vWESTERBEKE Engines Generators 312 I I I I 3 3 I 1 1 1 TO METRIC EQUIVALENT CHART Fractions of Decimal inMetric mmFractions of Decimal inMetric mman inch an inch 164 0015625 039688 3364 0515625 1309687 132 003125 079375 1732 053125 1349375 364 0046875 119062 3564 0546875 1389062 116 00625 158750 916 05625 1428750 564 0078125 198437 3764 0578125 1468437 332 009375 238125 1932 059375 1508125 764 0109375 277812 3964 0609375 1547812 18 0125 3175 58 0625 1587500 964 0140625 357187 4164 0640625 1627187 532 015625 396875 2132 065625 1666875 1164 0171875 436562 4364 0671875 1706562 3116 01875 476250 1116 06875 1746250 1364 0203125 515937 4564 0703125 1785937 732 021875 555625 2332 071875 1825625 1564 0234375 595312 4764 0734375 1865312 14 0250 635000 34 0750 1905000 1764 0265625 674687 4964 0765625 1944687 932 028125 714375 2532 078125 1984375 1964 0296875 754062 5164 0796875 2024062 5116 03125 793750 1316 08125 2063750 2164 0328125 833437 5364 0828125 2103437 1132 034375 873125 2732 084375 2143125 2364 0359375 912812 55164 0859375 2182812 38 0375 952500 78 0875 2222500 2564 0390625 992187 5764 0890625 2262187 1332 040625 1031875 2932 090625 2301875 2764 0421875 1071562 5964 0921875 2341562 716 04375 1111250 1516 09375 2381250 2964 0453125 1150937 6164 0953125 2420937 1532 046875 1190625 3132 096875 2460625 3184 0484375 1230312 6364 0984375 2500312 12 0500 1270000 1 100 2540000 WESTERBEKE Engines Generators 95 MECC ALTE GENERATOR ASSEMBLY OF THE GENERATOR TO THE ENGINE 1 Position the rotor assembly onto the flywheel aligning the holes in the drive discs with the holes in the flywheel Install the M8 x 125 x 25mm bolts blue loctite on threadsand torque to 21 Nm 16 ftlbInstall a threaded rod MI2 x 175 x 90mm long into the threaded end of the rotor shaft M8 X 125 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 175 nut Center the rear bearing in the bearing boss of the support plate Tighten the nut until the bear255ing 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 ftlbremove the nut washer and threaded rod 4 Rotate the generator by hand two full revolutions to ensure the generator rotates freely Reinstall the rear ventcover S Secure the generator to its rear isolators Route the generator wiring into the control box and mount the control box to the generator Reconnect all wire connections test run Engines Generators 94 MECC ALTE GENERATOR BREAKDOWN Periodically inspect the rotor carrier bearing Replace this bearing at 10000 hours of normal operation or sooner if wear is evident Inspect and clean the control box interior look for loose broken or burned wires and terminals Use low air pressure 25 psi maxto remove dirt and dust from components BEARING BRACKfT PARTS BREAKDOWN DISASSEMBLY Should it become necessary to disassemble the statorrotor assembly from the engine use the following as a guide 1 Properly supporlllift the rear of the engine to allow the 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 Remove all dirt oil grease and dust build up from the external surface of the generator Build267up reduces heat dissipation and causes the AC generator end to operate at a higher temperature This results in a loss of efficiency and reduces service life 4 Support the rotor assembly with a sling and using a 17mm box wrench unbolt the rotor assembly from the flywheel DISC EnQlnes Generators 93 WIRING SCHEMATIC EXCITER ROTORROTATING FIELD rI I EXCITER ROTOR I WINDINGS I 6TRANSIENT i I I I I I I I I I I I I j DIODE I I 1 EXCITER RDTOR WlIDIIGS B c ISOLATION DIODE PLATES GREEN Engines Generators 91 RED RED ROTOR LOW VOLTAGE267 EXCITER ROTOR AND ROTATING FIELD Position the exciter rotorrotating field so the transient suppressor is visible at the 12 OClock 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 shaftIf 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 REDTESTING THE EXCITER ROTOR WINDINGS These windings are tested in pairs A to B B to C and C to A as shown on the drawing c EXCITER ROTOR WINDINGS VIEW OF ROTOR FROM THE BEARING END 12 aCLOCK POSITION 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 wire of the particular diode and test its resistance in both directions A perfectly functioning diode will show a very high resistance in one direction and a very low resistance in the opposite direction A faulty diode will show either a very 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 WESTERBEKE Engines Generators 90 AdobeUCSEDE GENERATOR TESTING THE VOLTAGE ATTACH THE NEGATIVE TEST LEAD TO THE CASE TO GROUNDTO EXCITE THE GENERATOR 1 Lift the DCyellow wire and the DCblue wire off the regulator Attach the test leads to these wires as shown black to the blue wire red to the yellow wire 2 Connect the red test lead to the battery voltage 12VDCat the battery cable connection on the adjacent starter motor solenoid 3 Open the generators AC breaker start the generator and observe the AC output voltage between the line and neutral residual l520VACTHE POSITIVE TEST LEAD TO THE BATTERY fTERMINAL ON THE STARTER SOLENOIO VOLTAGE REGULATOR 4 Connect the black test lead to the metal case groundof the generator This will now put a 12VDC circuit through the exciter stalor of the generator 5 AC output voltage should be aboUl 30 higher lhan normal This indicates that the exciter stator main rotor and stator windings are OK 6 Monitor the auxiliary circuit voltage inlo tile regulator correct vollage should be 220 230 VAC indicating this circuit is ok vWESTERBEKE Engines Generators 89 NOTE AC GENERATOR 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 15 225 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 60 225 100 VAC 2 Open or shorted diodes in exciter rotor 1 to 3 diodes 5 Short in rotating field winding 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 STEADYneeds adjustment AC VOLTAGE DROP UNDER LOAD 1 Diodeson exciter rotor 60 267100 VOLTS AC breaking down when load is applied inductive12673 diodes Engines Generators 88 AdobeUCS B nonnally also sensing AdobeUCS5 9 1 3 5 7 9 7 4 4 6 5 7 4 AdobeUCSand corrosion cracking The AdobeUCSE F G H AdobeUCSD F TOOLS 6Joint 2 EB A B I A M12 x P125 8 Chamfer 1 mm 004 intDI B G c C 30 mm dia 118 in diaD 13 mm dia 051 in diaE Chamfer 3 mm 012 inH K F 3 mm 012 inJ L G 45 mm 177 inH 75 mm 295 inI 57 mm 224 inJ 85 mm 335 inK 70 mm 276 inL 394 mm 1551 in7Piece 3 A 26 mm 102 inQ 8 18 mm O7t inC 165 to 170 mm 0649610 06693 inD 15 mm 006 inN Q E 530 to 532 mm dia 20866 to 20945 in diaF 4955 to 4975 mm dia 19508 to 19587 in diaG 16 mm 063 inH Chamfer 1 mm 004 inI 85 mm dia 033 in diaJ 04 mm 00157 inK 3 mm 012 inL 19 mm 075 inM Chamfer 05 mm 002 inN 36 mm 142 in0 45 mm dia 177 in diap 078 ad 