls 01                           Shut off the fuel service valve at the engine when servicing
                                                                            the fuel system. Take care in catching any fuel that might
    BIhaust srsItJm compoOtlnis. Amnning engine gets                        spill. DO NOT allow any smoking, open flames, or other
    ,." "",!                                                                sources of fire near the fuel system or engine when servic-
                                                                            ing. Ensure proper ventilation exists when servicing the
    Always check the engine coolant level at the coolant                   fuel system.
     recovery tank.
                                                                           Do not alter or modify the fuel system.
                                                                           Be sure all fuel supplies have a positive shutoff valve.
I A WARNING: StBam can couse injury 01 death!                              Be certain fuel line fittings are adequately tightened and
                                                                            free of leaks.
    In case of an engine overheat, allow the engine to cool               Make sure a fire extinguisher is installed nearby and is
     before touching the engine or checking the coolant.                    properly maintained. Be familiar with its proper use.
                                                                            Extinguishers rated ABC by the NFPA are appropriate
                                                                            for all applications encountered in this enviromnent.




                                                   ~        WESTERBEKE
                                                            Engines & Generators

                                                                  i
                                                 SAFETY INSTRUCTIONS
ACCIDENTAL STARTING                                                        TOXIC EXHAUST GASES
    A WARNING: Accidental starting can cause injury                            A WARNING: Carbon monoxide (CO) is a deadly gas!
    111 death!

       Disconnect the battery cables before servicIng the engine!              Ensure that the exhaust system is adequate to expel gases
        generator. Remove the negative lead first and reconnect                  discharged from the engine. Check the exhaust system
        it last.                                                                 regularly for leaks and make sure the exhaust manifold!
                                                                                 water-injected elbow is securely attached.
       Make certain all personnel are clear of the engine before
        starting.                                                               Be sure the unit and its surroundings are well ventilated.
                                                                                 Run blowers when running the generator set or engine.
       Make certain all covers, guards, and hatches are re-
        installed before starting the engine.                                   Don't run the generator set or engine unless the boat is
                                                                                 equipped with a functioning marine carbon monoxide
                                                                                 detector that complies with ABYCA-24. Consult your boat
BATTERY EXPLOSION                                                                builder or dealer for installation of approved detectors.

    A WARNING: Battery explosion can cause injury                               For additional information refer to ABYC T-22
                                                                                 (educational information on Carbon Monoxide).
    at 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 flu-like symptoms,
  highly explosive gas, which can be Igmted 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 systems.
 Never connect the negative (-) battery cable to the posi-                  Exhaust sulfur causes rapid deterioration of copper tubing
  tive (+) connection terminal of the starter solenoid. Do                   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 toxic 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
  wristwatch, rings, and any other jewelry before handlIng
                                                                             symptoms or signs of carbon monoxide inhalation or
  the battery.                                                               poisoning are:
 Always turn the battery charger off before disconnecting                   Vomiting                  Inability to think coherently
  the battery connections. Remove the negatIve lead first
                                                                             Dizziness                 Throbbing in temples
  and reconnect it last whenservicing the battery.                                                     Muscular twitching
                                                                             Headache
BATTERY ACID                                                                 Nausea                    Weakness and sleepiness
                                                                           AVOID MOVING PARTS
    A WARNING: Sulfuric acid in batteries can cause
    _        injury or death!                                                  A WARNING: Rotating parts can cause injury
                                                                               or death!
       When servicing the battery or checking the electrolyte
        level, wear rubber gloves, a rubber apron, and eye protec-
                                                                                Do not service the engine while it is running. If a situation
        tion. Batteries contain sulfuric acid which is destructIve.
                                                                                 arises in which it is absolutely necessary to make operat-
        If it comes in contact with your skin, wash it off at once
                                                                                 ing adjustments, use extreme care to avoid touching mov-
        with water. Acid may splash on the skin or into the eyes
                                                                                 ing parts and hot exhaust system components.
        inadvertently when removing electrolyte caps.




                                                      -.,y   WESTERBEKE
                                                             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.
                                                                           tions when installing your engine.
      Keep protective shields and guards in their respective
      places at all times.                                                 ABYC (American Boat and Yacht Council)
                                                                           "Safety Standards for Small Craft"
     Do not check fluid levels or the drive belt's tension while
      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                15 East 26th Street
      be caught in these rotating parts.                                      New York, NY 10010
                                                                           NFPA (National Fire Protection Association)
HAZARDOUS NOISE                                                            "Fire Protection Standard for Motor Craft"
                                                                           Order from:
    A WARIIIING: High nIl. IBvels can cau. hBaring                            National Fire Protection Association
    /oss1                                                                    II Tracy Drive
                                                                             Avon Industrial Park
     Never operate an engine without its muffler installed.                 Avon, MA 02322
     Do not run an engine with the air intake (silencer)                  USCG (United States Coast Guard)
      removed.                                                             "USCG 33CFR183"
     Do not run engines for long periods with their enclosures            Order from:
      open.
                                                                             U.S. Government Printing Office
                                                                             Washington, D.C. 20404
    A WARIIIING: Do not WIlde In machlnory whsn YIIU arB
    mtmI1IIIt lIT physicallt IncapacltalBd by fatiguBI

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-I Exhaust systems
        P-4 Inboard engines
        E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                     -..v: WESJERBEKE
                                                             EngInes & Generstors

                                                                     iii
                                                     TABLE OF CONTENTS
  Testing for Overhaul. ...........................................2               Valves .......................................................... .41
       Engine Compression ...................................... 2                 Rocker Arm ................................................ .43
  Engine Troubleshooting ....................................... 3                 Timing Gear/Crankshaft .............................. 44
  General Description ............................................. 8              Camshaft ..................................................... .45
     Cylinder Block ............................................... 8              Idler Gear ................................................... ..46
     Half Floating Head Cover ............................. 8                     Balancing Shaft .......................................... .47
     Cylinder Head ................................................ 8             Piston/Connecting Rod ............................... .48
     Piston and Piston Rings ................................. 9                  Crankshaft. .................................................. .50
     Dynamic Balancer ......................................... 9                 Crankpin ...................................................... 51
     Governor ...................................................... 10           Cylinder ....................................................... 53
 Disassembly Procedures ................................. .. 11                   Oil Pump ...................................................... 53
     Generator ..................................................... 11        Servicing Specifi catIons ...................................55
     Radiator Models .......................................... II             Engine Adjustments........................................... 61
     Propulsion Engines ...................................... II                 I'    . T'Immg
                                                                                   nJectton   . .......................................... 61
     Preparation for Disassembly ........................ 11                      Valve Clearance ........................................... 62
     Remove Interior Components ...................... II                         Oil Pressure/Oil Change .............................. 63
     Remote Stop/Start Panel ............................ lla                  Fuel System .......................................................64
 Assembly Procedures ........................................ 12                  Injectors ....................................................... 65
     Surface Preparation ..................................... 12                 Injection Pump ............................................. 65
     Gasket Information ...................................... 12                 Glow Plugs .................................................. 65
 Engine Assembly Instructions...... ..................... 13                   Raw Water Pump ...............................................66
     Heat Exchanger ........................................... 13             Wiring Diagram (#52952) EDE ...........................67
     Marine Transmissions .................................. 13                Wiring Diagram (#54469) EDER ....................... 67a
    Radiators ...................................................... 13        Wiring Diagram (#31944) 65AFour ................ 67b
    Engine Tuning ............................................. 13             Specifications 65AFour ................................68
Disassembly/Assembly (Engine) ........................ 14                      Specifications 33Kw EOE .............................68a
    Cylinder Head and Valves ........................... 14                    Specifications 28.5Kw EDER ....................... 68b
    Cylinder Head Gasket ................................. 16                  Generator Specifications .................................. 69
    Governor Housing Assembly ...................... 18                        Torque Specifications .......................................70
    Injection Pump ............................................. 19            Special Tools .....................................................72
    Thermostat .................................................. .20          Generator Information ....................................... 83
    Injection Nozzle ........................................... 20            Terminal Board Connections ............................. 84
    Fuel Camshaft and Governor Weight.. ........ 23                            Electronic Regulator ......................................... 85
    Injection Pump Assembly ............................ 24                    Generator Servicing .......................................... 87
    Water Pump/Oil Cooler ............................... 26                   Generator Troubleshooting (Chart) ................... 88
    Gear Case..................................................... 27          EDE Testing the Voltage .................................... 89
    Oil Screw and Strainer ................................ 29                Internal Wiring Schematic ................................91
    Piston and Connecting Rod ......................... 29                    Changing Hertz and Voltage .............................92
    Flywheel and Crankshaft.. ........................... 31                  AC Output Configurations ................................. 92
    Flywheel Housing ........................................ 32              Generator Parts Breakdown ..............................93
    Crankshaft. ................................................... 33        Metric Equivalent .............................................. 95
Starter Motor Service ...... .................................. 34            Metric Conversion Chart ...................................96
Alternator Service ............................................. 37           Index ...............................................................97
Servicing (Engine) ............................................ .40
    Cylinder Head ............................................. .40



                                                      ~       WESTERBEKE
                                                              Engines & Generators

                                                                          1
                                              TESTING FOR OVERHAUL
 HOW TO DETERMINE ENGINE OVERHAUL PERIOD                                  ENGINE COMPRESSION
. Cause of Low Compression                                               Check the compression pressure. To do this warm the engine,
                                                                         remove all fuel injectors,or glow plugs, disconnect the fuel
Generally, the time at which an engine should be overhauled              shut-off solenoid wire, and install a compression adapter in
is determined by various conditions such as lowered engine               the injector hole or glow plug hole .. Connect a compression
power output, decreased compression pressure, and increased              tester on the adapter and crank the engine with the starter
fuel and oil consumption. The lowered engine power output                motor until the pressure reaches a maximum value. Repeat
is not necessarily due to trouble with the engine itself, but is         this process for each cylinder. Look for cylinders with
sometimes caused by injector nozzle wear or injection pump               dramatically lower compression than the average of the
wear. The decrease in compression pressure is caused by                  others.
many factors. It is, therefore, necessary to determine a cause
or causes on the basis of data produced by periodic                      COMPRESSION PRESSURE (Faclary Spec.)
inspection and maintenance. Oil analysis on a seasonal basis             at 250 RPM 626 PSI
is a good means of monitoring engine internal wear. When                            44 Kgl/cm'
caused by worn cylinders or piston rings, the following                             4.32 MPa
symptoms will occur:
                                                                         ALLOWABLE LIMIT
          1 Low engine power output
                                                                         al250 RPM 472 PSI
          2 Increased fuel consumption                                               33.2 Kgl/cm'
          3 Increased oil consumption                                                3.26 MPa
          4 Hard engine starting                                         If a weak cylinder is flanked by healthy cylinders, the
          5 Noisy engine operation                                       problem is either valve or piston-related. Check the valve
These symptoms often appear together. Symptoms 2 and 4                   elearances for the weak cylinder, adjust as needed, and test
can result also from excessive fuel injection, improper                  again. If the cylinder is still low, apply a small amount of oil
injection timing, and wear of the injectors. They are caused             into the cylinder to seal the rings, and repeat the test. If the
also by defective electrical devices such as the battery,                compression comes up, the rings are faulty.
alternator, starter and glow plugs. Therefore it is desirable to         Abnormally high readings on all cylinders indicate heavy
judge the optimum engine overhaul time by the lowered                    carbon accumulation, a condition that might be accompanied
compression pressure caused by worn cylinders and pistons                by high pressures and noise.
plus increased oil consumption. Satisfactory combustion is               NOTE: In case of severe vibrations and detonation noise, the
obtained only under sufficient compression pressure. If an               cause may be fuel injector problems, see FUEL INJECTORS.
engine lacks compression pressure, incomplete combustion                 Poor fuel quality, contaminants and loss ofpositive fuel
of fuel will take place even if other parts of the engine are            pressure to the injection pump will result in       faults.
operating properly. To determine the period of engine
overhaul, it is important to measure the engine compression
pressure regularly. At the same time, the engine speed at                    TESTING ENGINE
which the measurement of compression pressure is made                        COMPRESSION
should be checked because the compression pressure varies
with engine rpm. The engine rpm can be measured at the
front end of the crankshaft.

OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear
of these parts.
When decrease of compression pressure reaches the repair
limit, the engine must be overhauled.                                    When re-installing the glow            use anti-seize compound.

The engine requires overhaul when oil consumption is high,                                                            34.3 to 39.2 Nm
blowby evident, and compression valves are at minimum or                                    Nozzle holder             3.5 to 4.0 kgfm
below.                                                                                                                25.3 to 2B.9 ft-Ibs
                                                                                                                      t9.6 to 24.5 Nm
                                                                       Tightening torque    Over1low pipe nut         2.0 to 2.5 kgfm
                                                                                                                      14.5 to tB.t ftlbs
                                                                                                                      49.0 to 6B.6 Nm
                                                                                            Nozzle holder assembly    5.0 to 7.0 kglm
                                                                                                                      36.2 to 50.6 ftlbs


                                                          Engines & Generators

                                                                   2
                                             ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problems,
and the recommendations to overcome these problems.This chart may be of assistance in determining the need for an engine
overhaul.


       PROBLEM                                        PROBABLE CAUSE                                     VERIFICATION/REMEOY
 HARO STARTING              LOW CRANKING SPEEO
                            1. Engine oil viscosily too high.                            1. Replace engine oil with less viscous oil.
                            2. Rundown battery.                                         2. Recharge battery.
                            3. Worn battery.                                             3. Replace battery.
                            4. Battery terminals loosely connected.                      4. Clean terminals and correct cables.
                            5. Defective starter.                                        5. Repair or replace starter.
                            6. Defective main drive section.                             6. Check clutch for disengagement.

                            OEFECTIVE INJECTION SYSTEM
                            1. Air trapped in fuel passage.                              1. Bleed air from fuel system.
                            2. Clogged fuel filter.                                      2. Clean or replace filter.
                            3. Low injection pressure.                                   3. Adjust injection pressure.
                            4. Inadequate spray.                                        4. Clean or replace nozzle.
                            5. Injection pump delivering insufficient fuel.             5. Repair or replace injection pump.
                            6. Injection too early.                                     6. Adjust injection timing.

                            MAIN ENGINE TROUBLES
                            1. low compression.
                                 a. Incorrect valve clearance.                                a. Adjust valve clearance.
                                 b. Inadequate contact of valve seat.                         b. Lap valve.
                                 c. Valve stem seized.                                        c. Replace valve and valve guide.
                                 d. Broken valve spring.                                      d. Replace valve spring.
                                 e. Compression leaks through cylinder head gasket.           . Replace gasket.
                                 f. Piston ring seized.                                       f. Replace piston and piston ring.
                                 g. Worn piston ring and cylinder.                            g. Overhaul engine.
                            2. Burnt glow plug.                                         2. Replace glow plug.
                           3. Faulty glow plug operation.                               3. Correct lead wire connection.
                           4. Incorrect governor lever position.                        4. Set lever to starting position.
                           5. Governor spring out of POSITION                           5. Correct spring

 LOW OUTPUT                LOW COMPRESSION                                              See 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. Airtrapped in fuel system.                                1. Check and retighten connector.
                           2. Clogged filter.                                           2. Clean or replace filter.
                           3. Contaminated fuel tank.                                   3. Clean tank.
                           INSUFFICIENT INTAKE AIR
                           1. Clogged aireleaner.                                       1. Clean or replace air cleaner.


                                                                                                                                         (continued)


                                                         ~       WESTERBEKE
                                                                 Engines & Generators

                                                                              3
                                    ENGINE TROUBLESHOOTING
     PROBLEM                              PROBABLE CAUSE                                        VERIFICATION/REMEOY
LOW OUTPUT (c.nI.)    OVERHEATING
                     1. Low coolant level.                                     1. Add coolant.
                     2. Loose Vbelt.                                          2. Adjust or replace Vbelt.
                     3. Incorrect injection timing.                            3. Adjust injection timing.
                     4. low engine oil level.                                  6. Add engine oil.

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. Retig hten bolts.
                     4. Loose drain plug.                                      4. Retighten plug.
                     5. Looseoil pipe connector.                              5. Retighten oil connections.
                     6. Broken rocker cover gasket.                            6. Replace gasket.
                     7. Loose rocker cover attaching bolts.                    7. Relighten attaching bolts.

                     OIL LEVEL RISING
                     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.                                      3. Replace ring.
                     4. Worn piston or cylinder.                               4. Replace piston and rebore cylinder.

                     OIL LEVEL FALLING
                     1. Oelective stem seal.                                   1. Replace stem seal.
                     2. Worn valve and valve guide.                            4. Replace a valve and valve guide.

EXCESSIVE FUEL       ENGINE BODY TROUBLES
CONSUMPTION          1. Noisy knocking.                                        1. See KNOCKING.
                     2. Smoky exhaust.                                         2. See SMOKY EXHAUSr
                     3. Moving parts nearly seized or excessively worn.        3. Repair or replace.
                     4. Poor compression.                                      4. See LOW COMPRESSION; HARO STARTING.
                     5. Improper valve timing.                                 5. Adjust.
                     6. Improper valve clearance.                              6.Adjust.

                     INSUFFICIENT INTAKE AIR
                     1. Air intake obstructed.                                 1. Remove obstruction.

                     NOZZLE TROUBLES
                     1. Seized nozzle.                                         1. Replace.
                     2. Worn nozzle.                                           2. Replace.

                     IMPROPER FUEL                                             Replace with proper fuel.

                     FUEL LEAKS                                                Find fuel leaks.

SMOKY EXHAUST        WHITISH OR PURPLISH
                     1. Excessive engine oil.                                  1. Correct oil level.
                     2. Excessive rise of oil into combustion chamber.
                         a. Poor piston contact.                                     Check.
                         b. Seized piston ring.                                     b. Replace or clean.
                          c. Excessive piston-to-cylinder clearance.                c. Replace or correct.

                                                                                                                        (contmued)




                                                        Engines & Generators

                                                                   4
                                        ENGINE TROUBLESHOOTING
     PROBLEM                                   PROBABLE CAUSE                                       VERIFICATION/REMEDY
SMOKY EXHAUST (cant.,   WHITISH OR PURPLISH         (cant.,
                             d. Worn valve stem and valve guide.                          d. Replace.
                             e. Low engine oil viscosity.                                 e. Replace.
                              f. Excessive oil pressure.                                   I. Correct.
                        3. Injection timing is too late.                             3. Adjust.
                        4. Insufficient compression.                                 4. See LOW COMPRESSION; HARD STARTING.

                        BLACKISH OR DARK GRAYISH
                        1. Engine body troubles.
                             a. Poor compression.                                         a. See LOW COMPRESSION; HARD STARTING.
                             b. Improper valve clearance.                                 b. Adjust.
                        2. Insufficient intake air (air cleaner clogged).            2. Clean air cleaner.
                        3. Improper fuel.                                            3. Replace with proper fuel.

ABNORMAL SOUND          CRANKSHAFT AND MAIN BEARING
OR NOISE                1. Badly worn bearing.                                       1. Replace bearing and grind crankshaft.
                        2. Badly worn crankshaft.                                    2. Grind crankshaft.
                        3. Melted bearing.                                           3. Replace bearing and check lubrication system.

                        CONNECTING ROO AND CONNECTING ROD BEARING
                        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.

                        PISTON. PISTON PIN. AND PISTON RING
                        1. Worn cylinder.                                            1. Rebare cylinder to oversize and replace piston.
                        2. Worn 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.

                        VALVE MECHANISM
                        1. Worn camshaft.                                            1. Replace.
                        2. EXcessive valve clearance.                                2. Adjust.
                        3. Worn timing gear.                                         3. Replace.


ROUGH OPERATION         INJECTION PUMP SYSTEM
                        1. Uneven injection.                                         1. Adjust injection or replace parts.
                        2. Inadequate injection nozzle spray.                        4. Replace injection nozzle.


                        GOVERNING SYSTEM
                        1. Governor lever malfunctioning.                            1. Check governor shaft and correct operation.
                        2. Fatigued governor spring.                                 2. Replace.




                                                                                                                                   (continued)




                                                  "MJI"       WESTERBEKE
                                                              Engines & Generators

                                                                      5
                                          ENGINE TROUBLESHOOTING
      PROBLEM                                  PROBABLE CAUSE                                            VERIFICATION/REMEOY
KNOCKING                 ENGINE KNOCKS WITHOUT MUCH SMOKE
                         1. Main engine troubles.
                              a.Overheated cylinder.                                         a. See OVERHEATING; LOW OUTPUT.
                              b.Carbon deposits in cylinder.                                 b. Clean.
                         2. Too early injection timing.                                 2. Correct.
                         3. Too high injection pressure.                                3. Correct.
                         4. Improper luel.                                              4. Replace with proper fuel.

                         KNOCKING WITH DARK SMOKE
                         1. Poor compression.                                           1. See LOW COMPRESSION; HARD STARTING.
                         2. Injection pump malfunctioning.                              2. AdjusVRepair.
                         3. Improper nozzle.
                              a. Poor spray.                                                 a. Clean or replace nozzle.
                              b. Poor chattering.                                            b. Repair or replace nozzle.
                              c. After-injection drip.                                       c. Repair or replace nozzle.
                              d. Nozzle needle valve seized.                                 d. Replace.

INTERMlmNT               1. Fuellilter clogged.                                         1. Clean or replace.
EKHAUST SOUND            2. Fuel pipe sucks air.                                        2. Retighten pipe jOints or replace pipe.
                         3. Water mixed in fuel                                         3. Replace fuel.

OVERHEATING              1. V-belt slackening or slippery with oil.                     1. Adjust, replace or clean.
                         2. Damaged water pump.                                         2. Replace.
                         3. Lack of coolant.                                            3. Add.
                         4. Low oil level or poor oil quality.                          4. Add or change.
                         5. Knocking.                                                   5. See KNOCKING.
                         6. Moving parts seized or damaged.                             6. Replace.
                         7. Defective thermostat.                                       7. Replace.

LOW OIL PRESSURE         1. Worn Bearings.                                              1. Engine overhaul replace bearings.
                         2. Relief valve mallunction.                                   2. Overhaul oil pump.
                         3. Clogged oil cooler.                                         3. Repair.
                         4. Diesel dilution of the oil.                                 4. Injection pump repair.

HIGH OIL PRESSURE        1. Wrong type of oil.                                          1. Replace.
                         2. Relief valve defective                                      2. Replace.

RAW WATER IN CYLINDERS   1. Fail of syphon valve or exhaust system ..                   1. Clean out, inspect exhaust system, replace.

FUEL MIXING WITH         1. Injection pump broken.                                      1. Rebuild, replace.
LUBE OIL
                         2. Injection pump's plunger is worn.                           2. Replace.
                         3. Deficient nozzle injection.                                 3. Replace nozzle

WATER MIXING WITH        1. Delective head gasket.                                      1. Replace.
LUBE OIL                 2. Cylinder block/cylinder head flawed.                        2. Replace.


                                                                                                                                         (continued)




                                                                 Engines & Generators

                                                                        6
                               ENGINE TROUBLESHOOTING
               Problem                Probable Cause                                      Veriftcatlon/Remedy
 Exhaust smoking problems   1. Blue smoke.                            1. Incorrect grade of engine oil.
                                                                      1a. Crankcase is overfilled with engine oil (oil is blowing out
                                                                            through the exhaust).
                            2. White smoke.                           2. Engine is running cold.
                                                                      28. Faulty injector or incorrect injector timing.
                            3. Black smoke.                           3. Improper grade of fuel.
                                                                      3a. Fuel burn incomplete due to high back pressure in exhaust or
                                                                            insufficient air for proper combustion (Check for restrictions in
                                                                            exhaust system; check air intake.).
                                                                      3b.lmproperly timed injectors or valves or poor compression.
                                                                      3. lack of air - check air intake and air filter. Check for proper
                                                                          ventilation.
                                                                      3d. Overload.
LCD QISPLAYS
No LCD Display              1. Check battery.                         1. Battery on.
                            2. 20 amp breaker off.                    2. Turn breaker on.
Oil Pressure                1. Oil level low/oil leak.                1. Check oil level, add oil and repair leaks.
                            2. Lack of oil pressure                   2. Test oil pressure. If OK, test oil pressure sendor, inspect oil
                                                                            filter, inspect oil pump.
                            3. Ground connection.                     3. Check ground connection.
                            4. Faulty control module.                 4. Inspect all the plug connections/replace.
Coolant Temperature         1. Check system coolant level.            1. Add coolant. Check for leaks.
                            2. Check water pump drive belt.           2. Adjust belt tension, replace belt.
                            3. Faulty Temp sensor.                    3. Check sensor/replace.
                            4. Ground Connection.                     4. Check ground circuit.
                            5. Faulty control module.                 5. Check plug connectionslreplace.
Exhaust Temperature         1. Check sea water flow.                  1. Inspect thru hull fitling, hose and strainer. Correct as needed,
                            2. Faulty exhaust temp switch.            2. TesVreplace.
                            3. Ground Connection.                     3. Check ground circuit.
                            4. Faulty control module.                 4. Check plug connections.
                            5. Sea water pump.                        5. Inspect impeller/replace.
Battery Voltage             1. Check alternator drive belt.           1. Adjust tension/replace if worn.
                            2. Check charge voltage.                  2. Check excitation. replace/repair alternator
                            3. Check battery connections.             3. Check + and - cables from battery to engine.
                            4. Faulty control module.                 4. Check plug connectionslreplace.
Generator Voltage           1. Check AC voltage output.               1. Adjust voltageitroubleshoot generator for cause.
                            2. Faulty control module.                 2. Check plug connectionslreplace.
Generator Frequency         1. Check engine speed.                    1. Adjust.
                            2. Check fuel supply.                     2. Inspect filters/replace filters. Test fuel pump operation.
                            3. Amperage load.                         3. Check load with amprobe.
LED Display -               1. Compartment ambient temperature        1. Ventilate compartment.
edges tum pink.                too high.




                                          -.        WESTERBEKE
                                                     Engines & Generators

                                                              7
                                      I GENERAL DESCRIPTION
 CYLINDER BLOCK
    This engine employs separate type crankcases -
 the crankcase 1 with combustion parts and the
 crankcase 2 which supports the crankcase 1 and
 reduces noise.
    Since it is a hanger type, you can easily assem-
 ble and disassemble it. The cylinder is a linerless
 type which enables good cooling operation, less
 strain and good abrasion resistance.

 HALF-FLOATING HEAD COVER
    The rubber packing is fitting in to maintain the head
  cover 0.5 mm or so off the cylinder head. This
  arrangement helps reduce noise coming from the
. cylinder head.
                                             CYLINDER
                                             HEAD COVER




                         RUBBER
                         PACKING

                                                                            U---OIL   PAN




CYLINDER HEAD
   This engine employs a three valve system: two
inlet valves and double ports, and one exhaust
valve which produces good inlet inertia to
improve combustion efficiency and volumetric
efficiency. It also employs a new unique
combustion chamber with multiple injection
grooves.
   Besides the conventional cross port system, it
employs the forced cooling method between
valves to eliminate heat distortion, thus enabling
durable and reliable configuration.




                                                    En'glnes & Generators

                                                            8
                                    GENERAL DESCRIPTION
PISTON AND PISTON RINGS
   This engine employs the E-TVCS VERSION-II
so that the improved combustion surface at the
top of the piston enables more complete com-
bustion efficiency than the conventional models.            TOP RING   I I\
   The profile and the offset of the piston are
optimized to reduce piston slap. The oil jet at
the small end of the connecting rod reduces the
                                                               ~~~G    r; I \ - ....;:.
heat load of the piston.
   Three rings are installed in grooves in the
piston. The top ring is made of nitrizing steel to
                                                            OILRING    ~
get more reliability than the chrome plated ring.
                                                                                                PISTON
It is a keystone type ring to provide durability
against heavy load. At the Sliding part, a
special piston ring which is conformable to the
cylinder wall is employed. The second ring is
chrome-plated on the peripheral surface and it                                            ~~~_77GROOVES
is an undercut ring to prevent the holding of oil.        DEPRESSION
   The oil ring (3) has chamfered contact faces
and an expander ring, which increase the
pressure of the oil ring against the cylinder
wall.
   Several grooves are cut on the topland to
help heat dissipate and to prevent scuffing.

DYNAMIC BALANCER
   Engines are sure to vibrate due to the                                      PISTON TOPLAND
reciprocation of the pistons. theoretically, three
cylinder engines are much less prone to cause
vibration than four cylinder engines. However,
any engine has many moving parts in addition
to its pistons and cannot be completely free
from vibration.
   The four cylinder engine is fitted with
                                                                              BALANCER SHAFT
balanced weight on the crankcase to absorb the
second inertia mentioned above and reduce
vibration.




                                       -.v WESTERBEKE
                                             Engines & Generators

                                                     9
                                                                                                                FORK LEVER
                                           GENERAL DESCRIPTION                                                   2

 GOVERNOR
    This mechanism maintains engine speed at a
 constant level even under fluctuating loads and
 provides stable idling and regulates maximum
 engine speed by controlling the fuel injection
 rate.
    This engine uses a mechanical governor that
 controls the fuel injection rate at all speed                         SPRING PIN   (6)';~~~~Q\;;;;~-.T'J'!:="'5---
 ranges (from idling to maximum speed) by                                                                             GOVERNOR SPRING (4)
 utilizing the balance between the flyweight's
                                                                       SPEEO CONTROL--ttt+~r
 centrifugal force and spring tension.                                 LEVER
   A governor shaft for monitoring engine speed
 is independent of the injection pump shaft and                      FORK LEVER 1 (7)
 rotates at twice the speed of conventional types,
 providing better response to load fluctuation and
 delivering greater engine output.                             IDLE ADJUSTING BOLT-'Oll~::h;",,<

                                                                                        FLYWEIGH1l1 )
 At Start
     The stop solenoid (energized to run type) is
                                                                                    NOLOAD
  powered to release the stop lever.
     As no centrifugal force is applied to the                                      ROTATION
  flyweight (1), low tension of the start spring (2)
                                                                   OUTPUT LIMITING BOLT
. permits the control rack to move to the starting
  position, supplying the amount of fuel required to
  start the engine.

 At Idling
   Turn the speed control lever (3) clockwise to                   TORQUE LIMITING BOLT
idle the engine. It tensions the governor spring
                                                                        SPEEO CONTROL LEVER 131-H\+l
(4) to pull the fork lever 2.
   When the fork lever 2 is pulled, it moves the
torque spring pin (6) and fork lever 1 (7) in the
direction of the arrow A to restrain the weight.
In combination with the start spring tension, it
is balanced with the centrifugal force of the
flywheel weight to maintain idling.

                                                                                                        /ll-l.l..>..w.J-- CONTROL RACK
   At rated speed with full load and overload
   As the speed control lever is changed from the middle
 speed to high speed, the governor spring tension
increases to compress the torque spring and move the
fork lever 1 in the direction of the arrow A.
   The fork lever 2 moves until it reaches the output
limiting bolt to keep rated rotation and rated output.
   When the engine is overloaded, the engine rotating
speed decreases and the centrifugal force of flywheel                  To stop engine
weight decreases. Then the torque spring moves the                      When the stop solenoid is turned off, the spring
fork lever 1 in the direction of arrow A.                            tension of the solenoid is released, the rod extrudes and
   The control rack moves in the direction that increases            the stop lever moves the control rack in the direction of
fuel supply to increase the output. It is balanced with the          the arrow B which stops the engine.
centrifugal force of the flywheel weight to produce low-               To stop the engine manually, move the external stop
speed output (torque output).                                        lever to the left.

                                               '9Y'   WESTERBEKE
                                                      Engines & Generators

                                                              10
                                        DISASSEMBLY PROCECURES
GENERATOR                                                             PROPULSION ENGINE
Unplug and disconnect the electrical connections on the out-          Unplug the instrument panel wiring harness. Drain the
side and inside of the control box to allow for the removal of        transmission fluid and the transmission oil cooler hoses.
the control box off the AC generator end. NOTE: Properly              Detach the oil cooler hoses and unholt the transmission
photo or mark all connections to ensure proper reconnecting.          from the engine.
Remove the air hose between the control box and the engine            NOTE: Label any lines, hoses or cables as you separate them.
intake box. Separate the exhaust hose at the water injected
elbow and disconnect the fuel supply and return lines.                TRANSMISSION
Drain the engine oil and the coolant from the engine.                 If the transmission is not being rebuilt, it should be visually
Carefully support and then unbolt the generator backend               inspected. Flush out and pressure test the oil cooler and
from the engine.                                                      replace the coolant hoses. Inspect and lubricate the gear shift
Additional generator information will be found in the                 linkage and the propeller shaft coupling. Clean and repaint
GENERATOR section of this manual.                                     the transmission and change the transmission fluid.
                                                                      For transmission service and maintenance refer to the
                                      COOLANT DRAIN
                                      19MM HEX PLUG                   units Operator's mannal, To rebuild a transmission
                                                                      contact the transmission manufacturer for the location of




                                                                            DAMPER
                                                                            BOLTS




RADIATOR MODELS
Drain the coolant using the        petcock found at the base                                                   ''''',".     -WATER PUMP
Water Pump and Oil Cooler
Water Pump
1. Remove the pipe band and the water pipe_
2. Remove the water pump ..
  (When reassembling)
 When mounting the water pump, take care not to forget
   mounting the O-ring and not to let it out of position.



Oil Cooler
1. Remove the water pipe.
2. Remove the oil filter cartridge (2) and the oil cooler joint screw.                       WATER PIPE


3. Remove the oil cooler.
                                               39.2 to 44.1 Nm
Tightening torque    Oil cooler joint screw    4.0 to 4.5 kgfm
                                               28.9 to 32.5 ftlbs              OIL FILTER
                                                                                (2)




                                                                       COOLER




                                                          Englne~      & Generators

                                                                 26
                                                  DISASSEMBLY/ASSEMBLY
Gear Case
    Gear Case Cover
    1. Remove the gear case cover.
        (When reassembling)
       Confirm that the liquid gasket coating surface is free of water,
        dust and oil in order to maintain sealing effect.
       Carefully apply the adhesive evenly. Refer to the illustration .

 NOTE
  When mounting the adhesive-applied parts, take care to
   fit them to the mating parts.
  Assemble the adhesive-applied parts within ten minutes.
  Apply a liquid gasket (Three Bond 12170) to the gear case
   cover.
                                                    23.5 to 27.5 Nm
                         Gear case cover
    Tightening torque                               2.4 to 2.8 kgfm
                         mounting screw
                                                    17.4 to 20.3 h-Ibs                                       ,/,LIUIUIU   GASKET

Relief Valve
1. Remove the relief valve retaining screw.
2. Remove the relief valve (2), the spring (3) and the packing.
                                                    68.6 to 78.4 Nm
                         Relief valve retaining
    Tightening torque                               7.0 to B.O kgfm
                         screw
                                                    50.6 to 57.9 h-Ibs




Idle Gear and Camshaft
1. Remove three set screws of the idle gear and draw out the idle                                         ~ RELIEF
    gear 1, 2.                                                                                            ~VALVE (2)
2. Remove two set screws of the camshaft stopper and draw out
    the camshaft.                                                                                          !-SPRING (3)
    (When reassembling)
 Set the crankshaft at the top dead center of No. 1 and 4                                                ~PACKING
  cylinder and the camshaft key to the top position and align the
                                                                                     INJECTION            -RETAINING
  marks of idle gear 1        a.nd idle gear 2 to assemble them.                     PUMP GEAR (1)             SCREW
   Refer to the illustration .
 Mount the injection pump gear (1) after installing the gear
  case.
                                                   23.5 to 27.5 Nm
                        CamShaft set screw         2.4 to 2.8 kgfm
                                                   17.4 to 20.3 h-Ibs
Tightening torque
                                                   23.5 to 27.5 Nm
                        Idle gear mounting                                                           ..-i...-IDLE GEAR (1)
                                                   2.4 to 2.8 kgfm
                        screw
                                                   17.4 to 20.3 -Ibs

                                                                                                           CRANK
                                                      """ WESTERBEKE                                      'GEAR
                                                              Engines & Generators

                                                                        27
                                                DISASSEMBLYIASSEMBLY                                                    CAMSHAFT


Idle Gear 1 and Idle Gear 2 (For Balancer Modell
1. Remove the idle gear mounting screws.                                                o
                                                                             MOUNTING
2. Draw out the idle gear (2) and (3).                                       SCREWS
        (When reassembling)
        When install the idle gear (2) and (3), be sure to place the 4th
         cylinder piston at the top dead center in compression then,
         align all mating marks on each gear to assemble the tifTling
         gears, set the idle gear last.

                          Idle gear mounting        23.5 to 27.5 Nm ~
    Tightening torque                               2.4 to 2.8 kgfm
                          screw
                                                    17.4 to 20.3 ftlbs
                                                                                                        CRANK
                                                                                                        GEAR
Camshaft and Balancer Shaft (For Balancer Model)
1. Remove the camshaft set screws and draw out the camshaft.