45 Q 115 mm 045 inEngines Generaors 80 AdobeUCSE B AdobeUCS321Ie3 1F 321G c 4AA 78694114A B A o E A 5SPECIAL TOOLS Balancer Bushing Replacing Tools 3 4 5 Application Use to press fit the bushing No Name of Part 1 M AdobeUCSvalve valve AdobeUCSe MIgl L 2670 C 1 ci a b R U A C FI Cl C 2 SPECIAL TOOLS Injection Pumo Gear Puller Application Use for remove the injection pump gear from governor shaft A 10 rnm dia 039 in diaB M16 x Pitch 15 C 19 mm 075 in0 05 mm radius 002 in radiusE 089 rad 50 F 10 mm O39 inG 20 mm 079 inH 5 mm 020 InI 95 mm 374 inJ 125 rnm 493 inK 5 mm 020 inL M16 x Pitch 15 M 30 mm 118inN 95 mm 03740 in0 11 mm 04331 inp 95 mm 03740 inQ 155 mm 06102 inR 45 mm radius 01 B in radiusS 20 mm 079 inT 20 mm 079 inU 80 mm 31496 InW 12 rnm 047 inC2 Chamfer 20 mm 0079 inIdle Gear Bushing Replacing Tool Application Use to press out and to press fit the bushing 1 For idle gear bushing A 196 mm 77165 inB 37Smm 1476 InC 150 mm 59055 in0 4495 mm dia17697 in diaE 48100 to 48075 mm dia 18937 to 18927 in diaF 20 mm dia 07874 in diaa 63 lim 250 liinb 63 Jim 250 JiinCl Chamfer 10 mm 0039 inC2 Chamfer 20 mm 0079 inEngines Generators 75 AdobeUCSC 2 AdobeUCSmake them J 8 SPECIFICATIONS Item Size x Pitch N267m kgf267m ftlbs Governor housing mounting screw M6 x 10 98 to 113 10t0115 723 to 832 Antirotation nut M5 x 08 28 to 40 029 to 041 21 to 30 Balancer shaft set screw M8 x 125 235 to 275 24 to 28 174 to 203 Bearing case cover mounting screw M8 x 125 235 to 275 24 to 28 174 to 203 Alternator pulley nut 583 to 789 595 to 805 430 to 582 When the tightening torques are not specified tighten the screws bolts and nuts according to the table below Standard Screw and Bolt Special Screw and Bolt jNominal Diameter Unit N267m kgf267m It267lbs N267m kgf267m It267lbs M6 79 to 93 080 to 095 58 to 69 98 to t t3 tOO to 115 723 to 832 M8 t77 to 206 t8 to 2t 130 to 152 235 to 275 24 to 28 174 to 203 M10 392 to 451 40 to 46 289 to 333 48110559 49 to 57 354 to 412 M12 628 to 726 64 to 74 463 to 535 775 to 902 79 to 92 571 to 665 Screw and bolt material grades are shown by numbers punched on the screw and bolt heads Prior to tightening be sure to check out the numbers as shown below Punched number Screw and bolt material grade None or 4 Standard screw and bolt 8841 S20C 7 Spcial screw and bolt S43C S48C RefinedEngines Generators 71 AdobeUCSTORQUE SPECIFICATIONS NOTE 267For marked screws bolts and nuts on the table apply engine oil to their threads and seats before tightening The letter M in Size x Pitch means that the screw bolt or nut dimension stands for metric The size is the nominal outside diameter in mm of the threads The pitch is the nominal distance in mm between two threads Item Size x Pitch N267m kgf267m ftIbs Cylinder head cover screw 69 to 113 07 to 115 51 to 832 Cylinder head screw M12x 125 981 to 1079 100 to 110 723 to 796 Connecting rod screw M10 x 125 785 to 834 80 to 85 579 to 615 Flywheel screw M12 x 125 981 to 1078 100 to 110 723 to 796 Crankshaft screw M16x15 2550 to 2746 260 to 280 1881 to 2025 Main bearing case screw M14x15 1373to 1471 140 to 150 1013 to 1085 Rocker arm br dcket screw M10x125 490 to 559 50 to 57 362 to 412 Nozzle holdor assembly M20 x 15 490 to 686 50 to 70 362 to 506 Nozzle holder 343 to 392 35 to 40 253 to 289 Injection pipe retaining nut M12 x 15 226 to 363 23 to 37 166 to 268 Overflow pipe assembly retaining nut M12x15 196 to 245 20 to 25 145 to 181 Oil switch taper screw R 18 147 to 196 15 to 20 108 to 145 Oil cooler joint screw 392 to 441 40 to 45 289 to 325 Oil pump cover screw 79 to 93 080 to 095 58 to 69 Glow plugs M10 x 125 196 to 245 20 to 25 145 to 181 Starters terminal B mounting nut M8 x 125 98 to 118 10 to 12 72 to 87 Injection pump gear mounting nut M14x15 736 to 834 75 to 85 542 to 615 Injection pump unit mounting nut M8 x 125 177 to 206 18 to 21 130t0152 Gear case cover M8 x 125 235 to 275 24 to 28 174 to 203 Relief valve retaining screw 686 to 784 70 to 80 506 to 579 Idle gear mounting screw M8 x 125 235 to 275 24 to 28 174 to 203 Plate mounting screw M8 x 125 235 to 275 24 to 28 174 to 203 Camshaft set screw M8 x 125 235 to 275 24 to 28 174 to 203 Flywheel housing mounting screw M12 x 125 775 to 902 79 to 92 571 to 665 Crankcase 2 mounting screw M10 x 125 490 to 559 50 to 57 362 to 412 Injection pump mounting screw M8 x 125 235 to 275 24 to 28 174 to 203 Injection pump mounting nut M8 x 125 177 to 206 18t021 130 to 152 Boost Actuator 392 to 451 40 to 46 289 to 333 Governor weight mounting nut M12 x 125 628 to 726 64 to 74 463 to 535 Fuel camshaft stopper mounting screw 79 to 93 080 to 095 58 to 69 WESTERBEKE Engines Generators 70 3 3 3 3 3 3 3 3 SPECIFICATIONS 25521DKW EDE AC GENERATOR Single PhaseAC GENERATOR 3 PhaseSingle Phase Voltage vonage Regulalion Frequency Regulation Rating Volts AC0 Hz 1800 rpm1UIIW 50 Hz 1500 IJIIIO UIIW Generator Cooling rur requlremenls Single 3 phaseGenerator Compartment Ambient Temperature Brushless sixpole revoMng field Sealed lubricaled singlebearing design 12 Lead reconnectable Double Della for 1201240 valls 60hzSeries Slar for 230 volts 50hzWith solid slate vollage regulator 120 or 1201240 volts 60 hertz 230 Valls 50 Hertz 2612 no load to full load 3 Hertz 5no load to full load 120 volts 2125 amps 1201240 valls 21251063 amps 230 valls 913 amps 400 elm 113 emmNOTE Increase air supply 15 tor50 Hetlz opemNon 1500 rpm122F 50Cmaximum NOTE Fo253ed venOlaOon should be provided to maintain genemtor compartment lempemtures below 104F 40267CThree Phase Vollage 3 phase 60 HertzVoltage 3 Phase 50 HertzAmperage 3 phase 60 HertzAmperage 3 phase 50 HertzGenerator Cooling Air requirements 60 Hzat 1 BOO rpm Generator Compartment Ambient Temperalure Brushless sixpole revolving field Sealed lubricated singlebearing design 12 Lead reeonneelable Solid state vollage regulalor Low Voltage WYE 240 Valls High Voliage WYE 4BO Valls DELTA 277 Valls High Vollage WYE DELTA Low Vollage WYE High Vollage WYE DELTA 400 Volts 230 Volts 76 Amps 3B Amps 665 Amps High Vollage WYE 379 Amps DELTA 659 Amps 225 250 elm 566 637 emmNOTE Increase air supply 15 tor 50 Hetlz opemOon 1500 rpm122F 50Cmaximum NOTE Forced venOlation should be provided to maintain generator compartment tempellltures below 104260F 285235KW EDE AC GENERATOR Single PhaseAC GENERATOR 3 PhaseSingle Phase Brushless sixpole revolving field Three Phase Brushless Sixpole revolving field Sealed Sealed lubncated singlebearing design 12 lubricated singlebearing design 12 Lead Lead reconnectable Double Delta for 1201240 reconnectable Solid state vollage regulator volts 60hzSeries Star for 230 valls 50hzVoltage 3 phase Low Voltage WYE 240 Valls With solid state vonage regulator 60 HertzHigh Voltage WYE 4BO Valls Voltage 120 or 1201240 volts 60 hertz DELTA 277 Valls 230 Valls 50 Hertz Vollage 3 Phase High Vollage WYE 400 VoIIs Voltage Regulation 2612 no load to tuilioad 50 HertzDELTA 230 Volts Frequency Regulation 3 Hertz 5no load to fuilioad Amperage 3 phase Low Vonage WYE B58 Amps RatIng Volts AC60 HertzHigh Voltage WYE 429 Amps 0 Hz 1800 rpm120volls 2375 amps DELTA 743 Amps 1201240 valls 237511 BB amps Amperage 3 phase High Voltage WYE 424 Amps 50 Hz 1500 rpm230 volts 1022 amps 50 HertzDELTA 73B Amps Generator COOling 225 250 elm 566 637 emmAir requirements Generator Cooling 400 elm 113 emm60 Hzat 1 BOO rpm NOTE Increase air supply 15 for 50 Hetlz Air requirements opellltion 1500 rpmSingle 3 phaseNOTE Increase air supply 15 for 50 Hetlz opellltion 1500 rpmGeneralor Compartment 122F 50Cmaximum Ambient Temperature Generator Compartment 122F 50Cmaximum NOTE Forced venNfaNon should be provided Ambient Temperature to maintain generator compartment NOTE Forced ventilation shoufd be provided tempellltures below 104F 40267Cto maintain generator compartment tempellltures below 104F 40CtoY WESTERBEKE Engines Generators 69B SPECIFICATIONS 330260KW EDE AC GENERATOR Single Phase I AG GENERATOR 3 PhaseSingle Phase Brushless six267 pole revoMng field Three Phase Brushless revolving field Sealed Sealed lubncated slnglebeanng design 12 lubncated singlebeanng design 12 Lead Lead reconnectable Double Delta for 1201240 reconnectable Solid state voltage regulator volts 60hzSenes Star for 230 volts 50hzVonage 225 3 phase Low Voltage WYE 240 Volts With solid state voltage regulator 60 HertzHigh Voltage WYE 480 Volts Vottage 120 or 1201240 vans267 60 hertz DELTA 277 Valls 230 Volts267 50 Hertz Voltage267 3 Phase High Voltage WYE 400 Volts Voltage Regulalion 2612 no load to full load 50 HertzDELTA 230 Volts Frequency Regulation 3 Hertz 5no load to full load Amperage267 3 phase Low Voltage WYE 993 Amps Rating Vans AC60 HertzHigh Voltage WYE 496 Amps 60 Hz 1800 rpm120 volts 275 amps DELTA 860 Amps 1201240 volts 27511375 amps Amperage267 3 phase High Voltage WYE 469 Amps 50 Hz 1500 rpm230 volts 113 amps 50 HertzDELTA 816 Amps Generator Cooling 225 225 250 cfm 566 225 637 cmmAir requirements Generator COOling 500 cfm 141 cmm60 Hzat 1800 rpm NOlE Increase airsupply 15 far 50 Hertz Air requirements aperaffan 1500 rpmSingle 3 phaseNOlE Increase air supply 15 for 50 Hertz aperaUan 1500 rpmGenerator Compartment 122F 50Cmaximum Ambient Temperature Generator Compartment 122F 50Cmaximum NOlE Forred venUlaUan should be provided Ambient Temperature to maintain generator compartment NOlE Forred ventilation should be provided temperatures belaw 104F 40Cto maintain generator comparlment temperatures below 104F 40CWESTERBEKE Engines Generators 69A AdobeUCS3 3 AdobeUCS2 114 RRN AdobeUCS SIARHR sun l PIM243AT w TeM s 1 PIHAT SWITCH 225 I I I r AllRNATOR u I ALT LAII 0 LAI 9 225 S UUG I GID fHI 11 OJ CAPTAIN PANEL 65AFOUR WIRING DIAGRAM 39144 1 i 2671 U L Tc3 COR I TIM243R I Iqc lOB l08 HA 1 whW utbf F lIH SOL NOTE I fltlS 1 fROlCl243O 8f A RSrr CIRCUIT BRU243R LOeAlED IH SlUlR UcSSIYE CURREN Will CAUSE N 8REAHR 10 AND lH HGINE Will SIiUl POIN TNE BUltOnOWHR BE SUA IHAI TH243 NSTAlHflH HNa WIRING AND NGIN243 AR TO PlEY243NT e1IN HEAICAt AD HAWAhR 1 AN ON267orr IITCII SHOULO J BETWEEN THE BUIUT AHO HARTER TO DISCONnCl TH BATTEU IN AN lEAGUe AMD IHN IH243 BOAT A SWITCH WIIH A conlHUOIiS RATiNG or 15 AMPS Hl VOC In SUY243 IHIS TUNCTION THIS SWIICH SHOULD HOT BE USED 10 lAKE OR TH243 CIRCUI 1 TH PIU WIA AT HUG Z IS UNVS243O AND SHOULD BE INSULATED eVTAIN PANH OHLT 4 THE GliAl WIRE AT PLIIG l IS UHUSLD UD SHOULD B243 IIISUIA1243O AOHIAAl PANEL ONLI II L1 BlII lJ II 256 BALMAR HlO AMP All GU 1150liiJl MAU 1 SIDE III 8RM ITllei11 PRESTOI IIf1 EECENEVIIIE 90 AMP ALT 114lTlll 225 JMC 0 AC UP BAH a RED o MITSUBISHI 50 HlP AI I L L o 256 1 4 GRA 256 PRESIOI In 1 AMP It T rn I LI BLU HOI USEDUG 0 PINK NOH WIAt rOR BMlRI NHD 10 B243 UPGRlO1I TO AN e GAUGE fROM 10 GAUG 14 eRN IINIVERSAL PROPvJSION 14 IT R243D 14 PINK UtlU I V 114 BRN tl4 I SJAMP AlTERNATOR 9 STANDARD AlJRNATOR ON IH243 63B 63C 64A 71B B28 108B 108C lW i LJ ll LU FlGH 14 PINA lJ 4 LI BL LfSTfK 100 AMP AU CO III BU ON IHIS S ID III 8U Ml TAtHllij IGN 0 14981 INOT USEOI 4 HO 225 I 8 f 0 225225 GHO o WATER PUMP 052650 PARTS LIST PROPULSION ENGINES AND MARINE GENERATORS GASKET WEAR PLATE 302574 IMPELLER KIT 33KW EOE GENERATOR HOSE CONNECTIONS END COVER 049170 END COVER SCREWS 6M4x 10x8MM FRONT ASSEMBLY 034463 SCREW 4M6 X 125 X 16MM 017012 WASHER 4031783 ORING SPACER PRESSES AGAIN7 THE ORING SPACER PINS FIT AGAINST THE LlPSEAL REAR ASSEMBLY CIRCLIP GROOVE THE BEARINGS AGAINST THE CIRCLIP WESTERBEKE Engines Generators 66 CAM RETAINING SCREW SEE REAR ASSEMBLY BELOW SCREW 4MG x 125 x 16MM 017012 FLAT WASHER 4M6 031783 NOTE The parts slwwn along with a glycerine pack are included in WESTERBEKES PUMP KiT052650 with the exception of the pump body and the adapter flange SHAFT BALL BEARING 2CIRCLIP IVLLI 053366 CIRCLIP FITS INTO GROOVE IN PUMP BODY AdobeUCS9 fuel that replacement inlet AdobeUCSFUEL 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 1in the nozzle holder to adjust it See the Disassembling and Assembling for nozzle holder 1373 to 1471 MP Fuel injection pressure Factory spec 140 to 150 kgffem 1991102134 psi Reference225 Pressure variation with 001 mm 00004 indifference of adjusting washer thickness Approx 235 kPa 24 kgfcm 34 psiNozzle 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 1275 MPa 130 kgfcm 1849 psifor 10 seconds 3 If any fuel leak is found replace the nozzle piece No fuel leak at Valve seat tightness Factory spec 1275 MP 130 kgffem psi DISASSEMBLY Nozzle Holder 1 Secure the nozzle retaining nut 7with a vise 2 Remove the nozzle holder 1and take out parts inside When Assemble the nozzle in clean fuel oil 225 Install the push rod 4noting its direction 225 After assembling the nozzle be sure to adjust the fuel injection pressure 343 to 392 Nm Nozzle holder 35 to 40 kgf267m 253 to 289 ft267lbs 196 to 245 N267m Tightening torque Overflow pipe nut 20 to 25 kgf267m 145 to 18 I ftIbs 49010686 N267m Nozzle holder assembly 50 to 70 kgf267m 362 to 506 ftIbs yo WESTERBEKE Engines Generators 64 NOZZLE HOLDER 1GOOD PRESSURE TEST DEFECTIVE ADJUSTING JWASHER 1RETAINING NUT ADJUSTMENTS When installing the new oil filter element wipe the filter gaskets 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 lIHll OIL PRESSURE GAUGE TESTING OIL PRESSURE To test the oil pressure remove the oil pressure sender then install a mechanical oil pressure gauge in its place After wanning up