2. Remove the balancer shaft 1 set screws and draw out the
   balancer shaft 1.                                                                                         BALANCER
                                                                                                             SHAFT 1
3. Remove the balancer shaft 2 set screws and draw out the
   balancer shaft 2.
        (When reassembling)
                                                                                                        BALANCER
        When. install the balancer shaft 1 and 2, be sure to place the                                      2
         4th cylinder piston at the top dead center in compression then,
         align all mating marks on each gear to assemble the timing                     v

         gears, set the idle gear last.
                                                    23.5 to 27.5 Nm
                          Camshaft set screw        2.4 to 2.8 kgfm
                                                    17.4 to 20.3 ftlbs
Tightening torque
                                                    23.5 to 27.5 Nm                        o
                          Balancer shaft set screw 2.4 to 2.8 kgfm
                                                    17.4 to 20.3 Itlbs
                                                                                            o
Plate (Gear Case)
1. Remove the three plate mounting screws. Detach the plate.                                        o
                                                                                                o
        (When reassembling)
       Apply Three Bond 12170 adhesive or equivalent over the
        shaded zones on both sides of the gasket that will be
        sandwiched between the crankcase and plate.
       Be sure to fix the O-rings.                                                   GEAR
                                                                                      CASE
                                                   23.5 to 27.5 Nm                   PLATE
Tightening torque        Plate mounting screw      2.4 to 2.8 kgfm
                                                   17.4 to 20.3 ftlbs




                                                    LIQUID
                                                    GASKET
LIQUID
GASKET


                                                              I!ngfnes & Generators

                                                                    28
                                                 DISASSEMBLY/ASSEMBLY                                   OIL PAN

    Oil Pan and Oil Strainer
    1. Unscrew the oil pan mounting screws and remove the oil pan.

    2. Unscrew the oil strainer mounting screw, and remove the oil
       strainer (2).
      (When reassembling)
        Install the oil strainer, using care not to damage the. Oring.
        Apply liquid gasket (Three Bond 1217D) to the oil pan as
         shown.                                                                                    LIQUID
        Confirm that the liquid gasket coating surface is free of water,                          GASKET
         dust and oil in order to maintain sealing effect.                                                             o
      Carefully apply the adhesive evenly .
     NOTE
     When mounting the adhesive-applied parts, take care to
      fit them to the mating parts.
     Assemble the adhesive-applied parts within ten minutes.
     To avoid uneven tightening, tighten mounting screws in
      diagonal order from the center.
     After cleaning the oil strainer, install it.
     Attach the oil pan with its central drain plug facing toward
      the air suction side.
                                                                                  OIL STRAINER




PISTON AND CONNECTING ROD
Connecting Rod Cap
1. Remove the connecting rod screws (1) from connecting rod
   cap.
2. Remove the connecting rod caps.
        (When reassembling)
       Align the marks (a) with each other. (Face the marks toward
        the injection pump.)
       Apply engine oil to the connecting rod screws and lightly screw           CONNECTING
                                                                                  ROD SCREWS (1)
        it in by hand, then tighten it to the specified torque.
        If the connecting rod screw won't be screwed in smoothly,
                                                                                                              WRENCH
        clean the threads.
                                                                                                                  
        If the connecting rod screw is still hard to screw in, replace it.
       When using the existing crank pin bearing again, put tally
        marks on the crank pin bearing and the connecting rod in order
        to keep their positioning.
       Fit the crank pin bearing in place: its centrally groove side
        toward the connecting rod, and the non-grooved side toward
        the cap.
                                                  78.5 to 83.4 Nm
Tightening torque         Connecting rod screw    8.0 to 8.5 kgfm
                                                  57.9 to 61.5 ft-Ibs


                                                                                      ALIGN (a)

                                                      ~        WESTERBEKE
                                                               Engines & Generators

                                                                        29
                                       DISASSEMBLYI ASSEMBLY
 Pistons
 1. Turn the flywheel and set a piston to the top dead center.
2. Pull out the piston upward by lightly tapping it from the bottom
     of the crankcase with the grip of a hammer.
   (When reassembling)
  Before inserting the piston into the cylinder, apply enough
     engine oil to the cylinder.
  When inserting the piston into the cylinder, face the mark on
                                                                                           (6)
    the connecting rod to the injection pump .
 IMPORTANT
  Do not change the combination of cylinder and piston.
    Make sure of the position of each piston by marking. For
    example, mark "1" on the No.1 position.
 When inserting the piston into the cylinder, place the gap
    of the compression ring 1 on the opposite side of the                      (A)
    combustion chamber and stagger the gaps of the                             (8) Second Rlnl!l
    compression ring 2 and oil ring marking a right angle from                 (C) 011 Ring Gap                                  (e)
    the gap of the compression ring 1.                                         (D) Piston Pin Hole
                                                                                                       (a) 0.79 red. (45 j
 Carefully insert the. pistons using a piston ring
    compressor (1). Otherwise, their chrome-plated section
    may be scratched, causing trouble inside the liner.

Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool.
2. Put the fan shaped concave (8) on the piston as shown.

3. Remove the piston pin (1), and separate the connecting rod
     (7) from the piston.
   (When reassembling)
  Be sure to fix the crankpin bearing and the connecting rod are
     same I.D. colors.
 When. installing the ring, assemble the rings sa that the
     manufacture's mark (12) near the gap faces the top of the
     piston.
 When installing the oil ring onto the piston, place the expander
     joint (10) on the opposite side of the oil ring gap.
 Apply engine oil to the piston pin.                                           ,
                                                                                                                        (B)~
 When installing the piston pin, immerse the piston in 80C
                                                                           CONCAVE
    (176 of) oil for 10 to 15 minutes and insert the piston pin to the
    piston.
 Assemble the piston to the connecting rod with the aligning the (A) Connecting Rod 1.0. Color:
    direction of the fan shaped concave (8) of piston head and the
    mark (9) of connecting rod.
 The end faces of the oil ring are plated with hard chrome. In
                                                                                Blue or without color
                                                                            (B) Crankpin Bearing 1.0. Color:
                                                                                Blue or without cOlor~-
                                                                                                             0      '
                                                                                                                             /



                                                                                                                               Oil RING
    putting the piston into the cylinder, be careful not to get the oil                                                 .    /GAP
    ring scratched by the cylinder. Use the piston ring fitter to                           ~~r:n~~                     y        -
    tighten up the oil ring. If the ring's planting is scratched, it may                                                    ~
                            d      II      .         .    t bl          MARK THE SAME NUMBER ON
    get st uck on th e cy IIn er wa ,causing a serious rou e.            THE CONNECTING ROD AS THE
                                                                        . PISTON SO AS NOT TO CHANGE
                                                                          THE COMBINATION
                                                                                                                  MTGS. MAR (12)
                                              -..y:   WESTERBEKE
                                                      . Engines & Generators

                                                            30
                                           DISASSEMBLYI ASSEMBLY
Flywheel and Crankshaft
 Flywheel
1. Install the flywheel lock so that the flywheel does
   not turn .
 NOTE
  Do not use an impact wench. Serious damage will occur.
2. Detach the flywheel screws.
3. Remove the flywheel.
  (When reassembling)
 Apply ergine oil to the flywheel screws.
 Before fitting the flywheel and the crankshaft together, wipe
   oil, dust and other foreign substances off their mating faces.
 The flywheel and the crankshaft are fitting together in just one
   position. Make sure they are tightly fit and drive the bolts.
                                             98.110 107.9 Nm
 Tightening torque   Flywheel screw          10.0 to 1 t .0 kgfm            TOP MARK UP
                                             72.3 to 79.6 -Ibs


 Bearing Case Cover
  NOTE
   Before disassembling, check the side clearance of
     crankshaft. Also check it during reassembly.
 1. Remove the bearing case over mounting screws.
 2. Screw two removed screws into the screw hole (3) of bearing
     case cover to remove it.
   (When reassembling)
  IMPORTANT                                                                               TWO SCREW HOLES (3)
  In case of replacing the oil seal, use caution when
     installing the seal in the bearing case cover as not to
     install it tilted. The seal should be flush with the cover.
  Confirm that the liquid gasket coating surface is free of
    water, dust and oil in order to maintain sealing effect.
  Apply liquid gasket (Three Bond 12170) to the bearing
    case cover as shown.
  Before installing the bearing case cover I oil seal
    assembly, lube the seal and be careful not to damage the
    seal while installing the assembly.
    Install the bearing case cover I oil seal assembly to
    position the casting mark "UP" on it upward.
  Tighten the bearing case cover mounting screws with                                                LIQUID
                                                                                                      GASKET
    even force on the diagonal line.
 NOTE
  When mounting the adhesive-applied parts, take care to
    fit them to the mating parts.
  Assemble the adhesive-applied parts within ten minutes.
                                             23.5 to 27.5 Nm
                     Bearing case cove'r
Tightening torque                            2.4 to 2.8 kgfm
                     mounting screw
                                             17.4 to 20.3 -Ibs




                                                      Engines & Generators

                                                              31
                                        DISASSEMBLYIASSEMBLY
Flywheel Housing
1. Remove the flywheel housing.
  (When reassembling)
 Tighten the flywheel housing mounting screws with even force
   on the diagonal line.
 Make sure the crank cases 1 and 2 are clean. Install them in
   position, referring to the flywheel housing's contoured face.
                                             77.5 to 90.2 Nm
                     Flywheel housing
 Tightening torque                           7.9 to 9.2 kgfm
                     mounting screw
                                             57.1 to 66.5 Ibs

 Crankcase 2
 1. Remove the crankcase 2.
   (When reassembling)                                                                                                                       CRANKCASE 2
                                                                                                          0        0         ,0          0
 IMPORTANT                                                                 [/0                   0                                                  0          0"l


                                                                             SIT '1 ~
  Make sure the crankcase 1 and 2 are clean.                                                                                                    /
                                                                                     /~
                                                                                                                             ;J        \..                   \..0
                                                                                                                                                              ,
  Apply liquid gasket (Three Bond 12170) to the crankcase
                                                                                    Sil                                  ~
                                                                                                                                                     ~]
    2 as shown.                                                             o                         }(r9J                                                           0




                                                                                    ~
  Tighten the crankcase 2 mounting screws with even force                                1=              'fA,-
                                                                            0
                                                                                              0
                                                                                                                                  f-n                                     0



                                                                                                                                                 U~ -
    on the diagonal line.                                                                                     f-                  1-
  Confirm that the liquid gasket coating surface is free of                        fir                  1\ l=                   b)                                      0
                                                                                                           
    water, dust and oil in order to maintain sealing effect.                    0         0           0            0          0              0           0            0

  Carefully apply the adhesive evenly.                                                   co:,":::>                                          Jf~                      i5'J
                                                                            ~
                                                                                                                       )(,
                                                                                      ,
 NOTE                                                                      ,        ~
                                                                                                                                                             .<.J J
  When mounting the adhesive-applied parts, take care to
    fit them to the mating parts.
  Assemble the adhesive-applied parts within ten minutes.
                                            49.0 to 55.9 Nm
                     Crankcase 2 mounting
 Tightening torque                          5.0 to 5.7 kgfm
                     screw
                                            36.2 to 41.2 Ibs


Crankcase 1 and Crankcase 2
  (When reassembling)
 Match the crankcase 1 and 2, referring to the flywheel                                                                                 )(
                                                                                                                                   ~-'O\_.
   housing's contoured face.
 Tighten the crankcase 2 mounting screws loosely.
 Tighten up the jig to the specified torque same as the flywheel
   housing screw. This helps to minimize the level difference
   between the crankcase 1 and the crankcase 2 (at the flywheel                                                                                          CRANKCASE 1
   side). Possible gap must be 0.05 mm (0.0020 in.) or smaller.
                                            49.0 to 55.9 Nm
                     Crankcase 2 mounting
                                            5.0 to 5.7 kgfm
                     screw
                                            36.2 to 41.3 Itlbs
Tightening torque
                                            77.5 to 90.2 Nm
                     Flywheel housing
                                            7.9 to 9.2 kgfm
                     mounting screw
                                            57.1 to 66.5 ftlbs                                                                                               GAP



                                                                                                                                                              FLYWHEEL
                                                                                                                                                              HOUSING




                                            ~        WESTERBEKE
                                                     Engines & Generators

                                                            32
                                        DISASSEMBLYI ASSEMBLY
                                                                        1\
                                                                                .;..;:.!---CRANKCASE 2




                                                                                          JIG



Crankshaft                                                                   ~CRANKCASEI
1. Remove the main bearing case.
2. Remove the crankshaft.
  (When reassembling)
 Reassemble the main bearing case having the same number
   as the one engraved on the crankcase, and set the casting
   mark "F / W SIDE" on the main bearing case facing towards
   the flywheel side.
 Reassemble the thrust bearing (2), with the oil groove facing
   outside, into both side of the fourth main bearing case.
 Apply oil to the main bearing case screws and tighten them to
   the specified torque .
                                         137.3 to 147.1 Nm
                    Main bearing case
Tightening torque                        14.0 to 15.0 kgfm
                    screw
                                         101.3 to 108.5 -Ibs




                                                                /:
                                                                                 (21




              ~:a;;t~~~~~;:~;2:,-)FOURTH
              ,                      EARING MAIN
                                            CASE




                                            THRUST BEARING (2)

                                        ~
                                         --.v- WESTERBEKE
                                                 Engines & Generators

                                                     33
                                          STARTER MOTOR SERVICE
 Disassembling Motor                                                                 Gear                                      Set of Packings
 1. Disconnect the solenoid switch.                                                  Front Bracket                             Through Screw
 2. Remove the two through screws 9 ) and the                                        Solenoid Switch                           Armature
    two brush holder lock screws. take out the                                      Overrunning Clutch                         Yoke
    rear end frame (13) and the brush holder.
                                                                                     Internal Gear                             Brush Holder
 3. Disconnect the armature (10) and the yoke
    (11). Remove also the ball (7) from the tip of                                  Planetary Gear                             Rear End Frame
    {he armature.                                                                   Sail
 4. Remove the set of packings (8), the four


                                                                                                             '~~~.':,~:~
    planetary gears and another packing.                                       SOLENOID SWITCH
 5. Take out the shaft assembly. Take note of the
    position of the lever.

                                                                                                   fi~\i~          FOUR        BAL~(7)
                                                                                   rl'-\ll.'I'I''''-""''           PLANETARY
                                                                                                                   GEARS
                                                              GEAR  ..  _.-?
                                                              ASSEMBLY~
                                                                                   FRONT
 IMPORTANT                                                                        BRACKET
  Before disconnecting the yoke, put tally marks on the
    yoke and the front bracket.                                                                            ARMATURE (10)
  Take note of the positions of the set of packings and the
    setup bolt.
  Apply grease to the gears, bearings, shaft's sliding part
    and ball .
 NOTE
  Do not damage to the brush and commutator.
   (When reassembling)
  Apply grease (DENSO.CO. No. 50 or equivalent) to the parts
    indicated in the illiJstration.

Commutator and Mica
1. Check the contact face of the commutator for wear, and grind
   the commutator with emery paper if it is slightly worn.
2. Measure the commutator 0.0. with an outside micrometer at
   several points.
3. If the minimum 0.0. is less than the allowable limit, replace the
   armature.
4. If the difference of the O.D.'s exceeds the allowable limit,
   correct the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a
   saw blade and chamfer the segment edges.
                                                                                                SEGMENT~OEPTH OF MICA
                                            32mm
                        Factory spec.
                                            1.2598 in.
Commutator 0.0.
                                            31.4   mm                                         CORRECT                 INCORRECT
                       Allowable limit
                                            1.2362 in.

                                                                                                ~                  ~MICA
                                                                                                                  .;
                                            0.50 to 0.80 mm




                                                                                               -
                       Factory spec.
                                            0.0197 to 0.0315 in.
Mica undercut
                                            0.20 mm
                       Allowable limit
                                            0.0079 in.


                                                   -..yo"   WESTERBEKE
                                                            Engines & Generators

                                                                   34
                                            STARTER MOTOR SERVICE
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with
   emery paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke                             A BRUSH lENGTil
   assembly and brush holder.
                                             18.0mm
                       Factory spec.
                                             0.7086 in.
 Brush length CA)
                                             t t.O mm
                       Allowable limit
                                             0.433t in.



Armature Coil
1. Check the continuity across the commutator and armature coil
   core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator
   with an ohmmeter.
4. If it does not conduct, replace the armature.
                       Commutator
                                             Infinity
 Resistance            Armature coil core                                             INSPECTING THE ARMATURE COIL
                       Commutator segment OQ


Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
   overrunning direction and does not siip in the cranking
   direction.
4. If the pinion slips or does not rotate in the both directions,
   replace the overrunning clutch assembly.




                                                                                 INSPECTING THE OVERRUNING CLUTCH

Brush Holder
1. Check the continuity across the brush holder and the holder
   support with an ohmmeter.
2. lfit conducts, replace the brush holder.
                      Brush holder -Holder
Resistance                                   Infinity
                      support




                                                          Engines & Generators

                                                                35
                                           STARTER MOTOR SERVICE
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
    ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
   ohmmeter.
4. If it conducts, replace the yoke assembly.
                        Lead (1)  Brush (2)    o~l
 Resistance
                        Brush (2)  Yoke (3)    1nfinity



Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.


SlalQr
1. Measure the resistance across each lead of the stator coil with
   an ohmmeter.
2. If the measurement is not within factory specification, replace
   it.
3. Check the continuity across each stator coil lead and core with
   an ohmmeter.
4. If infinity is not indicated, replace it.
I Resistance          I Factory spec,          I Less than 1.0 n




                                                             Engines & Generators

                                                                   36
                                             ALTERNATOR SERVICE
 DESCRIPTION
 The stator is connected to a three-phase, full-wave bridge
rectifier package which contains six diodes. The bridge
converts the AC generated in the stator to a DC output for                                           60 AMP ALTERNATOR
battery charging and accessories,
Power to the regulator and the field of the integral regulator
alternator is provided by the field diode (or diode trio)
package contained in the alternator.
These alternators produce a rated output of 50 or 51 amps.
rated output is achieved at approximately 6000 alternator                                                    CASE GROUND
!pm at an ambient temperature of 75'F (23.8'C). The
alternators are designed to operate in an ambient temperature
range of -40' to 212'F (-40' to lOO'C).

INSPECnDN                                                                                                 REFER TO THE WIRING
                                                                                                          DIAGRAM IN THIS
                                                                                                          MANUAL FOR ALL
When rebuilding the engine, the alternator should be cleaned                                              WIRING CONNECnONS
and inspected. The housing can be wiped off with a solvent
and the alternator temninal studs should be cleaned with a
wire brush. Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness.
Thm the rotor pulley by hand. It should tum smoothly.                                                                 REAR
                                                                                       FRONT                          BRACKET (2)




                                                                                    --
                                                                                       BRACKET (1)




DISASSEMBLE ALTERNATOR
                                                                                    -
                                                                                    --
                                                                               REMOVE 4 SCREWS
Front Bracket
1. Remove the 4 screws.
2. Separate the fron! bracket (1) and the rear bracket (2) from
   each other.
 IMPORTANT
  Put a tally line on the front bracket and the rear bracket for
   reassembling them later.
Pulley
1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut
   using a M24 box wrench.
                                               58.3   to 78.9 Nm
 Tightening torque     Pulley nul              5.95   to 8.05 kgfm
                                               43.0   to 58.2 ftlbs
                                                                                        0-
                                                                                        0-
Rotor
                                                                                        0-
1. Remove the 4 screws and detach the bearing retainer.
                                                                                        0-
2. Temporarily install the nut on the pulley screw, and detach the
                                                                                       MOUNTING
   rotor.                                                                              SCREWS
Brush
1. When the rotor is detached, the 2 brushes are found to stretch
   out of the shaft hole.
                                                                                    TWO BRUSHES




                                                           Engin'!.s & Generators

                                                                  37
                                              ALTERNATOR SERVICE
Reassembling the Brush
1. Fit the brush with its sliding face in the clockwise direction
   when viewed from front.
 IMPORTANT
                                                                          TWO BRUSHES
  Be sure to keep the 2 brushes deep in the brush holder.
   Otherwise the rotor and the rear section can not be filted
   into position.
  Use a 4 mm hex. wrench to push the brushes into place.
 Using a pin-pointed (2 mm) punch, keep the brushes from
   popping out.
2. Match the tally line of the front section with that of the rear
   section.
                                                                                                       WRENCH
3. Tighten the 4 screws, and draw out the pin-pointed punch out
   of the brush holder.

                                                                                   PUNCH
    Bearing at Slip Ring Side
    1. Lightly secure the rotor (1) with a vise to prevent damage. and
       remove the bearing (2) with a puller.



                                                                                                                 MA7CHI!IG THE
                                                                                                                 TALLY LINES
                                                                         ROTOR
                                                                                                   BEARING (2)




Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.

SIatQr
1. Measure the resistance across each lead of the stator coil with
   an ohmmeter.
2. If the measurement is not within factory specification, replace
   it.
3. Check the continuity aoross each stator coil lead and core with
   an ohmmeter.
4. If infinity is not indicated, replace it.
IResistance           IFactory spec.       ILess than 1.0   (l




                                                                                           CHECKING CONTINUITY
                                                        Engines & Generstors

                                                                 38
                                          ALTERNATOR TESTING
BQlQr
1. Measure the resistance across the slip rings with an
   ohmmeter.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with an                          MEASURING
   ohmmeter.                                                                           SLIP RINGS
4. If infinity is not indicated, replace it.
I Resistance          I Factory spec.     12.8 to 3.3   (l


Slip Rino
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the 0.0. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace il.
                                           22.7 mm
                       Factory spec.
                                           0.894 in.
 Slip ring D.D.
                                           22.1 mm
                       Allowable limit
                                           0.870 in.


Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace il.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace il.                                        MEASURING BRUSH LENGTH
                                           18.5 mm
                       Factory spec.
                                           0.728 in.
Brush length
                                           5.0mm
                       Allowable limit
                                           0.1.97 in.


Rectifier
1. Check the continuity across each diode of rectifier with an
   ohmmeter.
2. The rectifier is normal if the diode in the rectifier conducts in
   one direction and does not conduct in the reverse direction.

IC Regulator
1. Check the continuity across the "B" terminal and the "F"
   terminal of IC regulator with an ohmmeter.
2. The IC regulator is normal if the conducts in one direction and
                                                                               CHECKING CONTINUITY
   does not conduct in the reverse direction.


                            B




                                                                                        B
                                                                                         8 TERMINAL


                             E
                                              ...v: WESTERBEKE
                                                        Engines & Generators

                                                             39
                                                                   SERVICING
      Cylinder Head
     Too Clearance
     1. Remove the cylinder head (remove the cylinder head gasket
         completely).
    2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to
         7 mm long fuse wires to 3 to 4 spots on the piston top with
         grease so as to avoid the intake and exhaust valves and the
         combustion chamber ports.
    3. Bring the piston to its middle position, install the cylinder head,
        and tighten the cylinder head screw to specification. (Head
        gasket must be changed to new one).
    4. Turn the crank shaft until the piston exceeds its top dead
                                                                                          3EEABAB1P056A
        center.
    5. Remove the cylinder head, and measure squeezed fuse wires
        for thickness.
    6. If the measurement is not within the specified value, check the
        oil clearance of the crankpin journal and the piston pin.
                                                      0.72 to 0.90 mm
                               Factory                0.0283 to 0.0354 in.
     Top clearance
                               spec.



                                                      98.1 to 107.9 Nm
                             Cylinder head mounting
     Tightening   torque                              10.0 to 11.0 kgfm
                             screw
                                                      72.3 to 79.6 ftlbs
                                                                                                                A

     Cylinder Head Surface Flatness                                                                       E               F
     1. Clean the cylinder head surface.
     2. Place a straightedge on the cylinder head's four sides (A), (B),                       c                                           o
        (C) and (D) and two diagonal (E) and (F) as shown in the
                                                                                                                B
        figure.
-       Measure the clearance with a feeler gauge.
    3. If the measurement exceeds the allowable limit, correct it with
        a surface grinder.
     IMPORTANT
      Do not place the straightedge on the combustion
        chamber.
      Be sure to check the valve recessing after correcting.
     Cylinder head surface                            0.05 mm
                              Allowable limit
     flatness                                         0.0020 in.

    Cylinder Head Flaw
    1. Prepare an air spray red check.(Code No. 0790931371).
    2. Clean the surface of the cylinder head with the detergent (2).
    3. Spray the cylinder head surface with the red permeative liquid
       (1). Leave it five to ten minutes after spraying.
    4. Wash away the red permeative liquid on the cylinder head                                    Ilil!mll   IDi s:m:r       illIl:IJIl
       surface with the detergent (2).                                                              Ac-AA      Ie-AS           A!i;f
    5. Spray the cylinder head surface with the white developer (3).
                                                                                                    8          ~              ~
    6. If flawed, it can be identified as red marks.'
                                                        ~~~WESTERBEKE
                                                                   Engines & Generators

                                                                            40
                                                                 SERVICING
Valve Recessing                                                                                      DEPTH
1. Clean the cylinder head, the valve face and seat                                                  GAUGE ,*-.l-U))
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
   valve.
   If it still exceeds the allowable limit after replacing the valve,
   replace the cylinder head.
                                                 (Protrusion)                           CYLINDER HEAD SURFACE               CYLINDER HEAD SURFACE
                       Factory     Intake        o mm (0 in.) to
                       spec.       valve         (recessing)
                                                 0.2 mm (0.0079 in.)                          ~~~(A~)~~~~\~i (8)
                                                 (Protrusion)
 Valve recessing
                       Factory     Exhaust       0.'5 mm (0.0059 in.) to
                       spec.       valve         (recessing) ,
                                                 0.05 mm (0.00t9 in.)                                                      (A)     Recessing
                       Allowable   (recessing)                                                                             (8)     Protrusion
                       limit       0.4 mm (0.0157 in.)


Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its
   seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply
   oil, then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
   rate. If it is 'Iess than 70 %, repeat valve lapping again.
 IMPORTANT
                                                                                                                                     .
  When valve lapping is performed, be sure to check the

                                                                                                               ( .....,
   valve recessing and adjust the valve clearance after




                                                                                        +0                                         0
   assembling the valve.

Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide section.
                                                                                                               ~.J
                                                                                                CORRECT          INCORRECT            INCORRECT
2. Measure the valve stem 0.0. with an outside micrometer.
3. Measure the valve guide 1.0. of the cylinder head at the most
   wear part as shown with a small hole
                                                                                              D.D.
   gauge.
   And calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the
   valves. If it still exceeds the allowable limit, replace the valve
   guide.

                                   Intake        6.960 to 6.975 mm
                        Factory    valve         0.2740 to 0.2746 in.
 Valve stem 0.0.
                        spec.      Exhaust       7.960 to 7.975 mm
                                   valve         0.3134 to 0.3140 in.                                            Intake          0.055 to 0.085 mm
                                                                                                     Factory     valve           0.0022 to 0.0033 in.

                                   Intake        7.030 to 7.045 mm          Clearance between        spec.       Exhaust         0.040 to 0.070 mm
                        Factory    valve         0.2768 to 0.2774 in.       valve stem and guide                 valve           0.0016 to 0.0028 in.
 Valve guide 1.0.
                        spec.      Exhaust       8.015 to 8.030 mm                                                               0.1 mm
                                                                                                     Allowable limit
                                   valve         0.3155 to 0.3161 in.                                                            0.0039 in.




                                                                 Engines & Generators

                                                                     41
                                                          SERVICING
 Replacing Valve Guide


                                                                                                                              '-
   (When removing)
 1. Using a valve guide replacing tool, press out the used valve
    guide.
   (When installing)                                                     f5       ~    L
                                                                                                ~

                                                                           "~M
 1. Clean a new valve guide, and apply engine oil to it.
 2. Using a valve guide replacing tool, press in a new valve guide                             :;
    until it is flush with the cylinder head as shown.                                     -

 3. Ream precisely the I.D. of the valve guide to the specified
                                                                               . ..l           J
    dimension .
 IMPORTANT
      Do not hit the valve guide with a hammer, etc. during
       replacement.
     (AI When ,emoving              (8)    When Inslalling

Correcting Valve and Valve Seat
 NOTE
    Before correcting the valve and seat, check the valve
     stem and the 1.0. of valve guide section, and repair them
     if necessary.
  After correcting the valve seat, be sure to check the valve
                                                                               VALVE
    recessing.                                                                 GUIDE
   1) Correcting Valve
1. Correct the valve with a valve refacer.
   2) Correcting Valve Seat                                                              (A)                        (8)
1. Slightly correct the seat surface with a 1.047 rad (60 0) (intake                   REMOVING                  INSTALLING
    valve) or 0.785 rad (45 0) (exhaust valve) seat cutter (Code No.
    07909-33102) .
2. Resurface the seat surface with a 0.523 rad (30 ') valve seat
    cutter to intake valve seat and with a 0.262 rad (15 ') valve
    seat cutter to exhaust valve seat so that the width is close to
    specified valve seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for .even valve seating,
    apply a thin film of compound between the valve face and
    valve seat, and fit them with valve lapping tool.                                              RESURFACING
4. Check the valve seating with prussian blue. The valve seating
    surface should show good contact ali the way around.
    (a) Identical Dimensions       (A)    Check Conlacl
    (bl Valve Seal Wldlh           (8)    Correcl Seal Wldlh
    (c) 0.523 rad (30  ) or       (C) Check Conlacl
     0.262 rad (15  )                                         A
 (d) 0.262 rad (15 ' ) or
     0.523 rad (30  )
 (e) 0.785 ,ad (45  ) or
     1.047 ,ad (60  )




                                                        Engines & Generators

                                                               42
                                                                 SERVICING
 Free Length and Tilt of Valve Spring
 1. Measure the free length (A) with vernier calipers. If the
     measurement is less than the allowable limit, replace it.
 2. Put the spring on a surface plate, place a square on the side
                                                                                                                                  VALVE SPRING
    of the spring, and check to see if the entire side is contact with
    the square. Rotate the spring and measure the maximum (8).
    If the measurement exceeds the allowable limit, replace.
 3. Check the entire surface of the spring for scratches. Replace
    it, if any.
                                         Intake     35.1 to 35.6 mm
                           Factory       valve      1.3819 to 1.4016 in.
                           spec.         Exhaust    41.7 to 42.2 mm
                                         valve      1.6417tol.6614in.
  Free length (A)
                                        Intake      34.6 mm
                           Allowable    valve       1.3622 in.                                 VALVE SPRING
                                                                                               TESTER
                           limit        Exhaust     41.2 mm
                                        valve       1.6220 in.


, Till (B)                , Allowable limil        , 1.0 mm
                                                     ~.039 in.


Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
   length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
                                                    63.547 N 131.5 mm                                                        0.016 to 0.045 mm
                                         Intake                                                          Factory spec.
                                                    6.48 kg1/31.5 mm         Oil clearance of rocker                         0.00063 to 0.00177 in.
                                         valve
                           Factory                  14.2561bs 11.2401 in.    arm shaft and bearing                          0.15 mm
                           spec.                                                                         Allowable limit
                                                    117.6 N 135 mm                                                          0.0059 in.
                                         Exhaust
                                                    12.0 kgfl35 mm
                                         valve
 Setting load 1 Selling                             26.4 Ibs 11.3780 in.
                                                                                                                            15.97310 15.984 mm
                                                                             ROC'Ker arm shaft 0.0.      Factory spec.
 length                                             45.864 N 131.5 mm                                                       0.6289 10 0.6293 in.
                                        Intake
                                                    4.68 kg! 131.5 mm                                                       16.0001016.018 mm
                                        valve                                Rocker arm 1.0. for shaft   Factory spec.
                           Allowable                10.2961bs 11.2401 in.                                                   0.6299 10 0.6306 in.
                           limit                    100.0 N 135 mm
                                        Exhaust
                                                    10.2 kgl/35 mm
                                        valve                                               MEASURING THE SHAFTS           0.0.
                                                    22.51bs 11.3780 in.
                                                                                                    .=,


Oil Clearance between Rocker Arm Shaft and Bearing
1. Measure the rocker arm bearing I. O. with an inside
    micrometer.
2. Measure the rocker arm shaft 0.0. with an outside
                                                                                                                           OIL CLEARANCE
    micrometer, and then calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the rocker
    arm and measure the oil clearance again. If it still exceeds the
    allowable limit, replace also the rocker arm shaft.
                                                                                                      MEASURING THE
                                                                                                      ROCKER ARM 1.0.




                                                         -..v: WESTERBEKE
                                                                 Engines & Generators

                                                                      43
                                                            SERVICING
Pysh Rod Alignment
1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the
   push rod.
                                               0.25mm
     Push rod alignment     Allowable limit                                               MEASURING PUSH ROD ALIGNMENT
                                               0.0098 in.


Qj! Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet Q.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder
   gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
   damaged, replace the tappet.
                                               0.020 to 0.062 mm                                                  0 0 00        00
                            Factory spec.
 Oil clearance between
 tappet and tappet guide
 bore                       Allowable limit
                                               0.0008 to 0.0024 in.
                                               0.07mm
                                                                                 MEASURING TAPPET           ~:O~
                                                                                                                   00         00

                                                                                                                                    C
                                               0.0028 in.
                                                                                                           ., ,.- ,...., ,--, ,..
                                                                                                             0    00     0   00

                                               23.959 to 23.980 mm
Tappet 0.0.                 Factory spec.
                                               0.9433 to 0.94t tin.
                                               24.000 to 24.02t mm
Tappat guide bore 1.0.      Factory spec.
                                               0.9449 to 0.9457 in.

Timing Gear and Camshaft
Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating
   gear.
3. If the backlash exceeds the allowable limit, check the oil
   clearance of the shafts and the gear.
4. If the oil clearance isn't proper, replace the gear.
                                              0.049 to O. t 93 mm                                                      0.044 to 0.177 mm
Backlash between           Factory spec.                                                        Factory spec.
                                              O.OOt 9 to 0.0076 in.    Backlash between idle                           O.OOt 7 to 0.0070 in.
crank gear and idle gear                                               gear 2 and injection
 t                                            0.22 mm                                                                  0.22 mm
                           Allowable limit                             pump gear                Allowable limit
                                              0.0087 in.                                                               0.0087 in.

                                              0.049 to O. t89 mm                                                       0.047 to 0.t82 mm
                           Factory spec.                                                        Factory spec.
Backlash between idle                         0.00t9 to 0.0074 in.     Backlash between cam                            O.OOt 8 to 0.0072 in.
gear 1 and cam gear                                                    geal and balancer gear
                                              0.22 rnm                 1                                               O.22mm
                           Allowable limit                                                      Allowable limit
                                              0.0087 in.                                                               0.0087 in.

                                              0.044 to O. t 85 mm                                                      0.044 to 0.183 mm
                           Factory spec.                               Backlash between idle    Factory spec.
Backlash between idle                         O.OOt 7 to 0.0073 in.                                                    0.0017 to 0.0072 in.
gear 1and idle gear 2
                                                                       gear 1 and balancer
                                              0.22 mm                 gear 2                                           0.22mm
                           Allowable limit                                                      Allowable limit
                                              0.0087 in.                                                               0.0087 in.
                                                                      ~-




                                                            Engines & Generators

                                                                44
                                                                  SERVICING
                                                                                            DIAL INDICATOR
 Idle Gear Side Clearance
 1. Set a dial indicator with its tip on the idle gear.
 2. Measure the side clearance by moving the idle gear to the
     front and rear.
 3. If the measurement exceeds the allowable limit, replace the
     idle gear collar.
                                                    0.15 to 0.30 mm
                              Factory spec.
                                                    0.0059 to 0.0118 in.
  Idle gear side clearance
                                                    0.9 rnm
                              Allowable limit
                                                    0.0354 in.




                                                                                         MEASURING GEAR SIDE CLEARANCE
 Camshaft Alignment
1. Support the camshaft with V block on the surface plate and set
   a dial indicator with its tip on the intermediate journal at right
   angle.
2. Rotate the camshaft on the V blocks and get the misalignment
   (half of the measuremeni).
3. If the misalignment exceeds the allowable limit, replace the
   camshaft.
                                                    0.01 mm
 Camshaft alignment           Allowable limit
                                                    0.00039 in.


Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the
   front and rear.
3. If the measurement exceeds the allowable limit, replace the
   camshaft stopper.
                                                   0.07 to 0.22 mm
                             Factory spec.
                                                   0.0028 to 0.0087 in.
 End play of camshaft
                                                   0.30 mm
                             Allowable limit
                                                   0.0118 in.

Cam Height
1.. Measure the height of the cam at its highest point with an                                   CAMSHAFT ALIGNMENT
    outside micrometer.
2. If the measurement is less than the allowable limit, replace the
    camshaft.
                                         Intake    37.63 mm
                             Factory     valve     1.4815 in.
                             spec.       Exhaust   38.96mm
Intake and exhaust cam                   valve     1.5338 in.
heighl                                   Intake    37.13 mm
                             Allowable   valve     1.4618 in.
                             limit       Exhaust   38.46 mm
                                         valve     1.5141 in.




                                                        ~         WESTERBEKE                MEASURING CAM HEIGHT
                                                                  Engines & Generators

                                                                      45
                                                           SERVICING
 Oil Clearance of Camshaft Journal
 1. Measure the camshaft journal 0.0. with an outside
     micrometer.
 2. Measure the cylinder block bore 1.0. for camshaft with an
     inside micrometer.
 3. If the oil clearance exceeds the allowable limit, replace the
     camshaft.
                                              0.050 to 0.091 mm                              MEASURING THE CYLINDER BORE 1.0.
                            Factory spec.
  Oil clearance of                            0.00t97 to 0.00358 in.
  camshaft journal                            0.15 mm
                            Allowable limit
                                              0.0059 in.


                                              45.934 to 45.950 mm
  Camshaft journal 0.0.     Factory spec.
                                              1.8084 to 1.8091 in.

                                              46.000 to 46.025 mm
 Camshaft bearing I.D.      Factory spec.
                                              1.81 I 0 to 1.8120 in.