the engine set the engine speed at idle and read the oil pressure gauge 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 grad255ualloss of oil pressure usually indicates worn bearings ENGINE OIL CHANGE 1 Draining the Oil Sump Discharge the used oil through the sump drain hose attached to the front of the enginewhile the engine is wann Drain the used oil completely replace the hose in its bracket and replace the end cap securely NOTE Thread size for the lube oil drain hose capped end is 114 NPT 11161 SOCKET WIPE SURFACE CLEAN BEFORE INSTALLING APPLY CLEAN ENGINE oL INSTALLING 3 Filling the Oil Sump Add new oil through the oil filler cap on the top of the engine or through the side oil filL After refilling run the generator for a few moments while checking the oil pressure Make sure there is no leakage around the new oil filter or from the oil drain system and stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the high mark on the dipstick should the engine require additional oil Use a heavy duty engine oil with an API classification of CF CG4 CH4 or CI4 Change the engine oil after an initial 50 hours of breakin operation and every 100 hours of operation thereafter For recommended oil use SAE 15W40 oil recommends the use of synthetic oil WIWUIVt USING AN 8MM lJ76 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 Mr WESTERBEKE Engines Generators 63 OIL GALLERY AdobeUCSENGINE ADJUSTMENTS Checking Valve Clearance 225 IMPORTANT 225 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 sidecomes to the compression top dead center 3 Before adjusting the valve clearance of intake valve adjust the 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 sideby your fingers and screw in the adjusting screw slowly until you feel the screw touch the top of valve stem then tighten the lock nut 6 Loosen the lock nut of adjusting screw push rod sideand 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 sideand the exhaust valve to the specified value Valve clearance Factory spec IN EX When No1 1s1 0 0 piston Is 2nd 0 cDmpressed 3rd Top Dead Cenler 41h When No1 1st piston is in 2nd 0 overlap 3rd posilion 41h Cylinder head cover Tightening torque screw IN 0 0 0 023 to 027 mm 0009t to OOtOS in EX IN EX 0 0 0 0 0 0 0 0 0 0 0 S9 to 113 Nm 07 to 115 kgl267m 51 to 832 ftIbs 62 ADJUSTING SCREWS LOCK NUT TIMING WINDOW ADJUSTING SCREWS ENGINE COLD023 027mm 00091 00106 inENGINE ADJUSTMENTS Injection Timing 1 Make sure of matching the injection timing align mark 1of the injection pump unit and the plate gearcaseas shown in the illustration 2 Remove the injection pipes 3 Remove the stop solenoid 4 Turn the flywheel viewed from flywheel sideuntil the fuel fills up to the hole of the delivery valve holder 2for No1 cylinder 5 After the fuel fills up to the hole of the delivery valve holder for No1 cylinder turn back clockwisethe flywheel around 157 rad 90 06 Turn the flywheel to set at around 035 rad 20 before TDC 7 Slowly turn the flywheel and stop turning 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 No1 piston 9 If the injection timing is not within the specification rotate the injection pump unit to adjust the injection timing 225 IMPORTANT 225 When installing the injection pump unit to the engine body follow the correct procedure 020 to 022 rad t t 5 to Factory 125before TDC Injection timing spec Injection pipe retaining 226 to 363 N267m 23 to 37 kgf267m nut 166 to 268 ftIbs Tightening torque Injection pump unit 177 to 206 N267m 18 to 21 kgf267m mounting nut 130 to t 52 ftIbs See the Injection Pump Unit Disassembly and Assemble section WESTERBEKE Engines Generators 61 aInjection Timing Advanced bInjection Timing Delayed VIEWING THE DELIVERY VALVE HOLDER DELIVERY VALVE FLYWHEEL VIEWING THE FLYWHEEL SPECIFICATIONS LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed 49 kPa 05 kgfcm2 7 psi At Rated Speed 196 to 392 kPa 1471 kPa 20 to 40 kgfcm2 15 kgfcm2 28 to 57 psi 213 psi Engine Oil Pressure Switch Working Pressure 392 to 588 kPa 04 to 06 kgfcm2 56 to 84 psi Inner Rotor to Outer Rotor Clearance 004 to 016 mm 03mm 00016 to 00063 in 00118 in Outer Rotor to Pump Body Clearance 0100 to 0184 mm 03mm 00039 to 00072 in 00118 in Rotor to Cover Clearance 0025 to 0075 mm 0225 mm 00010 to 00030 in 00089 in Relief Valve Working Pressure 885 kPa 904 kgfcm2 129 psi ELECTRICAL SYSTEM Item Factory Specificatioil Allowable Limit Commutator 00 32 mm 314 mm 12598 in 12362 in Mica Undercut 05mm 02mm 00197 in 00079 in Brush StarterLength 18 mm 11 mm 07086 in 04331 in Alternator Noload Voltage 14 Vat 4000 minI rpmRotor Coil Resistance 28 to 33 Q Slip Ring 00 227 mm 221 mm 0894 in 0870 in Brush 185 mm 50mm 0728 in 0197 in Glow Plug Resistance Approx 10 Q vWESTERBEKE Engines Generators 60 SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Tappet to Tappet Guide Clearance 0020 to 0062 mm 007 mm 00008 to 00024 in 00028 in Tappet Guide Bore 24000 to 24021 mm 1009449 to 09457 in Tappet 23959 to 23980 mm 0009433 to 09441 in Camshaft Side Clearance 007 to 022 mm 03mm 00028 to 00087 in 00118 in Alignment 001 mm 000039 in Cam Height IN 3763 mm 3713 mm 14815 in 14618 in EX 3896 mm 3846 mm 15338 in 15141 in Camshaft Oil Clearance 0050 to 0091 mm 015 mm 000197 to 000358 in 00059 in Camshaft Journal 45934 to 45950 mm 0018084 to 18091 in Camshaft Bearing 46000 to 46025 mm D18110to 18120 in FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing V3300E2B 020 to 022 rad 115 to 125260before TDC V3300TE2B 011 toO13 rad 65 to 75 0before TDC Fuel Injection Nozzle Injection Pressure 1373 to 1471 MPa 140 to 150 kgfcm2 1991 to 2134 psi Valve Seat When the pressure is Tightness 1275 MPa 130 kgfcm2 1849 psithe valve seat must be fuel tightness COOLING SYSTEM Item Factory Specification Allowable Limit Thermostat Valve Opening 745 to 785 260c Temperature 1661 to 1733 OF Valve Opening Temperature 90260C Opened 194 OF CompletelyI Engines Generators 59 SPECIFICATIONS Item Factory Specification Allowable Limit Timing Gear Idle Gear 1 to Crank 0049 to 0193 mm 022 mm Gear 00019 to 00076 in 00087 in BacklashIdle Gear 1 to Cam 0049 to 0189 mm 022 mm Gear Backlash00019 to 00074 in 00087 in Idle Gear 1 to Idle 0044 to 0185 mm 022 mm Gear 2 Backlash00017 to 00073 in 00087 in Idle Gear 2 to Injection Pump 0044 to 0177 mm 022 mm Gear 00017 to 00070 in 00087 in BacklashCam Gear to 0047 to 0182 mm 022 mm Balancer Gear 1 Backlash00018 to 00072 in 00087 in Idle Gear 1 to 0044 to 0183 mm 022 mm Balancer Gear 2 Backlash00017 to 00072 in 00087 in Idle Gear Shaft 1 2 to Idle Gear 1 2 Oil Clearance 0050 to 0091 mm 010mm Bushing 00020 to 00036 in 00039 in Idle Gear 1 2 45025 to 45050 mm Bushing 17726 to 17736 