Oil Clearance between Idle Gear Shaft 1, 2 and Idle Gear 1, 2
Bushing
1. Measure the idle gear shaft 0.0. with an outside micrometer.
2. Measure the idle gear bushing 1.0. with an inside micrometer,                                              o
                                                                                                               o         o


    and calculate the oil clearance.
3. If the. oil clearance exceeds the allowable limit, replace the
   bushing.
                                              0.050 to 0.091 mm
 Clearance between idle     Factory spec.
                                              0.0020 to 0.0036 in.
 gear 1, 2 shaft and idle
 gear 1, 2 bushing                            0.10 mm
                            Allowable limit
                                              0.0039 in.


 Idle gear 1, 2 bushing                       45.025 to 45.050 mm
                            Factory spec.
 1.0.                                         1.7726 to 1.7736 in.

                                              44.959 to 44.975 mm
 Idle gear " 2 shaft D.D.   Factory spec.
                                              1.7700 to 1.7707 in.


Replacing Idle Gear Bushing
  (When removing)
1. Using an idle gear bushing replacing tool, press out the used
   bushing.
  (When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
   engine oil to them.
2. Using an idle gear bushing replacing tool, press in a new
                                                                                  REMOVING
                                                                                                                    INSTALLING




   bushing (service parts) to the specified dimension.




                                                                                   REPLACING THE IDLER GEAR BUSHING



                                                  ~        WESTERBEKE
                                                           Engines & Genera/ors

                                                                 46
                                                         SERVICING
                                                                                                      BALANCER SHAFT
                                                                                                                  O""-~
Balancer-shaft Side Clearance
1. Set a dial indicator with tip on the balancer shaft.
                                                                                                                          1)=
                                                                                                                            \


2. Measure the side clearance by moving the balancer shaft to
   the front and rear.
3. If the measurement exceeds the allowable limit, replace the
   balancer shaft.
                                            0.070 to 0.220 mm
                          Factory spec.     0.0028 to 0.0087 in.
 End play of balancer
 shaft
                          Allowable limit
                                            0.3 mm
                                            0.0118 in.
                                                                                              ~              OJ   L\\ ~
                                                                                     MEASURING THE SIDE CLEARANCE
Balancer-shaft Alignment
1. Support the balancer shaft with V blocks on the surface plate
   and set a dial indicator with its tip on the intermediate journal              BALANCER SHAFT
                                                                                  ALIGNMENT
   at high angle.
2. Rotate the balancer shaft on the V block and get the
   misalignment (half of the measurement).                                                               o
                                                                                                             ,-
                                                                                                             -

3. If the misalignment exceeds the allowable limit, replace the
   balancer shalt.
                                                                          INSPECTING THE - - - - - - - - - - l
Balancer shaft                              O.02mm                        BALANCER SHAFT
                          Allowable Jimil
a1lgnmenl                                   0.0008 in.                    ALIGNMENT

Oil Clearance of Balancer-shaft Journal                                         CYLINDER BLOCK BORE
1. Measure the balancer ~h.aft journal 0.0. with an outside
    micrometer.
2. Measure the cylinder block bore 1.0. (A), (8) for balancer shaft
    with an inside micrometer.
3. If the clearance exceeds the allowable limit, replace the
    balancer shaft.
                                            0.070 to 0.159.mm
                          Factory spec.
                                            0.0028 to 0.0063 in.
Oil clearance of
bah;lncershaft journal                     O.2mm
                          Allowable limit
                                            0.0079 in.


Balancer-shaft journal                      50.92 to 50.94 mm
                          Factory spec.
0.0.                                        2.0047 to 2.0055 in.

Balancer-shaft bearing                      51.01 to 51.08 mm
                          Factory spec.
J.D.                                        2.0083 10 2.0110 in.



                                                                                       BALANCER SHAFT
                                                                                       JOURNAL

                                                                                                                          ..   ---  ./
                                                                                                                                 /-----,   ..




                                                 .... WESTERBEKE
                                                                                     SHAFT JOURNAL
                                                                                                      --c-J
                                                                                     MEASURING tHE BALANCER



                                                         Engines & Generators
                                                                   47
                                                                     SERVICING
                                                                                               MEASURING PISTON PIN BORE
 Piston and Connecting Rod
 Piston Pin Bore I.D.
 1. Measure the piston pin bore I.D. in both the horizontal and
    vertical directions with a cylinder gauge.
                                                                                                 I
 2. If the measurement exceeds the allowable limit, replace the                               PISTON PIN
    piston.                                                                                   BORE

                                                        30.000 to 30.013 mm
                             Factory spec.
                                                        1.1811 to 1.1816 in.
  Piston pin bore I.D.
                                                        30.05 mm
                             Allowable limit
                                                        1.1831 in.


Clearance between Piston Ring and Groove                                                                   (A)            a
1. Remove carbon from the ring grooves.                                                                TOP RING               FACTORY
                                                                                                                              SPECIFICATION
2. Measure the clearance between the ring and the groove with
   a feeler gauge or depth gauge.
3. If the clearance exceeds allowable limit, replace the ring since
   compression leak and oil shortage result.
4. If the clearance still exceeds the allowable limit after replacing
   the ring, replace the piston.
                                                        0.093 to 0.120 mm
                             Compression ring 2
                                                        0.0037 to 0.0047 in.
 Factory spec.
                                                        0.020 to 0.060 mm
                             Oil ring
                                                        0.0008 tq 0.0023 in.

                                                        0.20 mm
                             Compression ring 2
                                                        0.0079 in.
 Allowable limit
                                                        0.15 mm
                             Oil ring
                                                        0.0059 In.


 Factory specification: 8
                                         I    More than 0.2 mm
                                                        0.0079 in.
                                                                                            MEASURING THE PISTON RING CLEARANCE


  (A) Top Ring (Key Store Type)                (B) 2nd, 011 Ring

Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (the least
   worn out part) with the piston.
                                                                                                                         PISTON RING GAP
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the piston ring.
                                                       0.30 to 0.45 mm
                            Factory spec.
                                                       O.Ot 18 to 0.0177 in.
Compression ring 1. 2
                                                       1.25 mm
                            Allowable limit
                                                       0.0492 in.


                                                       0.25 to 0.45 mm
                            Factory spec.
                                                       0.0098 to 0.0177 in.
Oil ring
                                                       1.25 mm
                            Allowable limit
                                                       0.0492 in.



                                                                                                     MEASURING THE RING GAP

                                                          ...v WESTERBEKE
                                                                     Engines & Generators

                                                                         48
                                                             SERVICING
 Oil Clearance between Piston Pin and Small End Bushing
 1. Measure the 0.0. of the piston pin where it contacts the
     bushing with an outside micrometer.
 2. Measure the 1.0. of the piston pin bushing at the connecting
     rod small end with a cylinder gauge.
     Calculate the oil clearance.
 3. If the clearance exceeds the allowable limit, replace the
     bushing.
     If it still exceeds the allowable limit, replace the piston pin.
                                                0.020 to 0.040 mm                     MEASURING THE PISTON PIN
 Oil clearance between       Factory spec.
                                                0.0008 to 0.0016 in.
 piston pin and small end
 bushing                                        O.15mm
                             Allowable limit
                                                0.0059 in.
                                                                               When Removing     "                       Installing
                                                30.006 to 30.011 mm
 Piston pin 0.0.             Factory spec.
                                                1.1813to 1.1815 in.

                                                30.031 to 30.046 mm
 Small end bushing 1.0.      Factory spec.
                                                1.1823 to 1.1829 in.


Replacing Small End Bushing
  (When removing)
1. Press out the used bushing using a small end bushing
   replacing tool.                                                                      REPLACING THE SMALL END BUSHING
  (When installing)
1. Clean a new small end bushing and bore, and apply engine oil                           0.26   'ad (15 ')
   to them.                                                                                      (e)
                                                                                                              (1) Seam
2. Insert a new bushing onto the tool and press-fit it with a press
   so that the seam (1) of bushing position as shown
   until it is flush with the connecting rod.

Connecting Rod Alignment
 NOTE
  Since the 1.0. of the connecting rod small end bushing is
   the basis of this check, check the bushing for wear
   beforehand.
 1. Remove the piston pin in the connecting rod.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool                       ALIGNING THE CONNECTING ROD
    (Code No. 07909-31661).
4. Put a gauge over the piston pin, and move it against the face
    plate.
5. If the gauge does not fit squarely against the face plate,
    measure the space between the pin of the gauge and the face
    plate.
6. If the measurement exceeds the allowable limit, replace the
    connecting rod.
Connecting rod                                 O.05mm
                            Allowable limit
alignment                                      0.0020 in .




                                                     ..... WESTERBEKE
                                                             Engines & Generators

                                                                  49
 Crankshaft                                                       SERVICING                CRANKSHAFT SIDE
Crankshaft Side Clearance                                                                  CLEARANCE
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the
   front and rear.                                                                       DIAL
3. If the measurement exceeds the allowable limit, replace the                           INDICATOR
   thrust bearings.
4. If the same size bearing is useless because of the crankshaft
   journal wear, replace it with an oversize one referring to the
   table and figure.
                                                     0.15 to 0.31 mm
                            Factory spec.
 Crankshaft side                                    .0.0059 to 0.0122 in.
 clearance                                           0.50mm
                            Allowable limit
                                                    0.0197 in.                              CRANKSHAFT
                                                                                            JOURNAL
   (Reference)                                                                              DIMENSIONS
  Oversize dimensions of crankshaft journal
                        O.2mm                        O.4mm
 Oversize
                        0.008 in.                    0.016 in.
                        29.20 to 29.25 mm            29.40 to 29.45 mm
 Dimension A
                        1.1496101.1515 in.           1.1574 to 1.1594 in.
                                                                                                o
                        169.1 to 169.15 mm           169.2 to 169.25 mm
 Dimension B
                        6.6575 to 6.6594 In.         6.6614 to 6.6634 in.

                        2.8 to 3.2 mm radius        2.8 to 3.2 mm radius ,
 Dimension C
                        0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
                                                            (O.B-S)                                          CRANKSHAFT JOURNAL
 The crankshaft journal must be fine-finished to higher than V'ilVV


Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and
   set a dial indicator with its tip on the intermediate journal at
   right angle.
2. Rotate the crankshaft on the V block and get the misalignment
   (half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
                                                                                                                             ~
                                                                                                                              /
   crankshaft.
                                                   0.02mm                                                        CRANKSHAFT
Crankshaft alignment       Allowable limit
                                                   0.00079 in .




                                                        ...v: WESTERBEKE
                                                                  Engines & Generators

                                                                      50
                                                                    SERVICING
    Oil Clearance between Crankpin and Crankpin Bearing
                                                                                                PlASTIGAGE
     1. Clean the crankpin and crankpin bearing.
    2. Put a strip of plastigage on the
        center of the crankpin.
    3. Install the connecting rod cap and tighten the connecting rod
        screws to the specified torque, and remove the cap again.
    4. Measure the amount of the flattening with the scale, and get
        the oil clearance.
    5. If the oil clearance exceeds the allowable limit, replace the
        crankpin bearing.
    6. If the same size bearing is useless because of the crankpin
        wear, replace it with an undersize one referring to the table .

 NOTE                                                                                                       B
  Never insert the plastigage into the crankpin oil hole.
  Be sure not to move the crankshaft while the connecting
   rod screws are tightened.
                                                                                                             a     o
                                                       52.977 to 52.990 mm
    Crankpin 0.0.             Factory spec.
                                                       2.0857 to 2.0862 in.
                                                                                            CRANKSHAFT

                                                       0.018 to 0.051 mm
    Oil clearance between     Factory spec.
                                                       0.0007 to 0.0020 in.
    crankpin and crankpln
    bearing                                            0.20 mm
                              Allowable limit
                                                       0.0079 in.
                                                                                                                 1.0. COLOR

Oil Clearance between Crankpin and Crankpin Bearing
(Continued)
 IMPORTANT                                                                                                            CRANKPIN
  STD size crankpin bearing.                                                                                          BEARING
   To replace it with a specific STD service part, make sure
   the crankpin bearing has the same ID color as the                                                                   CENTER
   connecting rod.                                                                                                     WAll
                                                                                                                       THICKNESS
               Connecting rod                     Crankpin bearing
10 Color
              Large-end in. dia.     Class      Part code      Center wall thick

             56.01 to 56.02 mm                                1.496 to 1.501 mm
     Blue                             L
             2.2051 to 2.2055 in.                             0.0589 to 0.0591 in.

 Without     56.00 to 56.Q1 mm                                1.491 to 1.496 mm
                                      S
  color      2.2047 to 2.2051 in.                             0.0587 to 0.0589 in.

     Undersize dimensions of crankpin
                         O.2mm                         0.4 mm
Undersize
                         0.008 in.                     0.Q16 in.

                         2.8 to 3.2 mm radius          2.8 to 3.2 mm radius
Dimension A
                         0.1102 to 0.1260 in. radius   0.1102 to 0.1260 in. radius

                         1.0 to 1.5 mm radius          1.0 to 1.5 mm radius
Dimension B
                         0.0394 to 0.0591 in. radius   0.0394 to 0.0591 in. radius

                        52.777 to 52.790 mm            52.577 to 52.590 mm
Dimension C
                        2.077810 2.0783 In.            2.07DO to 2.0705 in.

                                                   (0.8S)
The crankpin must be fintl-fjl'Jished to higher than vvvv


                                                             ~       WESTERBEKE
                                                                     Engines & Generators

                                                                           51
                                                                   SERVICING
 Oil Clearance between Crankshaft Journal and Crankshaft
  Bearing
  1. Clean the crankshaft journal and crankshaft bearing.
 2. Put a strip of press gauge on the
     center of the journal.
  IMPORTANT
   Never insert the press gauge into the oil hole of the
    journal.
 3. Install the main bearing case and tighten the screws to the
    specified torque, and remove the cases again.
 4. Measure the amount of the flattening with the scale and get the
    oil clearance.
 5. If the clearance exceeds the allowable limit, replace the
    crankshaft bearing.
                                                      74.977 to 74.990 mm
  Crankshaft journal 0.0.   Factory spec.
                                                      2.9518 to 2.9524 in.                             A                         A

                                                      0.018 to 0.062 mm
 Oil clearance between      Factory spec.
                                                      0.0007 to 0.0024 in.
 crankshaft journal and                                                                                                      c
 crankshaft bearing                                   0.20 mm                                     B
                            Allowable limit
                                                      0.0079 in.
                                                                                                                         A
  (Reference)
  Undersize dimensions of crankshaft journal.                                                             CRANKSHAFT JOURNAL
                        O.2mm                         OAmm
 Undersize
                        0.008 in.                     0.016 in.

                        2.8 to 3.2 mm radius          2.8 to 3.2 mm radius
 Dimension A
                        0.1102 to 0.1260in. radius    0.1102 to 0.1260 in. radius

                        1 .0 to 1.5 mm radius         1.0 to 1.5 mm radius
 Dimension B
                        0.0394 to 0.0591 in. radius   0.0394 to 0.0591 In. radius

                       74.777 to 74.790 mm            74.577 to 74.590 mm
 Dimension C
                       2.9440 to 2.9445 in.           2.9361 to 2.9366 in.

                                                  (0.8-5)
 The crankpin must be fine-finished to higher than vvvv



                                                                                          CRANKSHAFT                SLEEVE
Replacing Crankshaft Sleeve
                                                                                                       CRANKCASE    GUIDE
1. Remove the used crankshaft sleeve (1) using a special-use                                           SLEEVE (1)
                                                                                                                                     AUXILIARY
   puller set.                                                                                                                       SOCKET
                                                                                                 o
2. Set the sleeve guide (4) to the crankshaft.
3. Heat a new sleeve to a temperature between 150 to 200C
   (302 to 392 OF), and fix the sleeve tothe crankshaft as shown.

4. Press fit the sleeve using the auxiliary socket for pushing .
 NOTE
  Mount the sleeve with its largely chamfered surface
   facing outward.




                                                       .... WESTERBEKE
                                                                   Engines & Genera/ors

                                                                        52
                                                                 SERVICING
 Cylinder
 Cylinder Wear
 1. Measure the 1.0. of the cylinder at the six positions
    with a cylinder gauge to find the maximum and minimum I.O.'s.
 2. Get the difference (Maximum wear) between the maximum
    and the minimum l.o.'s.
 3. If the wear exceeds the allowable limit, bore and hone to the
    oversize dimension. (Refer to "Correcting Cylinder".)
 4. Visually check the cylinder wall for scratches. If deep
    scratches are found, the cylinder should be bored. (Refer to
                                                                                                         A
    "Correcting Cylinder".)
                                                    98.000 10 98.022 mm
                         Factory spec.
                                                    3.8582103.8591 in.
  Cylinder Bor. t.D.                                                                                     B
                                                    98.15 mm
                         Allowable limit
                                                    3.8642 in.


  (A) Top                                  (a)   Right-angled to Piston Pin                              C
  (B) Middle                               (b)   Piston Pin Direction
  (C) Bottom (Skirt)
                                                                                                 MEASURING CYLINDER WEAR
Correcting Cylinder (Oversize + 0.5 mm)
1. When the cylinder is worn beyond the allowable limit, bore and                                        ,                        , ,....
   hone it to the specified dimension.
                                                                                                         ,                        ,
                                                                                                                                  ,
                                                                                                         :CYLINoER 1.0.
 Cylinder t.D. (2)       Factory spec.
                                                    98.500 to 98.522 mm                                  ,BEFORE CONNECTiON:
                                                                                                         ,
                                                                                                         ,                        ,
                                                                                                               --
                                                                                                                              . ,,,
                                                                                                             -



                                                                                                         , ..
                                                    3.8780 to 3.8788 in.                                              (1 )
                                                   98.65mm
                                                                                                         :
 Maximum wear           Allowable limit
                                                   3.88"9 in.
                                                                                                         ,
                                                                                                         ,                        ,
                                                                                                                      (2)         ,
                                                                                                         ,                        ,
                        Horn to 1.2 to 2.0 mm .uR max.                                                   ,
                                                                                                         ,       'CYLINDER 1.0.   ,
                                                                                                                                  ,
 Finishing              V'lV'l                                                                           ,
                                                                                                         ,
                                                                                                                  OVERSIZE        ,
                                                                                                                                  ,
                         (0.000047 to 0.000079 in. /JR max.)                                             ,
                                                                                                         ,                        ,
                                                                                                                                  ,
                                                                                                         ,                        ,
                                                                                                                                  ,
2. Replace the piston and piston rings with oversize (0.5                                                ,
                                                                                                         ,                        ,
                                                                                                         ,                        , '-'
   mm)ones.
.NOTE
  When the oversize cylinder is worn beyond the a"owable
                                                                                                     -                             r--

   limit, replace the cylinder block with a new one.



Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and
   the outer rotor with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil
   pump rotor assernbly.
                                                   0.04 to 0.16 mm
Clearance between       Factory spec.                                                   FEELER
                                                   0.0016 to 0.0063 in.
inner rotor and outer                                                                   GAUGE
rotor                                              0.3 mm
                        Allowable limit
                                                   0.0118 in .


                                                      ...v: WESTERBEKE
                                                                 Engines & Generators

                                                                     53
                                                            SERVICING
Clearance between Outer Rotor and Pump Body
                                                                                                FEELER
1. Measure the clearance between the outer rotor and the pump                                   GAUGE
   body with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil
   pump rotor assembly.
                                               0.100 to 0.184 mm
 Clearance between         Factory spec.
                                               0.0039 to 0.0072 in.
 outer rotor and pump
 body                                          0.3   mm
                          Allowable limit
                                               0.0118 in.




Clearance between Rotor and Cover
1. Put a strip of plastigage onto the
   rotor face with grease.
2. Install the cover and tighten the screws with the specified
   torque.
3. Remove the cover carefully, and measure the amount of the
   flattening with the scale and get the clearance.
4. If the clearance exceeds the allowable limit, replace oil pump
   rotor assembly and the cover.
                                               0.02510 0.075 mm
                          Factory spec.
Clearance between                              0.0010 to 0.0030 in.
rotor and cover                                0.225 mm
                          Allowable limit
                                               0.0089 in.

                                                                                   PLASTIGAGE
                                               7.9 to 9.3 Nm
Tightening torque       Oil pump cover screw   0.80 to 0.95 kgfm
                                               5.8 to 6.9 tt-Ibs .




                                                 ..,y"      WESTERBEKE
                                                            Engines & Generators

                                                                54
ENGINE BODY
                                  SERVICING SPECIFICATIONS
                           Item                                 Factory Specification        Allowable Limit
Cylinder Head Surface                 Flatness                                                  0.05 mm
                                                                            -                   0.0020 in.
Top Clearance                         V3300-E2B                    0.72 to 0.90 mm
                                                                 0.0283 to 0.0354 in.
                                                                                                    -
                                      V3300-T -E2B                 0.92101.10 mm
                                                                 0.0362 to 0.0433 in.
                                                                                                    -
Compression Pressure                  V3300-E2B                        4.32 MPa I              3.26 MPal
                                                                     250 min" 1 (rpm)        250 min ' (rpm)
                                                                      44 kgf/cm2 I            33.2 kgf/cm 2 I
                                                                     250 min ' (rpm)        250 min ' (rpm)
                                                                        626 psi I               472 psi I
                                                                     250 min ' (rpm)        250 min ' (rpm)
                                      V3300-T-E2B                      3.92 MPal               2.99 MPal
                                                                     250 min ' (rpm)        250 min ' (rpm)
                                                                      40 kgf/cm21             30.5 kgf/cm 2 I
                                                                     250 min ' (rpm)        250 min- 1 (rpm)
                                                                        569 psi I               434 psi I
                                                                     250 min ' (rpm)        250 min- 1 (rpm)
Variance Among Cylinders                                                    -                 10 % or less
Valve Seat Width                      IN.                               2.12 mm
                                                                        0.0835 in.
                                                                                                   -
                                      EX.                               2.12 mm
                                                                        0.0835 in.
                                                                                                   -
Valve Seat Angle                      IN.                               1.047 rad
                                                                           60
                                                                              0                    -
                                      EX.                               0.785 rad
                                                                           45
                                                                              0                    -
Valve Face Angle                      IN.                               1.047 rad
                                                                           60
                                                                              0                    -
                                      EX.                              0.785 rad
                                                                          45
                                                                             0                     -
Valve Recessing                       IN.                             -0.2 to 0 mm             -0.4 mm
                                                                     -0.079 to 0 in.          -0.0157 in.
                                      EX.                         -0.05 to 0.15 mm             -0.4 mm
                                                                -0.0019 to 0.0059 in.         -0.0157 in.
Valve Clearance (Cold)                                            0.23 to 0.27 mm
                                                                0.0091 to 0.0106 in.
                                                                                                   -
Intake Valve Timing                   Open                           0.24 rad (14 0)
                                                                     before T.D.C.
                                                                                                   -
                                                                                     0
                                      Close                          0.61 rad (36
                                                                      after B.D.C.
                                                                                         )
                                                                                                   -
                                                                                     0
Exhaust Valve Timing                  Open                           0.79 rad (45 )
                                                                     before B.D.C.
                                                                                                   -
                                      Close                          0.29 rad (17 0)
                                                                      altel" LQ,C_.__.
                                                                                                   -
                "~-.
                                                                                                             --
                                     ,."WESTERBEKE
                                            , Engines & Generators

                                                  55
                                       SERVICING SPECIFICATIONS
                                Item                             Factory Specification      Allowable Limit
 Valve Stem to Valve Guide                 Clearance (IN.)         0.055 to 0.085 mm            0.1 mm
                                                                   0.0022 to 0.0033 in.        0.0039 in.
                                           Valve Stem 0.0.         6.960 to 6.975 mm
                                           (IN.)                   0.2740 to 0.2764 in.
                                                                                                     -
                                           Valve Guide 1.0.        7.030 to 7.045 mm
                                           (IN.)                   0.2768 to 0.2774 in.
                                                                                                     -
                                           Clearance (EX.)         0.040 to 0.070 mm            0.1 mm
                                                                   0.0016 to 0.0028 in.        0.0039 in.
                                           Valve Stem 0.0.         7.960 to 7.975 mm
                                           (EX.)                   0.3134 to 0.3140 in.
                                                                                                     -
                                           Valve Guide 1.0.        8.015 to 8.030 mm
                                           (EX.)                   0.3155 to 0.3161 in.
                                                                                                     -
Valve Spring                               Intake                    35.1 to 35.6 mm           34.6 mm
                                                                   1.3819 to 1.4016 in.        1.3622 in.
                                           Exhaust                   41.7 to 42.2 mm           41.2 mm
                                                                   1.6417to 1.6614in.          1.6220 in.
Setting Load I Setting Length              Intake                                         45.864 N 131.5 mm
                                                                  63.547 N I 31.5 mm
                                                                                          4.68 kgf I 31.5 mm
                                                                  6.48 kgf 131.5 mm
                                                                                          10.296 Ibs 11 .2401
                                                                 14.256 Ibs 11.2401 in.
                                                                                                  in.
                                           Exhaust                 117.6 N I 35 mm          100 N 135 mm
                                                                    12 kgf 135 mm          10.2 kgf 135 mm
                                                                  26.4 Ibs 11.3780 in.    22.51bs 11.3780 in.
Tilt (Valve Spring)                                                                             1.0mm
                                                                           -                   0.039 in.
Rocker Arm Shaft to Rocker Arm             Oil Clearance          0.016 to 0.045 mm           0.15 mm
                                                                 0.00063 to 0.00177 in.       0.0059 in.
                                           Rocker Arm Shaft       15.973 to 15.984 mm
                                           0.0.                   0.6289 to 0.6293 in.
                                                                                                  -
                                           Rocker Arm 1.0. for   16.000 to 16.018 mm
                                           Shaft                  0.6299 to 0.6306 in.
                                                                                                  -

Valve Arm Bridge and Valve Arm Bridge      Clearance              0.018 to 0.042 mm           0.15 mm
Shaft                                                             0.0007 to 0.0017 in.        0.0059 in.
                                           Valve Arm Bridge       9.050 to 9.065 mm
                                           (1.0.)                 0.3563 to 0.3569 in.
                                                                                                 -
                                           Valve Arm Bridge
                                                                  9.023 to 9.032 mm
                                           Shaft
                                                                  0.3552 to 0.3556 in.
                                                                                                 -
                                           (0.0.)
Push Hod                                   Alignment                                         0.25 mm
                                                                          -                  0.0098 in.




                                           ~     WESTERBEKE
                                                Engines & Generators

                                                       56
                                    SERVICING SPECIFICATIONS
                             Item                                  Factory Specification    Allowable Limit
Piston Ring Gap                            Compression Ring            0.30 to 0.45 mm        1.25 mm
                                           1                         0.0118 to 0.0177 in.     0.0492 in.
                                           Compression Ring            0.30 to 0.45 mm        1.25 mm
                                           2                         0.0118 to 0.0177 in.     0.0492 in.
                                           Oil Ring                    0.25 to 0.45 mm        1.25 mm
                                                                     0.0098 to 0.0177 in.     0.0492 in.
Connecting Rod                             Alignment                                          0.05 mm
                                                                             -                0.0020 in.
Piston Pin to Small End Bushing            Clearance                0.020 to 0.040 mm         0.15 mm
                                                                    0.0008 to 0.0016 in.      0.0059 in.
                                           Piston Pin               30.006 to 30.011 mm
                                           (0.0.)                    1.1813t01.1815in.
                                                                                                  -
                                           Small End Bushing        30.031 to 30.046 mm
                                           (1.0.)                    1.1823 to 1.1829 in.
                                                                                                  -
                                                                                                              -
Crankshaft                                 Side Ciearance             0.15toO.31 mm           0.50 mm
                                                                    0.0059 to 0.0122 in.      0.0197 in.
                                           Alignment                                          0.02 mm
                                                                             -               0.00079 in.
Crankshaft Journal                         0.0                      74.977 to 74.990 mm
                                                                     2.9518 to 2.9524 in.
                                                                                                  -
Crankshaft Journal to Crankshaft Bearing   Oil Clearance            0.018 to 0.062 mm         0.20 mm
                                                                    0.0007 to 0.0024 in.      0.0079 in.
Crank Pin                                  0.0.                    52.977 to 52.990 mm
                                                                    2.0857 to 2.0862 in.
                                                                                                  -
Crank Pin to Pin Bearing                   Oil Clearance            0.018 to 0.051 mm         0.20 mm
                                                                    0.0007 to 0.0020 in.      0.0079 in.
Cylinder Bore                              1.0.                    98.000 to 98.022 mm        98.15 mm
                                                                    3.8582 to 3.8591 in.      3.8642 in.
Cylinder Bore                              1.0.                    98.500 to 98.522 mm        98.65 mm
(Oversize)                                                          3.8780 to 3.8788 in.      3.8839 in.




                                           ~      WESTERBEKE
                                                  Engines & Generators

                                                        57
                                       SERVICING SPECIFICATIONS
                                Item                                Factory Specification   Allowable Limit

Timing Gear                                 Idle Gear 1 to Crank
                                                                     0.049 to 0.193 mm        0.22 mm
                                            Gear
                                                                     0.0019 to 0.0076 in.     0.0087 in.
                                            (Backlash)
                                            Idle Gear 1 to Cam
                                                                     0.049 to 0.189 mm        0.22 mm
                                            Gear
                                                                     0.0019 to 0.0074 in.     0.0087 in.
                                            (Backlash)
                                           Idle Gear 1 to Idle
                                                                      0.044 to 0.185 mm       0.22 mm
                                           Gear 2
                                                                     0.0017 to 0.0073 in.     0.0087 in.
                                           (Backlash)
                                           Idle Gear 2 to
                                           Injection Pump             0.044 to 0.177 mm       0.22 mm
                                           Gear                      0.0017 to 0.0070 in.     0.0087 in.
                                           (Backlash)
                                           Cam Gear to
                                                                     0.047 to 0.182 mm        0.22 mm
                                           Balancer Gear 1
                                                                     0.0018 to 0.0072 in.     0.0087 in.
                                           (Backlash)
                                           Idle Gear 1 to
                                                                     0.044 to 0.183 mm        0.22 mm
                                           Balancer Gear 2
                                                                     0.0017 to 0.0072 in.     0.0087 in.
                                           (Backlash)
Idle Gear Shaft 1, 2 to Idle Gear 1, 2     Oil Clearance            0.050 to 0.091 mm         0.10mm
Bushing                                                             0.0020 to 0.0036 in.      0.0039 in.
                                           Idle Gear 1, 2
                                                                    45.025 to 45.050 mm
                                           Bushing
                                                                     1.7726 to 1.7736 in.
                                                                                                  -
                                           (1.0.)
                                           Idle Gear 1, 2 Shaft     44.959 to 44.975 mm
                                           (0.0.)                    1.7700 to 1.7707 in.
                                                                                                  -
Idle Gear                                  Side Clearance             0.15to 0.30 mm           0.9 mm
                                                                    0.0059 to 0.0118 in.      0.0354 in.
Balancer Shaft (Balancer Model Only)       Side Clearance             0.07 to 0.22 mm          0.3mm
                                                                    0.0028 to 0.0087 in.      0.0118 in.
Balancer Shaft (Balancer Model Only)       Alignment                                           0.02 mm
                                                                             -                0.0008 in.
Balancer Shaft (Balancer Model Only)       Oil Clearance             0.070 to 0.159 mm         0.2mm
                                                                    0.0028 to 0.0063 in.      0.0079 in.
                                           Balancer Shaft
                                                                    50.92 to 50.94 mm
                                           Journal
                                                                    2.0047 to 2.0055 in.
                                                                                                 -
                                           (0.0.)
                                           Balancer Bearing          51.01 to 51.08 mm
                                           (1.0.)                   2.0083 to 2.0110 in.
                                                                                                 -
Piston Pin Bore                            1.0.                    30.000 to 30.013 mm       30.05 mm
                                                                    1.1811 to 1.1816 in.     1.1831 in.
Compression Ring 2 to Ring Groove          Clearance                 0.093 to 0.120 mm        0.20 mm
                                                                    0.0037 to 0.0047 in.     0.0079 in.
Oil Ring to Ring Groove                    Clearance                  0.02 to 0.06 mm        0.15 mm
                                                                    0.0008 to 0.0023 in.     0.0059 in.

                                           ~      WESTERBEKE
                                                  Engines & Generators
                                                       58
                                SERVICING SPECIFICATIONS
                         Item                                Factory Specification       Allowable Limit
Tappet to Tappet Guide              Clearance                 0.020 to 0.062 mm             0.07 mm
                                                              0.0008 to 0.0024 in.          0.0028 in.
                                    Tappet Guide Bore         24.000 to 24.021 mm
                                    (1.0.)                     0.9449 to 0.9457 in.
                                                                                               -
                                    Tappet                    23.959 to 23.980 mm
                                    (0.0.)                     0.9433 to 0.9441 in.            -
Camshaft                            Side Clearance              0.07 to 0.22 mm             0.3mm
                                                              0.0028 to 0.0087 in.         0.0118 in.
                                    Alignment                                               0.01 mm
                                                                         -                 0.00039 in.
Cam Height                          IN.                              37.63 mm              37.13 mm
                                                                     1.4815 in.            1.4618 in.
                                    EX.                              38.96 mm              38.46 mm
                                                                     1.5338 in.            1.5141 in.
Camshaft                            Oil Clearance              0.050 to 0.091 mm            0.15 mm
                                                             0.00197 to 0.00358 in.        0.0059 in.
                                    Camshaft Journal         45.934 to 45.950 mm
                                    (0.0.)                    1.8084 to 1.8091 in.
                                                                                               -
                                    Camshaft Bearing         46.000 to 46.025 mm
                                    (!.D.)                    1.8110to 1.8120 in.
                                                                                               -

FUEL SYSTEM
                         Item                                 Factory Specification       Allowable Limit
Injection Timing                     V3300-E2B                      0.20 to 0.22 rad
                                                                    (11.5 to 12.5)                -
                                                                     before T.D.C.
                                     V3300-T-E2B                    0.11 toO.13 rad
                                                                      (6.5 to 7.5 0)               -
                                                                     before T.D.C.
Fuel Injection Nozzle                Injection Pressure        13.73 to 14.71 MPa
                                                               140 to 150 kgf/cm 2                 -
                                                                1991 to 2134 psi
                                     Valve Seat               When the pressure is
                                     Tightness               12.75 MPa (130 kgf/cm2.
                                                             1849 psi). the valve seat
                                                                                                   -
                                                              must be fuel tightness

COOLING SYSTEM
                         Item                                Factory Specification       Allowable Limit
Thermostat                          Valve Opening                   74.5 to 78.5 c
                                    Temperature                    166.1 to 173.3 OF
                                                                                                   -
                                    Valve Opening
                                    Temperature                         90C
                                    (Opened                             194 OF
                                                                                                -
                                    Completely)

                                   I~IWESTERBEKE
                                          I Engines & Generators
                                                 59
                                    SERVICING SPECIFICATIONS
LUBRICATING SYSTEM
                             Item                                 Factory Specification     Allowable Limit
Engine Oil Pressure                      At Idle Speed                                          49 kPa
                                                                               -              0.5 kgf/cm2
                                                                                                 7 psi
                                         At Rated Speed                 196 to 392 kPa        147.1 kPa
                                                                       2.0 to 4.0 kgf/cm2     1.5 kgf/cm2
                                                                          28 to 57 psi         21.3 psi
Engine Oil Pressure Switch               Working Pressure              39.2 to 58.8 kPa
                                                                       0.4 to 0.6 kgf/cm2         -
                                                                         5.6 to 8.4 psi
Inner Rotor to Outer Rotor               Clearance                   0.04 to 0.16 mm           0.3mm
                                                                   0.0016 to 0.0063 in.       0.0118 in.
Outer Rotor to Pump Body                 Clearance                  0.100 to 0.184 mm          0.3mm
                                                                   0.0039 to 0.0072 in.       0.0118 in.
Rotor to Cover                           Clearance                 0.025 to 0.075 mm          0.225 mm
                                                                   0.0010 to 0.0030 in.       0.0089 in.
Relief Valve                             Working Pressure                  885 kPa
                                                                         9.04 kgf/cm2             -
                                                                            129 psi


ELECTRICAL SYSTEM

                             Item                                 Factory Specificatioil    Allowable Limit
Commutator                               0.0.                               32 mm              31.4 mm
                                                                           1.2598 in.          1.2362 in.

Mica                                     Undercut                           0.5mm               0.2mm
                                                                           0.0197 in.          0.0079 in.
Brush (Starter)                          Length                              18 mm               11 mm
                                                                           0.7086 in.          0.4331 in.

Alternator                               No-load Voltage         14 Vat 4000 min-I (rpm)          -
Rotor Coil                               Resistance                       2.8 to 3.3 Q            -
Slip Ring                                0.0.                              22.7 mm             22.1 mm
                                                                           0.894 in.           0.870 in.

Brush (Alternator)                       Length                            18.5 mm              5.0mm
                                                                           0.728 in.           0.197 in.

Glow Plug                                Resistance                     Approx. 1.0 Q             -




                                        ..-v- WESTERBEKE
                                                Engines & Generators

                                                     60
                                                  ENGINE ADJUSTMENTS
  Injection Timing
 1. Make sure of matching the injection timing align mark (1) of the
      injection pump unit and the plate (gearcase), as shown in the
      illustration.
 2. Remove the injection pipes.
 3. Remove the stop solenoid.
 4. Turn the flywheel counterclockwise (viewed from flywheel
      side) until the fuel fills up to the hole of the delivery valve
      holder (2) for No.1 cylinder.
 5. After the fuel fills up to the hole of the delivery valve holder for
      No.1 cylinder, turn back (clockwise) the flywheel around 1.57
      rad (90 0).                                                                            (a)    Injection Timing Advanced
 6. Turn the flywheel counterclockwise to set at around 0.35 rad                             (b)    Injection Timing Delayed
      (20 ~) before T.D.C.
                                                                                        VIEWING THE DELIVERY
 7. Slowly turn the flywheel counterclockwise and stop turning                          VALVE HOLDER
     when the fuel begins to come up, to get the present injection
     timing.
8. Check to see the degree on flywheel.
     The flywheel has mark "1 TC", "10" and "20" for the crank angle
     before the top dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate the
     injection pump unit to adjust the injection timing .
 IMPORTANT
  When installing the injection pump unit to the engine
     body, follow the correct procedure.