in 10Idle Gear 1 2 Shaft 44959 to 44975 mm 0017700 to 17707 in Idle Gear Side Clearance 015to 030 mm 09 mm 00059 to 00118 in 00354 in Balancer Shaft Balancer Model OnlySide Clearance 007 to 022 mm 03mm 00028 to 00087 in 00118 in Balancer Shaft Balancer Model OnlyAlignment 002 mm 00008 in Balancer Shaft Balancer Model OnlyOil Clearance 0070 to 0159 mm 02mm 00028 to 00063 in 00079 in Balancer Shaft 5092 to 5094 mm Journal 20047 to 20055 in 00Balancer Bearing 5101 to 5108 mm 1020083 to 20110 in Piston Pin Bore 10 30000 to 30013 mm 3005 mm 11811 to 11816 in 11831 in Compression Ring 2 to Ring Groove Clearance 0093 to 0120 mm 020 mm 00037 to 00047 in 00079 in Oil Ring to Ring Groove Clearance 002 to 006 mm 015 mm 00008 to 00023 in 00059 in WESTERBEKE Engines Generators 58 SPECIFICATIONS Item Factory Specification Allowable Limit Piston Ring Gap Compression Ring 030 to 045 mm 125 mm 1 00118 to 00177 in 00492 in Compression Ring 030 to 045 mm 125 mm 2 00118 to 00177 in 00492 in Oil Ring 025 to 045 mm 125 mm 00098 to 00177 in 00492 in Connecting Rod Alignment 005 mm 00020 in Piston Pin to Small End Bushing Clearance 0020 to 0040 mm 015 mm 00008 to 00016 in 00059 in Piston Pin 30006 to 30011 mm Small End Bushing 30031 to 30046 mm 1011823 to 11829 in Crankshaft Side Ciearance 015toO31 mm 050 mm 00059 to 00122 in 00197 in Alignment 002 mm 000079 in Crankshaft Journal 00 74977 to 74990 mm 29518 to 29524 in Crankshaft Journal to Crankshaft Bearing Oil Clearance 0018 to 0062 mm 020 mm 00007 to 00024 in 00079 in Crank Pin 00 52977 to 52990 mm 20857 to 20862 in Crank Pin to Pin Bearing Oil Clearance 0018 to 0051 mm 020 mm 00007 to 00020 in 00079 in Cylinder Bore 10 98000 to 98022 mm 9815 mm 38582 to 38591 in 38642 in Cylinder Bore 10 98500 to 98522 mm 9865 mm Oversize38780 to 38788 in 38839 in WESTERBEKE Engines Generators 57 SPECIFICATIONS Item Factory Specification Allowable Limit Valve Stem to Valve Guide Clearance IN0055 to 0085 mm 01 mm 00022 to 00033 in 00039 in Valve Stem 00 6960 to 6975 mm IN02740 to 02764 in Valve Guide 10 7030 to 7045 mm IN02768 to 02774 in Clearance EX0040 to 0070 mm 01 mm 00016 to 00028 in 00039 in Valve Stem 00 7960 to 7975 mm EX03134 to 03140 in Valve Guide 10 8015 to 8030 mm EX03155 to 03161 in Valve Spring Intake 351 to 356 mm 346 mm 13819 to 14016 in 13622 in Exhaust 417 to 422 mm 412 mm 16417to 16614in 16220 in Setting Load I Setting Length Intake 63547 N I 315 mm 45864 N 1315 mm 648 kgf 1315 mm 468 kgf I 315 mm 10296 Ibs 11 2401 14256 Ibs 112401 in in Exhaust 1176 N I 35 mm 100 N 135 mm 12 kgf 135 mm 102 kgf 135 mm 264 Ibs 113780 in 2251bs 113780 in Tilt Valve Spring10mm 0039 in Rocker Arm Shaft to Rocker Arm Oil Clearance 0016 to 0045 mm 015 mm 000063 to 000177 in 00059 in Rocker Arm Shaft 15973 to 15984 mm 00 06289 to 06293 in Rocker Arm 10 for 16000 to 16018 mm Shaft 06299 to 06306 in Valve Arm Bridge and Valve Arm Bridge Clearance 0018 to 0042 mm 015 mm Shaft 00007 to 00017 in 00059 in Valve Arm Bridge 9050 to 9065 mm 1003563 to 03569 in Valve Arm Bridge 9023 to 9032 mm Shaft 0003552 to 03556 in Push Hod Alignment 025 mm 00098 in WESTERBEKE Engines Generators 56 AdobeUCSENGINE BODY SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Cylinder Head Surface Flatness 005 mm 00020 in Top Clearance V3300E2B 072 to 090 mm 00283 to 00354 in V3300T E2B 09210110 mm 00362 to 00433 in Compression Pressure V3300E2B 432 MPa I 326 MPal 250 min 1 rpm250 min267 rpm44 kgfcm2 I 332 kgfcm2 I 250 min267 rpm250 min267 rpm626 psi I 472 psi I 250 min267 rpm250 min267 rpmV3300TE2B 392 MPal 299 MPal 250 min267 rpm250 min267 rpm40 kgfcm21 305 kgfcm2 I 250 min267 rpm250 min1 rpm569 psi I 434 psi I 250 min267 rpm250 min1 rpmVariance Among Cylinders 10 or less Valve Seat Width IN 212 mm 00835 in EX 212 mm 00835 in Valve Seat Angle IN 1047 rad 600 EX 0785 rad 450 Valve Face Angle IN 1047 rad 600 EX 0785 rad 450 Valve Recessing IN 02 to 0 mm 04 mm 0079 to 0 in 00157 in EX 005 to 015 mm 04 mm 00019 to 00059 in 00157 in Valve Clearance Cold023 to 027 mm 00091 to 00106 in Intake Valve Timing Open 024 rad 14 0before TDC Close 061 rad 360after BDC Exhaust Valve Timing Open 079 rad 450before BDC Close 029 rad 17 0altel LQC WESTERBEKE Engines Generators 55 Clearance between Outer Rotor and Pump Body 1 Measure the clearance between the outer rotor and the pump body with a feeler gauge 2 If the clearance exceeds the allowable limit replace the oil pump rotor assembly Clearance between Factory spec outer rotor and pump body Allowable limit Clearance between Rotor and Cover 1 Put a strip of plastigage onto the rotor face with grease 0100 to 0184 mm 00039 to 00072 in 03 mm 00118 in 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 Factory spec 002510 0075 mm Clearance between 00010 to 00030 in rotor and cover 0225 mm Allowable limit 00089 in 79 to 93 N267m Tightening torque Oil pump cover screw 080 to 095 kgf267m 58 to 69 ttIbs y WESTERBEKE Engines Generators 54 PLASTIGAGE FEELER GAUGE Cylinder Cylinder Wear SERVICING 1 Measure the 10 of the cylinder at the six positions with a cylinder gauge to find the maximum and minimum IOs 2 Get the difference Maximum wearbetween the maximum and the minimum los 3 If the wear exceeds the allowable limit bore and hone to the oversize dimension Refer to Correcting Cylinder4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder should be bored Refer to Correcting Bor tD ATop BMiddle CBottom SkirtFactory spec Allowable limit 98000 10 98022 mm 385821038591 in 9815 mm 38642 in aRightangled to Piston Pin bPiston Pin Direction Correcting Cylinder Oversize 05 mm1 When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension Cylinder tD 2Factory spec 98500 to 98522 mm 38780 to 38788 in Maximum wear Allowable limit 9865mm 3889 in Horn to 12 to 20 mm uR max Finishing VlVl 0000047 to 0000079 in JR max2 Replace the piston and piston rings with oversize 05 mmNOTE 225 When the oversize cylinder is worn beyond the aowable 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 Factory spec 004 to 016 mm Clearance between 00016 to 00063 in inner rotor and outer rotor Allowable limit 03 mm 00118 in v WESTERBEKE Engines Generators 53 FEELER GAUGE A B C MEASURING CYLINDER WEAR CYLINoER 10 BEFORE CONNECTiON 1 2 CYLINDER 10 OVERSIZE rSERVICING 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 225 IMPORTANT 225 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 Crankshaft journal 00 Factory spec 74977 to 74990 mm 29518 to 29524 in Factory spec 0018 to 0062 mm Oil clearance between 00007 to 00024 in crankshaft journal and crankshaft bearing Allowable limit 020 mm 00079 in Reference225 Undersize dimensions of crankshaft journal