                                                 0.20 to 0.22 rad (t t .5 " to
                                                 12.5") before T.D.C.
                        Factory
 Injection timing
                        spec.
                                                                                                          DELIVERY
                                                                                                          VALVE

                                                 22.6 to 36.3 Nm
                      Injection pipe retaining
                                                 2.3 to 3.7 kgfm
                      nut
                                                 16.6 to 26.8 ft-Ibs
Tightening torque
                                                 17.7 to 20.6 Nm
                      Injection pump unit
                                                 1.8 to 2.1 kgfm
                      mounting nut
                                                 13.0 to t 5.2 ft-Ibs


   See the "Injection Pump Unit" Disassembly
   and Assemble section.




                                                                                                                        FLYWHEEL



                                                                                                   VIEWING THE FLYWHEEL


                                                       ~         WESTERBEKE
                                                                 Engines & Generators

                                                                        61
                                                        ENGINE ADJUSTMENTS
Checking Valve Clearance
 IMPORTANT
     Valve clearance must be checked and adjusted when
      engine is cold.
1.    Remove the head cover.
2.    Align the HC mark of flywheel and the convex of flywheel
      housing timing windows so that the first piston (gear case side)
     comes to the compression top dead center.
3.   Before adjusting the valve clearance of intake valve, adjust the                       TIMING WINDOW
     bridge to set the height of intake valve.
4.   Loosen the lock nut      and return the adjusting screw
5.   Slightly push the rocker arm (intake side) by your fingers and
                                                                                                                     ADJUSTING
     screw in the adjusting screw slowly until you feel the screw                                                    SCREWS
     touch the top of valve stem, then tighten the lock nut.
6.   Loosen the lock nut      of adjusting screw       (push rod side)
     and insert the thickness gauge between the rocker arm and
     the bridge head. Set the adjusting screw to the specified
     value, then tighten the lock nut.
7.   Adjust the clearance between the rocker arm (exhaust side)
     and the exhaust valve to the specified value.
                                                     0.23 to 0.27 mm
 Valve clearance            Factory spec.
                                                     0.009t to O.OtOS in.


                                  IN    EX      IN     EX      IN     EX
           When No.1      1s1     0     0       0      0       0      0
           piston Is                                           0
                          2nd           0              0                        ADJUSTING
           cDmpressed
           Top Dead       3rd                   0                     0         SCREWS
           Cenler         41h
                                                           .
           When No.1      1st
           piston is in   2nd     0             0                     0        LOCK NUT
           overlap        3rd                          0       0
           posilion
                          41h                                  0      0


                                                     S.9 to 11.3 N'm
                          Cylinder head cover
Tightening torque                                    0.7 to 1.15 kglm
                          screw
                                                     5.1 to 8.32 ft-Ibs


                                                                                                            (ENGINE COLD)
                                                                                                            0.23 - 0.27mm
                                                                                                            (0.0091 . 0.0106 in)




                                                                          62
                                           ENGINE ADJUSTMENTS
                                                              When installing the new oil filter element, wipe the filter
                                                              gasket's sealing surface on the engine block free of oil and
                                                         .    apply a thin coat of clean engine oil to the rubber gasket
                                                           "~ on the new oil filter. Screw the filter onto the threaded oil
                                                        '"    filter nipple, and then tighten the filter firmly by hand.

                                               'lIHl'l'.:;;""
                                                                "                       .       ," .
                                                                                                        "
                                                                                               ,'.:': .::.

                                                                                                             APPLY CLEAN
                                                                                                             ENGINE o/L
                                                                                                                  INSTALLING
     OIL PRESSURE GAUGE


TESTING OIL PRESSURE
To test the oil pressure, remove the oil pressure sender, then
install a m,echanical oil pressure gauge in it's place. After
wanning up the engine, set the engine speed at idle and read               WIPE SURFACE CLEAN
the oil pressure gauge.                                                    BEFORE INSTALLING.
OIL PRESSURE WILL RANGE BETWEEN 50 AND 55PSI AT 1800 RPM

LOW OIL PRESSURE
The specific safe minimum oil pressure is 5 - 10 psi. A grad-            3. Filling the Oil Sump. Add new oil through the oil filler
ualloss of oil pressure usually indicates worn bearings.                    cap on the top of the engine or through the side oil filL
                                                                            After refilling, run the generator for a few moments while
ENGINE OIL CHANGE                                                           checking the oil pressure. Make sure there is no leakage
1. Draining the Oil Sump. Discharge the used oil through                    around the new oil filter or from the oil drain system, and
   the sump drain hose (attached to the front of the engine)                stop the engine. Then check the quantity of oil with the
   while the engine is wann. Drain the used oil completely,                 lube oil dipstick. Fill to, but not over the high mark on the
   replace the hose in its bracket, and replace the end cap                 dipstick, should the engine require additional oil.
   securely.
   NOTE: Thread size for the lube oil drain hose capped end              Use a heavy duty engine oil with an API classification of CF,
   is 114 NPT.                                                           CG-4, CH-4 or CI-4. Change the engine oil after an initial 50
                                                                         hours of break-in operation, and every 100 hours of operation
                                                                         thereafter. For recommended oil use SAE 15W-40
                                         ~':I~-8mlm       [11/161 SOCKET
                                                                         (oil viscosity). WESTERBEKE recommends the use of
                                                                         synthetic oil.




                                            W",IWUIVt  USING AN 8MM {lJ/76', SOCKET
                                                        THE OIL OR PUMP THE WARMED
                                                   UP THRU THE HOSE


2. Replocing the Oil Filter. When removing the used oil
   filter, you may find it helpful and cleaner to punch a hole
   in the upper and lower portion of the old filter to drain the
   oil from it into a container before removing it This helps
   to lessen spillage. A small style automotive filter wrench
   should be helpful in removing the old oil filter.
  NOTE: Do not punch this hole without first loosening the
  filter to make certain il can be removed!                                                                                  OIL GALLERY
                                                "Mr       WESTERBEKE
                                                          Engines & Generators

                                                                63
                                                          FUEL SYSTEM
 Fuel Injection Pressure
 1. Set the injection nozzle to a nozzle tester.
 2. Slowly move the tester handle to measure the pressure at
    which fuel begins jetting out from the nozzle.
 3. If the measurement is not within the factory specifications,
    replace the adjusting washer (1) in the nozzle holder to adjust
      it.
      See the "Disassembling and Assembling" for nozzle holder.
                                                  13.73 to 14.71 MP.
 Fuel injection pressure      Factory spec.       140 to 150 kgffem'
                                                                                                            PRESSURE TEST
                                                  1991102134 psi


     (Reference)
     Pressure variation with 0.01 mm (0.0004 in.) difference of
      adjusting washer thickness.
      Approx. 235 kPa (2.4 kgf/cm', 34 psi)

Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the
   nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.

Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester.
2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm',                                  GOOD   DEFECTIVE
   1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.

                                                  No fuel leak at
                                                  12.75 MP.
 Valve seat tightness         Factory spec.
                                                  130 kgffem'
                                                  iB4~ psi

                             DISASSEMBLY                                                                            ADJUSTING
                                                                                                           J....._-WASHER (1)
Nozzle Holder
1. Sec.ure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
     (When reassembling)
 Assemble the nozzle in clean fuel oil.
 Install the push rod (4), noting its direction.
 After assembling the nozzle, be sure to adjust the fuel injection
  pressure.                                                                         NOZZLE
                                                 34.3 to 39.2 Nm                    HOLDER (1)
                           Nozzle holder         3.5 to 4.0 kgfm
                                                 25.3 to 28.9 ftlbs

                                                 19.6 to 24.5 Nm                                                   RETAINING NUT (7)
Tightening torque          Overflow pipe nut     2.0 to 2.5 kgfm
                                                 14.5 to 18. I ft-Ibs

                                                 49.01068.6 Nm
                        Nozzle holder assembly   5.0 to 7.0 kgfm
                                                 36.2 to 50.6 ft-Ibs



                                                    ...,yo    WESTERBEKE
                                                             Engines & Generators

                                                                    64
                                                      FUEL SYSTEM

  GLOW FLUGS                                                                                         GLOW PLUGS
  To inspect the plug, remove the electrical terminal connections,
  then unscrew each plug from the cylinder head. Thoroughly
  clean each plug's tip and threads with a soft brush and cleaning
  solution to remove any carbon and oil deposits. Visually
  examine the plug tip for electrical erosion if this is evident,
  replace the glow plug.
  Touch one prod to the glow plug's wire connection, and the                TIP'
  other to the body of the glow plug, as shown. A good glow
                                                                                                 +
  plug will have a 1.0 - 1.5 ohm resistance. This method 'can              TIGHTENING TORQUE
                                                                           1.0 - 1.5 M-KG (7 -11 Fr-LB)
  be used with the plug in or out of the engine. You can also use
  an ammeter to test the power drain (8 - 9 amps per plug)                                                   - - - - FROM INJECTORS

  Re-install the plugs in the engine and test them again. The
  plugs should get very hot (at the terminal end) within 7 to 15                                                   FUEL RETURN
  seconds_ If the plugs don't heat up quickly, check for a short
  circuit. When reinstalling the glow phigs, use anti-seize
  compound on the threads. (sparingly).

  FUEL INJECTION PUMP                                                FUEL RETURN
  The fuel injection pump is the most important component of
  the diesel engine and, therefore, calls for the utmost caution
  in handli ng. The fuel injection pump has been thoroughly
  bench-tested and should not be tampered with.
 Speed (hertz) and timing are the only adjustments the
 servicing dealer can perform on the injection pump. See the
 ENGINE ADJUSTMENT section in this manual. Other types
 of adjustments or repairs must be performed by a qualified
                                                                                                                  FUEL FILTER
 injection service shop.
 NOn: When servicing the jnjection pump, the service shop
 must be advised that the pump is being used in a generator
 application.


                                                    , BLEED SCREW - THE INJECTION PUMP
                                                      BLEEO SCREW SHOULD BE LEFr IN THE
                                                      OPEN POSITION. mls WILL ALLOW FOR
                                                      AIR IN THE FUEL SYSTEM TO BE
       ACTUATOR                                       DELIVERED BACK THRU THE FUEL
                                                      RETURN SYSTEM DURING ENGINE
. <>                                                  OPERATION.

        ,-



                                FUEL INJECTION                                             FUELIN~
                                PUMP
 FUEL LI FT PUMP                                                               INLET FUEL FILTER
 Periodically check the fuel connections to and out of the                     1_ Shut off the fuel supply to the generator. Disconnect the
 pump and make sure that no leakage is present and that the                       fuel supply line to the inlet filter and unscrew the filter
 fittings are tight and secure. The DC ground connecl1on at                       from the pump inlet. Take care to catch any fuel that may
 one of the pumps mounting bolts should be clean and well                         be present.
 secured by the mounting bolt to ensure proper pump
                                                                               2. Thread on the replacement inlet filter and connect the fuel
 When energized thru the preheat circuit, the fuel lift pump                      supply line. Use care when connecting and tightening the
 will purge air from the fuel system and provide a continuous                     fuel supply line so as not to distort the inlet filter.
 flow of fuel as the engine is running.
                                                     ...v- WESTERBEKE
                                                             Engines & Generators

                                                                      65
                     RAW WATER PUMP #052650 PARTS LIST
                 PROPULSION ENGINES AND MARINE GENERATORS

                                                                                CAM RETAINING SCREW
                             33KW EOE GENERATOR
                             HOSE CONNECTIONS


                WEAR PLATE
                302574

          IMPELLER KIT
GASKET




                                                                              SEE REAR ASSEMBLY BELOW

                  ~_~         END COVER
                              049170                                     SCREW (4) MG x 1.25 x 16MM
                                                                     017012 FLAT WASHER (4) M6 031783
    END COVER SCREWS (6)
    M4x 1.0x8MM
    034463                                 FRONT ASSEMBLY
                                                                             NOTE: The parts slwwn along with
                                                                             a glycerine pack are included in
                        SCREW (4) M6 X 1.25 X 16MM                           WESTERBEKE'S PUMP KiT#052650
                    017012        WASHER (4) 031783                          with the exception of the pump body
                                                                             and the adapter flange.




                                                                                    SHAFT BALL BEARING (2)




                                    O-RING ~nUULU'~H
     SPACER PRESSES AGAIN:;7
     THE O-RING. SPACER                 CIRCLIP GRO,OVE'
     PINS FIT AGAINST THE LlPSEAL                                    CIRCLIP I"'V",LLI
                                            THE BEARINGS             053366
                                            AGAINST THE CIRCLIP


             REAR ASSEMBLY                                                      CIRCLIP FITS INTO
                                                                                GROOVE IN PUMP BODY




                                        ~     WESTERBEKE
                                              Engines & Generators

                                                  66
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                                                I Engines & Generators
                                                                                67
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                                                                                                                                                 (each wlndlng) ___ 0.041
I             -     I             I   '--                 I    I     I
I                  L              I                       L- -       I.                                                                          AUXIlIARY._ _ _ _ 0.9
L                       ---r----- -----...1                                                                                                      EXCITER STATOR_ll.3
    -                     ~                                                                                                                      EXCITER ROTOR __ . O. 72
    .~mp
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                        o In\c::=J                                                                     NO LOAO         7.0 VUC          215 VAC
                                                                                                       FULllOAU        14.0 VUC         222 VAC
                  D     VOLTAGE RmULATOR
                                                       'WE
                                                   YEllOW
                                                                    , "",",WESTERBEKE
                                                                              , Engines & Generators

                                                                                      86
                                               GENERATOR SERVICING
  TESTING THE MAGNETIC PICK UP COIL                                           MAGNETIC PICKUP [MPU] INSTALLATION
  Test the speed sensor connector for voltage and resistance                  The MPU is installed in the threaded opening on the side
  values.                                                                     of the flywheel bellhousing. This positions the MPU over
  If the values are correct, remove and inspect the magnetic                  the teeth of the flywheel ring gear.
  pick up. With the wires disconnected, unscrew the                           Viewing through this opening, manually rotate the engine
  magnetic pick up from the generator housing and visually                    crankshaft so as to position the flat of one of tlle ring
  inspect the contact end. If any damage is detected, replace                 gear's teeth directly under the opening. Thread the MPU
  the unit.                                                                   into the opening until it gently contacts the flat of this
                                                                              tooth (Thread is 3/8" x 24). Back the MPU out of the
  NOTE: Carefully/allow the installation instructions                         opening one tum and then lock it in this position with
  provided with the new magnetic pick up coil.
                                                                              the jam nut. This will position the end of the MPU
                                                                              approximately 0.030 inches away from the flats of the
  SPEED SENSOR TEST VALUES
                                                                              ring gear teeth.
  Voltage (whIle cranking)
  1.5 - 2.5 VAC                                                               To en~ure the MPU is positioned correctly, slowly rotate
                                                                              the crankshaft by 360" by hand to assure there is no
                                                                              physical contact between the MPU and the ring gear teeth.
                                                                              If contact is felt between the MPU and the flywheel teeth,



                                                   '
  Resistance (al rest) 950 -1000 ohm
                                                                              the MPU may be damaged. Remove the MPU and inspect
                                                                              it. Replace if necessary and repeat the above
                                                                              installation procedure.
WIRES                                                                         NOTE: When replacing the Magnetic Pick-Up (MPU) it



                                                  a
                                                                              MUST be replaced without cutting and splicing into the
                               ~MIPU-I~AGINE1'ICPICK-UP                       existing wiring cable. Doing so will cause a erratic AC
                                                          .                   signal to the controller.

                                                  ~                 0.03010




                                                      """ WESTERBEKE
                                                              Engines & Generators

                                                                   87
                           GENERATOR TROUBLESHOOTING
                            NOTE: AC GENERATOR TROUBLESHOOTING MUST
                           BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ.

            FAULT                                                 PROBABLE CAUSE
NO AC VOLTAGE OUTPUT AT NO LOAD.        1. Short or open in the                4. Open in exciter
                                           main stator winding.                   stator winding.
                                        2. Shorted suppressor                  5. Open in rotating
                                           on exciter rotor.                      field winding.
                                        3. Four or more shorted or             6. Shorted condenser
                                           open diodes on exciter rotor.          on exciter rotor.

RESIDUAL VOLTAGE PRODUCED AT            1. Blown 6 AMP fuse                    3. Shorted or open main
NO LOAD 15  20 VOLTS AC.                  auxiliary circuit feed to AVA.         stator auxiliary winding.
                                        2. Faulty voltage regulator

LOW AC VOLTAGE OUTPUT AT                1. Reset voltage potentiometer.        4. Faulty voltage regulator.
NO LOAD 60  100 VAC.

                                        2. Open or shorted diodes in.          5. Short in rotating field winding.
                                           exciter rotor 1 to 3 diodes.
                                        3. Open or short in one of the three   6. Short in the exciter stator.
                                           exciter rotor windings.

HIGH AC OUTPUT VOLTAGE                  1. Reset voltage potentiometer.
150 VAC OR HIGHER.
                                        2. Faulty voltage regulator.

UNSTABLE VOLTAGE OUTPUT.                1. STB pod on regulator                2. Faulty voltage regulator.
(ENGINE SPEED STEADY)                      needs adjustment.

AC VOLTAGE DROP UNDER LOAD              1. Diode(s) on exciter rotor
60 100 VOLTS AC.                          breaking down when load is
                                           applied (inductive) 13 diodes.




                                        Engines & Generators

                                               88
                                      EDE GENERATOR TROUBLESHOOTING
                                                    TESTING THE VOLTAGE

                                                                                             THE POSITIVE TEST LEAD
                                                                                      TO THE BATTERY (f) TERMINAL
                                                                                      ON THE STARTER SOLENOIO.




ATTACH THE NEGATIVE TEST LEAD
TO THE CASE (TO GROUND).

                                                                                                               -~AlI1mM,OTIr. VOLTAGE
                                                                                                                  -REGULATOR




    TO EXCITE THE GENERATOR
    1. Lift the (DC+) yellow wire and the (DC-) blue wire off          4. Connect the black test lead (-) to the metal case (ground)
       the regulator. Attach the test leads to these wires as             of the generator. This will now put a 12VDC circuit
       shown: black to the blue wire, red to the yellow wire.             through the exciter stalor of the generator.
    2. Connect the red test lead (+) to the battery voltage            5. AC output voltage should be aboUl 30% higher lhan normal.
       (12VDC) at the battery cable connection on the adjacent            This indicates that the exciter stator, main rotor and stator
       starter motor solenoid.                                            windings are OK.
    3. Open the generator's AC breaker. start the generator and        6. Monitor the auxiliary circuit voltage inlo tile regulator,
       observe the AC output voltage between the line and                 correct vollage should be 220 - 230 VAC indicating this
       neutral (residual l5-20VAC).                                       circuit is ok.




                                                   ...v- WESTERBEKE
                                                          Engines & Generators

                                                                  89
                                 EXCITER ROTOR TROUBLESHOOTING
LOW VOLTAGE EXCITER ROTOR                                             TESTING THE EXCITER ROTOR WINDINGS
AND ROTATING FIELD                                                     These windings are tested in pairs: A to B, B to C, and C to A
                                                                       as shown on the drawing.
Position the exciter rotor/rotating field so the transient
suppressor is visible at the 12 O'Clock position.

TESTING THE ROTATING FIELD WINDINGS
Place the ohm meter probes on the two large red wires (+)
and (-). These are the connecting wires for the rotating field
windings.
These wires do not need to be lifted off their connections
unless, when testing, there is an ohm valve discrepancy or a
continuity to ground (the rotor shaft).
If this occurs, lift these two /large field wires off the diode
plates, isolate them, and repeat the above test.
NOTE: When removing these wires, be careful notto drop the
screws or washers into the rotor.

                                                                                                                                         c
(+)
(RED)



                                                                                                                    EXCITER ROTOR WINDINGS


                                                                        Disconnect these three wires from the diode bridge plates
                                                                        taking care not to drop any screws or washers.
                                                                        With the wires clear from the bridge plates, test each pair
                                                                        with an ohm meter, A to B, B to C, and C to A.
                                                                        No continuity should be found between the rotor and any of
                                                                        these three winding pairs.
                                                                        TESTING THE DIODES
                                                                        Diodes can be checked with an ohmmeter. Disconnect the
                       VIEW OF ROTOR                                    wire of the particular diode and test its resistance in both
                       FROM THE                                         directions. A perfectly functioning diode will show a very
                       BEARING END                                      high resistance in one direction and a very low resistance in
                                                                        the opposite direction. A faulty diode will show either a very
                       12 a-CLOCK POSITION                              low resistance, or an infinite resistance in both directions.
                                                                        Should the whole bridge be replaced, remember to tighten
                                                                        the screws with a suitable wrench and strictly comply with
                                                                        the polarities and internal wiring diagrams in       manual.




                                                                                                        ~~~~f--DIDDE
                                                    ~        WESTERBEKE
                                                             Engines & Generators

                                                                  90
                INTERNAL WIRING SCHEMATIC
                EXCITER ROTOR/ROTATING FIELD
                                                            TRANSIENT
         r------------                                      - --- i
         I                                                              I
         I   EXCITER ROTOR                                              I
                                                                        I
         I   WINDINGS
         I                                                              I
         I                                                              I
         I                           (6)                                I
         I             ~--I-Dt
         I
         I             -"<------j   DIODE   I--~~~
         I
        : _______________________
        1                       - -'I
                                   I




                                                                            +
                              +                       RED
                        B


                                              GREEN

                                                      RED
                              +
                       c
EXCITER RDTOR
WlIDIIGS
                               ISOLATION
                               DIODE PLATES




                             Engines & Generators

                                    91
                                          CHANGING HERTZ AND VOLTAGE
                                                                                 3. There are three line connections. When an L3 is not
 .A CAUTION: As a precaution against an                                               present on the AC tenninal block, insulate and tie off
                                                                                      the L3 connection from the Voltage Sensing Board.
  URlntlmttonat statt,shutoftlM#AmpDt:lmlak8r-                  ..-
  on the control panel.                                                          4.   Inside the control box, locate the ECU and position the
                                                                                      HertzlFrequency dip switch in the correct position for the
                                                                                      HertzlFrequency desired.
1. Refer to the previous page that illustrates the various AC
   voltage output configurations for both the 60 Hertz and                       5.   Verify all connections are correct and tum off any AC
   50 Hertz applications. Select the configuration for the                            panel breakers;
   HertzIVoltage required.                                                       6.   Start the generator and monitor Ule AC output voltage at
2. Reconfigure the 12 AC connections on the tenninal                                  the generator's tenninal board. Line to line, line to neutral.
   board carefully following the illustration. Reference                              Adjust the voltage regulator board as needed to obtain the
   below the voltage sensing diagram and it;s connections                             correct voltage. Check the generator hertz/frequency with
   to the AC tenninal block. There are three line                                     your hertz meter.
   connections when needed and a neutral. These                                  7.   Turn on the AC panel breakers and load unit and monitor
   connections MUST correspond to and be connected to                                 the operation.
   the line (L) connections on the AC tenninal board and                                                                                   DIP SWITCH
   the neutral connection as well to it's corresponding
   connection. Failure to properly connect these voltage
   sense connections can result in an AC output voltage                           WHEN CHANGING mE GEN1'RATi~RS'~
   fault shut down either from low or high AC voltage or                          FREQUENCY (50160 HZ) SWITCH 11
   incorrect AC voltage displayed on the LCD display.                             ON mE CONmOL PANEL ECU
                                                                                . BOARD MUST BE SWITCHED:                         ECU SWITCHES
NOTE: When reconfiguring the AC output. ensure that the                         . ON FOR 50 HZ AND OFF FOR 60 HZ.
AVR Neutral and line connections are properly connected to
the AC terminal block.
                                          AC OUTPUT CONFIGURATIONS
                                      VOLTAGE SENSING BOARD CONNECTIONS




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                                                                                                                                               [Ii]
           o                                        120240V/60 H1
                                                    IIO-220V/SO HI                                          240V/60 Hz
                                                                                                            220V/50 HI


                                                       25.5-33.0 EDE I-PHASE / 3-PHASE                             NOTE: Tie off the L3 sensing
                                                                                                                   connection when not in use.

                                                -.,.y"    WESTERBEKE
                                                          Engines & Generators

                                                                  92
                                           MECC ALTE GENERATOR
                                    MAINTENANCE/PARTS BREAKDOWN
INSPECTION/CLEANING
Periodically inspect the rotor carrier bearing. Replace this          Remove all dirt, oil, grease and dust build up from the
bearing at 10,000 hours of normal operation or sooner if              external surface of the generator. Buildup reduces heat
wear is evident.                                                      dissipation and causes the AC generator end to operate at a
Inspect and clean the control box interior, look for loose,           higher temperature. This results in a loss of efficiency and
broken, or burned wires and terminals. Use low air pressure           reduces service life.
(25 psi max.) to remove dirt and dust from components.




                  BEARING SUPP'OR~~
                  BRACKfT




       PARTS BREAKDOWN




DISASSEMBLY
Should it become necessary to disassemble the stator/rotor            4. Support the rotor assembly with a sling and using a
assembly from the engine, use the following as a guide.                  17mm box wrench, unbolt the rotor assembly from the
1. Properly supporlllift the rear of the engine to allow the             flywheel.
    generator to be unbolted from the rear support isolators.
2. Mark, then disconnect the electricalleds that exit the
    generator from their connections in the control box. Be
    sure to properly mark the connection points the generator
    leds connect to. Make an illustration if needed whether
    the generator is to be reinstalled or a replacement is to
    be installed. This is to ensure proper reconnection of
    electricalleds. Unbolt the control box and lift it off the
    generator.
3. Remove the rear vent cover. Support the generator with a
    sling or fabricated lifting eye. Using a 17mm socket
    wrench remove the four bolts that attach the generator
    stator housing assembly to the flywheel housing.
    carefully work the stator assembly off the rear bearing
    and off and over the rotor assembly.

                                                                                                                                DISC
                                                         EnQlnes.& Generators

                                                                 93
                                            MECC ALTE GENERATOR

 ASSEMBLY OF THE GENERATOR TO THE ENGINE
 1. Position the rotor assembly onto the flywheel aligning the         4. Rotate the generator by hand two full revolutions to
    holes in the drive discs with the holes in the flywheel.              ensure the generator rotates freely. Reinstall the rear
    Install the M8 x 1,25 x 25mm bolts (blue loctite on                   vent-cover.
    threads) and torque to 21 Nm (16 ft-lb). Install a threaded        S. Secure the generator to its rear isolators. Route the
    rod MI2 x 1.75 x 90mm long into the threaded end of                   generator wiring into the control box and mount the
    the rotor shaft.                                                      control box to the generator. Reconnect all wire
                                                                          connections. test run.

         M8 X 1.25 X 25MM BOLTS




ROD


                       DRIVE

2. With the aid of a sling or fabricated lifting eye, support
   the stator housing assembly and carefully guide it over
   the rotor assembly until the rear bearing contacts the
   bearing boss in the rear support.
3. Place a large washer of at least 80mm in diameter with a
   center hole of 15mm onto the threaded rod followed by a
   12mm x 1.75 nut. Center the rear bearing in the bearing
   boss of the support plate. Tighten the nut until the bear-
   ing seats fully into the boss. Secure the stator housing
   assembly to the bell housing using the four MIO x 35mm
   screws. Torque to 35 Nm (25 ft-lb). remove the nut.
   washer and threaded rod.




                                                       Engines & Generators

                                                             94
                DECIMAL TO METRIC EQUIVALENT CHART

Fractions of                                      Fractions of
               Decimal (in.)   Metric (mm)                       Decimal (in.)   Metric (mm)
  an inch                                           an inch
    1/64         0.015625        0.39688             33/64         0.515625       13.09687
    1/32         0.03125         0.79375             17/32         0.53125        13.49375
   3/64          0.046875        1.19062             35/64         0.546875       13.89062
   1/16           0.0625         1.58750             9/16           0.5625        14.28750
   5/64          0.078125        1.98437             37/64         0.578125       14.68437
   3/32          0.09375         2.38125             19/32         0.59375        15.08125
   7/64          0.109375        2.77812             39/64         0.609375       15.47812
    1/8           0.125           3.175               5/8           0.625         15.87500
   9/64          0.140625        3.57187             41/64         0.640625       16.27187
   5/32          0.15625         3.96875             21/32         0.65625        16.66875
   11/64         0.171875        4.36562             43/64         0.671875       17.06562
   3116           0.1875         4.76250             11/16          0.6875        17.46250
   13/64         0.203125        5.15937             45/64         0.703125       17.85937
   7/32          0.21875         5.55625             23/32         0.71875        18.25625
   15/64         0.234375        5.95312             47/64         0.734375       18.65312
    1/4           0.250          6.35000              3/4           0.750         19.05000
   17/64         0.265625       6.74687              49/64         0.765625       19.44687
   9/32          0.28125        7.14375              25/32         0.78125        19.84375
  19/64         0.296875        7.54062              51/64        0.796875        20.24062
   5116          0.3125         7.93750              13/16         0.8125         20.63750
  21/64         0.328125        8.33437             53/64         0.828125        21.03437
  11/32          0.34375        8.73125             27/32          0.84375        21.43125
  23/64         0.359375        9.12812             55164         0.859375        21.82812
   3/8            0.375         9.52500               7/8           0.875         22.22500
  25/64         0.390625        9.92187             57/64         0.890625        22.62187
  13/32          0.40625        10.31875            29/32          0.90625        23.01875
  27/64         0.421875        10.71562            59/64         0.921875        23.41562
   7/16          0.4375         11.11250            15/16          0.9375         23.81250
  29/64         0.453125        11.50937            61/64         0.953125        24.20937
  15/32          0.46875        11.90625            31/32          0.96875        24.60625
  31/84         0.484375        12.30312            63/64         0.984375        25.00312
   1/2            0.500         12.70000              1             1.00          25.40000




                                ..... WESTERBEKE
                                      Engines & Generators

                                             95
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
    Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
    Feet (It) x .305 = Meters (m)< 3.281 = Feet
    Miles x 1.609 = Kilometers (km) x .0621 = Miles

DISTANCE EQUIVALENTS
   1 Degree of latitude =60 Nm =111.120 km
   1 Minute of latitude = 1 Nm = 1.852 km
VOLUME
   Cubic Inches (in') x 16.387 = Cubic Centimeters x .061 =in'
   Imperial Pints (IMP pt) x .568 = liters (l) x 1.76 = IMP pt
   Imperial Quarts (IMP qt) x 1.137 = liters (l) x.88 = IMP qt
   Imperial Gallons (IMP gal) x 4.546 = liters (l) x .22 = IMP gal
   Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
   Imperiat Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
   Ftuid Ounces x 29.573 = Milliliters x .034 = Ounces
   US Pints (US pI) x .473 = liters(l) x 2.113 = Pints
   US Quarts (US qt) x .946 = liters (l) x 1.057 = Quarts
   US Gallons (US gal) x 3.785 = liters (l) x .264 = Gallons
MASS-WEIGHT
   Dunces (oz) x 28.35 = Grams (g) x .035 = Ounces
   Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds
PRESSURE
   Pounds Per Sq In (psi) x 6.895 = Kilopascats (kPa) x .145 = psi
   Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
   Inches of Water (H,O) x .07355 = Inches of Mercury x 13.783 = H,O
   tnches of Water (H,O) x .03613 = psi x 27.684 = H,O
   Inches of Water (H,O) x .248 = Kllopascals (kPa) x 4.026 = H,O

TORQUE
   Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 "in-Ib
   Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738 = ft-Ib
VELOCITY
   Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER
   Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUa CONSUMPTION
   Miles Per Hour IMP (MPG) x .354 = Kilometers Per liter (Km/L)
   Kilometers Per liter (Krnll) x 2.352 = IMP MPG
   Miles Per Gallons US (MPG) x .425 = Kilometers Per liter (Krnll)
   Kilometers Per liter (Km/l) x 2.352 = US MPG
TEMPERATURE .
   Degree Fahrenheit (OF) = (DC X 1.8) + 32
   Degree Celsius (DC) = (OF - 32) x .56

UQUID WEIGHTS
  Diesel Oil =1 US gallon =7.13 Ibs
  Fresh Water = 1 US gallon = 8.33 tbs
  Gasoline = 1 US gallon = 6.1 Ibs
  Salt Water = 1 US gallon = 8.56 tbs


                         ~       WESTERBEKE
                                 Engines, & Generators

                                         96
                                                                                      INDEX
AC Output Configurations ................................................ 72                       Fuel Camshaft .............................................................. 23
Alternator Service ............................................................ 35                 Gear Case Cover .......................................................... 27
Assembly Procedures ........................................................ 12                    Gear Case Plate ............................................................ 28
Compression Pressure ........................................................ 2                    Governor Fork Lever. ................................................... 2 I
Cylinder Block .................................................................... 8              Governor Housing Assembly ...................................... 18
Cylinder Head .................................................................... 8               Governor Weight .......................................................... 23
Disassembly Procedures .................................................... I I                    Idle Gears ...................................................................... 28
Dynamic Balancer .............................................................. 9                  Idle Gear/Camshaft ...................................................... 27
Electronic Regulation ........................................................ 85                  Injection Nozzle ............................................................ 20
Engine Troubleshooting ...................................................... 3                    Injection Pump .............................................................. 24
Exciting the Generator ...................................................... 89                   Injection Pump Unit .................................................... 19
Exciter Rotor Troubleshooting .......................................... 90                        Installing InjectiGn Pump ............................................ 25
General Description ............................................................. 8                Oil Pan/Oil Strainer ...................................................... 29
Generator - General Information ...................................... 83                          Piston/Connecting Rod ................................................ 29
Generator Parts Breakdown .............................................. 93                        Pistons ......................................................................... 30
Senerator Testing Voltage ................................................ 89                      Plate - Gear Case .......................................................... 28
Governor ............................................................................ I 0          Rocker Arm/Push Rod .................................................. 15
Head Cover .......................................................................... 8            Stop Lever .................................................................... 22
Internal Wfring Schematic ................................................ 91                      Thermostat .................................................................... 20
Magnetic Pick-Up Coil .................................................... 87                      Valve ............................................................................ 16
Metric Conversion Chart ..................................................95                       Water Pump/Oil Cooler ................................................ 26
Metric Equi valent Chart .................................................... 96                 Engine Adjustments
Parts Breakdown - Generator ............................................ 92                        Fuel Injection ................................................................ 64
PistonlPiston rings ..............................................................9                Fuel Lift Pump .............................................................. 65
Service Specifications ...................................................... 55                   Glow Plugs .................................................................. 65
Special Tools .................................................................... 72              Injection Timing .......................................................... 61
Specifications (65A-Four) ................................................ 68                      Injectors ........................................................................ 64
Specifications (33 EDE) .................................................... 69                    Inlet Fuel Filter ............................................................ 65
Specificatinns (28.5 EDER) ............................................ 69a                        Oil Filter ...................................................................... 63
Specifications - Servicing ................................................. .55                   Oil Pressure .................................................................. 63
Starter Motor Service ........................................................ 34                  Raw Water Pump .......................................................... 66
Terminal Board Connections ............................................ 84                         Valve Clearance ............................................................ 62
Testing for OverhauL .......................................................... 2                Engine Servicing
Testing Voltage .................................................................. 89              Balancer Shaft Alignment ........................................... .47
Torque Specifications ........................................................ 70                  Balancer Shaft Side Clearance ................................... .47
Transmission (Marine) ............................................ 11 & 13                         Cam Height ................................................................. .45
Troubleshooting .................................................................. 3               Camshaft Alignment ................................................... .45
Troubleshooting Chart (Generator) .................................. 88                            Camshaft lournal ......................................................... .46
Tuning Operations ............................................................. I 3                Connecting Rod Alignment ......................................... .49
Water Pump ...................................................................... 66               Crankshaft ................................................................... .50
Wiring Diagrams .............................................................. 67                  Crankshaft Sleeve ........................................................ 52
Wiring Schematic - Internal .............................................. 91                      Cylinder ........................................................................ 53
Disassembly/Assembly                                                                               Cylinder Head ............................................................. .40
   Bearing Case Cover ...................................................... 3 I                   Idler Gear Bushing ..................................................... .46
   Boost Arms ...................... ' ........................................... 21              Oil Clearance - CrankpiniBearing ............................... .51
   Connecting Rod Cap .................................................... 29                      Oil Clearance - Crankshaft lournaVBearing ................ 52
   Crankcases 1 & 2 .......................................................... 32                  011 Pump ...................................................................... 53
   Crankshaft .................................................................... 33              Piston and Connecting Rod ......................................... .48
   Cylinder Head Gasket .................................................. 16                      Piston Ring Gap ........................................................... .48
   Cylinder Head Tappet .................................................. 15                      Timing Gear/Camshaft ............................................... .44
   Cylinder HeadlYalves .................................................. 14                      Top Clearance .............................................................. 40
   Fan Drive (Industrial) .................................................. 26                    Valve GuideNalve Seat ............................................... .42
   Aywheel and Crankshaft .............................................. 31                        Valve Lapping .............................................................. 41
   Aywheel Housing ....................................................... .32                     Valve Spring ............................................................... .43


                                                                     -..y:      WESTERBEKE
                                                                                Engines & Generators

                                                                                            97
                 -.v- WESTERBEKE
                    Engines & Generators




3,1)91117-1138


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