Undersize O2mm OAmm 0008 in 0016 in Dimension A 28 to 32 mm radius 28 to 32 mm radius 01102 to 01260in radius 01102 to 01260 in radius Dimension B 1 0 to 15 mm radius 10 to 15 mm radius 00394 to 00591 in radius 00394 to 00591 In radius Dimension C 74777 to 74790 mm 74577 to 74590 mm 29440 to 29445 in 29361 to 29366 in 085The crankpin must be finefinished to higher than vvvv Replacing Crankshaft Sleeve 1 Remove the used crankshaft sleeve 1using a specialuse puller set 2 Set the sleeve guide 4to the crankshaft 3 Heat a new sleeve to a temperature between 150 to 200260C 302 to 392 OFand fix the sleeve to267the crankshaft as shown 4 Press fit the sleeve using the auxiliary socket for pushing 225 NOTE 225 Mount the sleeve with its largely chamfered surface facing outward WESTERBEKE Engines Generaors 52 B CRANKSHAFT o A A c A CRANKSHAFT JOURNAL SLEEVE CRANKCASE GUIDE SLEEVE 1AUXILIARY SOCKET SERVICING Oil Clearance between Crankpin and Crankpin Bearing 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 225 NOTE 225 Never insert the plastigage into the crankpin oil hole 225 Be sure not to move the crankshaft while the connecting rod screws are tightened Crankpin 00 Factory spec 52977 to 52990 mm 20857 to 20862 in Factory spec 0018 to 0051 mm Oil clearance between 00007 to 00020 in crankpin and crankpln bearing Allowable limit 020 mm 00079 in Oil Clearance between Crankpin and Crankpin Bearing Continued225 IMPORTANT 225 STD size crankpin bearing To replace it with a specific STD service part make sure the crankpin bearing has the same ID color as the connecting rod Connecting rod Crankpin bearing 10 Color Largeend in dia Class Part code Center wall thick Blue 5601 to 5602 mm L 1496 to 1501 mm 22051 to 22055 in 00589 to 00591 in Without 5600 to 56Q1 mm S 1491 to 1496 mm color 22047 to 22051 in 00587 to 00589 in 225 Undersize dimensions of crankpin Undersize O2mm 04 mm 0008 in 0Q16 in Dimension A 28 to 32 mm radius 28 to 32 mm radius 01102 to 01260 in radius 01102 to 01260 in radius Dimension B 10 to 15 mm radius 10 to 15 mm radius 00394 to 00591 in radius 00394 to 00591 in radius Dimension C 52777 to 52790 mm 52577 to 52590 mm 2077810 20783 In 207DO to 20705 in 08267SThe crankpin must be fintlfjlJished to higher than vvvv WESTERBEKE Engines Generators 51 PlASTIGAGE B a CRANKSHAFT o 10 COLOR CRANKPIN BEARING CENTER WAll THICKNESS SERVICING Crankshaft Side 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 3 If the measurement exceeds the allowable limit replace the 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 Factory spec 015 to 031 mm Crankshaft side 00059 to 00122 in clearance 050mm Allowable limit 00197 in Reference225 Oversize dimensions of crankshaft journal Oversize O2mm O4mm 0008 in 0016 in Dimension A 2920 to 2925 mm 2940 to 2945 mm 114961011515 in 11574 to 11594 in Dimension B 1691 to 16915 mm 1692 to 16925 mm 66575 to 66594 In 66614 to 66634 in Dimension C 28 to 32 mm radius 28 to 32 mm radius 01102 to 01260 in radius 01102 to 01260 in radius OBSThe crankshaft journal must be finefinished to higher than VilVV 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 measurement3 If the misalignment exceeds the allowable limit replace the crankshaft Crankshaft alignment Allowable limit 002mm 000079 in v WESTERBEKE Engines Generators 50 CRANKSHAFT SIDE CLEARANCE DIAL INDICATOR CRANKSHAFT JOURNAL DIMENSIONS o CRANKSHAFT JOURNAL 225 CRANKSHAFT Oil Clearance between Piston Pin and Small End Bushing 1 Measure the 00 of the piston pin where it contacts the bushing with an outside micrometer 2 Measure the 10 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 Factory spec 0020 to 0040 mm Oil clearance between 00008 to 00016 in piston pin and small end bushing Allowable limit O15mm 00059 in MEASURING THE PISTON PIN When Removing Installing Piston pin 00 Factory spec Small end bushing 10 Factory spec Replacing Small End Bushing When removing30006 to 30011 mm 11813to 11815 in 30031 to 30046 mm 11823 to 11829 in 1 Press out the used bushing using a small end bushing replacing tool When installing1 Clean a new small end bushing and bore and apply engine oil to them 2 Insert a new bushing onto the tool and pressfit it with a press so that the seam 1of bushing position as shown until it is flush with the connecting rod Connecting Rod Alignment 225 NOTE 225 Since the 10 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 Code No 07909316614 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 alignment Allowable limit O05mm 00020 in WESTERBEKE Engines Generators 49 REPLACING THE SMALL END BUSHING 026 ad 15 e1Seam ALIGNING THE CONNECTING ROD 1 2 o Oil Clearance of Camshaft Journal 1 Measure the camshaft journal 00 with an outside micrometer 2 Measure the cylinder block bore 10 for camshaft with an inside micrometer 3 If the oil clearance exceeds the allowable limit replace the camshaft Factory spec 0050 to 0091 mm Oil clearance of 000t97 to 000358 in camshaft journal 015 mm Allowable limit 00059 in Camshaft journal 00 Factory spec 45934 to 45950 mm 18084 to 18091 in Camshaft bearing ID Factory spec 46000 to 46025 mm 181 I 0 to 18120 in Oil Clearance between Idle Gear Shaft 1 2 and Idle Gear 1 2 Bushing 1 Measure the idle gear shaft 00 with an outside micrometer 2 Measure the idle gear bushing 10 with an inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the bushing Clearance between idle Factory spec gear 1 2 shaft and idle gear 1 2 bushing Allowable limit Idle gear 1 2 bushing Factory spec 10 Idle gear 2 shaft DD Factory spec Replacing Idle Gear Bushing When removing0050 to 0091 mm 00020 to 00036 in 010 mm 00039 in 45025 to 45050 mm 17726 to 17736 in 44959 to 44975 mm 17700 to 17707 in 1 Using an idle gear bushing replacing tool press out the used bushing When installing1 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 bushing service partsto the specified dimension WESTERBEKE Engines Generaors 46 MEASURING THE CYLINDER BORE 10 o o o REMOVING 225 225 INSTALLING REPLACING THE IDLER GEAR BUSHING 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 Factory spec 015 to 030 mm 00059 to 00118 in Idle gear side clearance 09 rnm Allowable limit 00354 in 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 measuremeni3 If the misalignment exceeds the allowable limit replace the camshaft Camshaft alignment Allowable limit Camshaft Side Clearance 001 mm 000039 in 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 Factory spec 007 to 022 mm 00028 to 00087 in End play of camshaft 030 mm Allowable limit 00118 in Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 If the measurement is less than the allowable limit replace the camshaft Intake 3763 mm Factory valve 14815 in spec Exhaust 3896mm Intake and exhaust cam valve 15338 in heighl Intake 3713 mm Allowable valve 14618 in limit Exhaust 3846 mm valve 15141 in WESTERBEKE Engines Generators 45 DIAL INDICATOR MEASURING GEAR SIDE CLEARANCE CAMSHAFT ALIGNMENT MEASURING CAM HEIGHT 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 Push rod alignment Allowable limit 025mm 00098 in MEASURING PUSH ROD ALIGNMENT Qj Clearance between Tappet and Tappet Guide Bore 1 Measure the tappet QD with an outside micrometer 2 Measure the ID 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 Factory spec 0020 to 0062 mm 0000 00 00 00 Oil clearance between 00008 to 00024 in tappet and tappet guide bore Allowable limit 007mm 00028 in MEASURING TAPPET C Tappet 00 Factory spec Tappat guide bore 10 Factory spec Timing Gear and Camshaft Timing Gear Backlash 23959 to 23980 mm 09433 to 094t tin 24000 to 2402t mm 09449 to 09457 in 1 Set a dial indicator lever typewith 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 isnt proper replace the gear Factory spec 0049 to O t 93 mm Backlash between OOOt 9 to 00076 in Backlash between idle crank gear and idle gear t Allowable limit 022 mm 00087 in gear 2 and injection pump gear Factory spec 0049 to O t89 mm Backlash between idle 000t9 to 00074 in Backlash between cam gear 1 and cam gear 022 rnm Allowable limit 00087 in geal and balancer gear 1 Factory spec 0044 to O t 85 mm Backlash between idle OOOt 7 to 00073 in gear 1 and idle gear 2 022 mm Allowable limit 00087 in Backlash between idle gear 1 and balancer gear 2 Engines Generators 44 000000 Factory spec 0044 to 0177 mm OOOt 7 to 00070 in Allowable limit 022 mm 00087 in Factory spec 0047 to 0t82 mm OOOt 8 to 00072 in Allowable limit O22mm 00087 in Factory spec 0044 to 0183 mm 00017 to 00072 in Allowable limit 022mm 00087 in Free Length and Tilt of Valve Spring 1 Measure the free length Awith 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 of the spring and check to see if the entire side is contact with the square Rotate the spring and measure the maximum 8If the measurement exceeds the allowable limit replace 3 Check the entire surface of the spring for scratches Replace it if any Intake 351 to 356 mm Factory valve 13819 to 14016 in spec Exhaust 417 to 422 mm valve 16417tol6614in Free length AIntake 346 mm Allowable valve limit 13622 in VALVE SPRING TESTER Exhaust valve Till B Allowable limil Valve Spring Setting Load 412 mm 16220 in 10 mm in 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 Intake 63547 N 1315 mm valve 648 kg1315 mm Oil clearance of rocker Factory 142561bs 112401 in arm shaft and bearing spec 1176 N 135 mm Exhaust 120 kgfl35 mm valve Setting load 1 Selling 264 Ibs 113780 in ROCKer arm shaft 00 length 45864 N 1315 mm Intake valve 468 kg 1315 mm Allowable 102961bs 112401 in Rocker arm 10 for shaft limit 1000 N 135 mm Exhaust Factory spec Allowable limit Factory spec Factory spec VALVE SPRING 0016 to 0045 mm 000063 to 000177 in 015 mm 00059 in 1597310 15984 mm 06289 10 06293 in 160001016018 mm 06299 10 06306 in 102 kgl35 mm valve 2251bs 113780 in MEASURING THE SHAFTS 00 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 00 with an outside 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 v WESTERBEKE Engines Generators 43 MEASURING THE ROCKER ARM 10 OIL CLEARANCE Replacing Valve Guide When removing1 Using a valve guide replacing tool press out the used valve guide When installing1 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 ID of the valve guide to the specified dimension 225 IMPORTANT 225 Do not hit the valve guide with a hammer etc during replacement AI When emoving Correcting Valve and Valve Seat 225 NOTE 8When Inslalling 225 Before correcting the valve and seat check the valve stem and the 10 of valve guide section and repair them if necessary 225 After correcting the valve seat be sure to check the valve recessing 1Correcting Valve 1 Correct the valve with a valve refacer 2Correcting Valve Seat 1 Slightly correct the seat surface with a 1047 rad 60 0intake valveor 0785 rad 45 0exhaust valveseat cutter Code No 0790933102 2 Resurface the seat surface with a 0523 rad 30 valve seat cutter to intake valve seat and with a 0262 rad 15 valve seat cutter to exhaust valve seat so that the width is close to specified valve seat width 212 mm 00835 in3 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 4 Check the valve seating with prussian blue The valve seating surface should show good contact ali the way around aIdentical Dimensions bl Valve Seal Wldlh c0523 rad 30 225 or 0262 rad 15 225 d0262 rad 15 or 0523 rad 30 225 e0785 ad 45 225 or 1047 ad 60 225 ACheck Conlacl 8Correcl Seal Wldlh CCheck Conlacl A f5 L l VALVE GUIDE J A8REMOVING INSTALLING RESURFACING Engines Generators 42 Valve Recessing 1 Clean the cylinder head the valve face and seat 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 Intake o mm 0 into spec valve recessing02 mm 00079 inValve recessing Exhaust 05 mm 00059 into spec valve recessing 005 mm 000t9 inAllowable recessinglimit 04 mm 00157 inValve 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 225 IMPORTANT 225 When valve lapping is performed be sure to check the valve recessing and adjust the valve clearance after assembling the valve Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem 00 with an outside micrometer 3 Measure the valve guide 10 of the cylinder head at the most wear part as shown with a small hole 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 6960 to 6975 mm Factory valve 02740 to 02746 in Valve stem 00 spec Exhaust 7960 to 7975 mm valve 03134 to 03140 in DEPTH GAUGE lUCYLINDER HEAD SURFACE CYLINDER HEAD SURFACE 80 CORRECT DD Factory ARecessing 8Protrusion 0 INCORRECT INCORRECT Intake 0055 to 0085 mm valve 00022 to 00033 in Intake 7030 to 7045 mm Clearance between spec Exhaust 0040 to 0070 mm Factory valve 02768 to 02774 in Valve guide 10 spec Exhaust 8015 to 8030 mm valve 03155 to 03161 in valve stem and guide valve 00016 to 00028 in Allowable limit 01 mm 00039 in Engines Generators 41 Cylinder Head Too Clearance 1 Remove the cylinder head remove the cylinder head gasket completely2 Bring the piston to its top dead center fasten 15 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 one4 Turn the crank shaft until the piston exceeds its top dead 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 072 to 090 mm Factory 00283 to 00354 in Top clearance spec Cylinder head mounting 981 to 1079 N267m Tightening torque 100 to 110 kgf267m screw 723 to 796 ft267lbs Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder heads four sides ABCand Dand two diagonal Eand Fas shown in the figure Measure the clearance with a feeler gauge 3 If the measurement exceeds the allowable limit correct it with a surface grinder 225 IMPORTANT 225 Do not place the straightedge on the combustion chamber 225 Be sure to check the valve recessing after correcting Cylinder head surface flatness Cylinder Head Flaw Allowable limit 005 mm 00020 in 1 Prepare an air spray red checkCode No 07909267313712 Clean the surface of the cylinder head with the detergent 23 Spray the cylinder head surface with the red permeative liquid 1Leave it five to ten minutes after spraying 4 Wash away the red permeative liquid on the cylinder head surface with the detergent 25 Spray the cylinder head surface with the white developer 36 If flawed it can be identified as red marks Engines Generators 40 3EEABAB1P056A A E F c o B Ililmll IDi smr illIlIJIl AcAA IeAS Aif 8 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 ohmmeter 4 If infinity is not indicated replace it I Resistance I Factory spec 128 to 33 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 00 of slip ring with vernier calipers 4 If the measurement is less than the allowable limit replace il Factory spec 227 mm 0894 in Slip ring DD Allowable limit 221 mm 0870 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 Factory spec 185 mm 0728 in Brush length Allowable limit 50mm 0197 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 does not conduct in the reverse direction B E v WESTERBEKE Engines Generators 39 MEASURING SLIP RINGS MEASURING BRUSH LENGTH CHECKING CONTINUITY B 8 TERMINAL ALTERNATOR SERVICE Reassembling the Brush 1 Fit the brush with its sliding face in the clockwise direction when viewed from front 225 IMPORTANT 225 Be sure to keep the 2 brushes deep in the brush holder TWO BRUSHES Otherwise the rotor and the rear section can not be filted into position 225 Use a 4 mm hex wrench to push the brushes into place 225 Using a pinpointed 2 mmpunch keep the brushes from popping out 2 Match the tally line of the front section with that of the rear section 3 Tighten the 4 screws and draw out the pinpointed punch out of the brush holder Bearing at Slip Ring Side 1 Lightly secure the rotor 1with a vise to prevent damage and remove the bearing 2with a puller 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 I Resistance I Factory spec I Less than 10 l ROTOR Engines Generstors 38 PUNCH WRENCH BEARING 2MA7CHIIG THE TALLY LINES CHECKING CONTINUITY ambient temperature alternators are STARTER MOTOR SERVICE Field Coil 1 Check the continuity across the lead 1and brush 2with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2and yoke 3with an ohmmeter 4 If it conducts replace the yoke assembly Resistance Lead 1225 Brush 2o Brush 2225 Yoke 31nfinity 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 10 n Engines Generators 36 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 Awith vernier calipers 3 If the length is less than the allowable limit replace the yoke assembly and brush holder Factory spec 180mm 07086 in Brush length CAAllowable limit t tO mm 0433t 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 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 Brush Holder 1 Check the continuity across the brush holder and the holder support with an ohmmeter 2 lfit conducts replace the brush holder Resistance Brush holder Holder support Infinity Engines Generators 35 A BRUSH lENGTil INSPECTING THE ARMATURE COIL INSPECTING THE OVERRUNING CLUTCH 9 brush holder allowable limit the mica AdobeUCS W I ASSEMBLY Flywheel Housing 1 Remove the flywheel housing When Tighten the flywheel housing mounting screws with even force on the diagonal line 225 Make sure the crank cases 1 and 2 are clean Install them in position referring to the flywheel housings contoured face Flywheel housing 775 to 902 N267m Tightening torque mounting screw 79 to 92 kgf267m 571 to 665 253267Ibs Crankcase 2 1 Remove the crankcase 2 When IMPORTANT 225 Make sure the crankcase 1 and 2 are clean 225 Apply liquid gasket Three Bond 12170to the crankcase 2 as shown 225 Tighten the crankcase 2 mounting screws with even force on the diagonal line 225 Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect 225 Carefully apply the adhesive evenly 225 NOTE 225 When mounting the parts take care to fit them to the mating parts 225 Assemble the parts within ten minutes Crankcase 2 mounting Tightening torque screw Crankcase 1 and Crankcase 2 When to 559 N267m 50 to 57 kgf267m 362 to 412 253267Ibs 225 Match the crankcase 1 and 2 referring to the flywheel housings contoured face 225 Tighten the crankcase 2 mounting screws loosely 225 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 sidePossible gap must be 005 mm 00020 inor smaller Crankcase 2 mounting 490 to 559 N267m 50 to 57 kgf267m screw 362 to 413 It267lbs Tightening torque Flywheel housing 775 to 902 N267m 79 to 92 kgf267m mounting screw 571 to 665 ft267lbs WESTERBEKE Engines Generators 32 0 0 0 0 260 SIT 1 o Sil r9J 1 fA0 0 f260 fir 1 l 225 0 0 0 0 co CRANKCASE 2 0 0 0 0l J 0 0 fn 0 1b 0 0 0 0 0 i5J J J CRANKCASE 1 GAP FLYWHEEL HOUSING AdobeUCS1 t the top t t t 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 2When Install the oil strainer using care not to damage the O267ring 225 Apply liquid gasket Three Bond 1217Dto the oil pan as shown 225 Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect 225 Carefully apply the adhesive evenly 225 NOTE 225 When mounting the parts take care to fit them to the mating parts 225 Assemble the parts within ten minutes 225 To avoid uneven tightening tighten mounting screws in diagonal order from the center 225 After cleaning the oil strainer install it 225 Attach the oil pan with its central drain plug facing toward the air suction side PISTON AND CONNECTING ROD Connecting Rod Cap 1 Remove the connecting rod screws 1from connecting rod cap 2 Remove the connecting rod caps When Align the marks awith each other Face the marks toward the injection pump225 Apply engine oil to the connecting rod screws and lightly screw it in by hand then tighten it to the specified torque If the connecting rod screw wont be screwed in smoothly clean the threads If the connecting rod screw is still hard to screw in replace it 225 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 225 Fit the crank pin bearing in place its centrally groove side toward the connecting rod and the nongrooved side toward the cap 785 to 834 N267m Tightening torque Connecting rod screw 80 to 85 kgf267m 579 to 615 ftIbs OIL STRAINER CONNECTING ROD SCREWS 1ALIGN aWESTERBEKE Engines Generators 29 OIL PAN LIQUID GASKET WRENCH 225 o AdobeUCSthe top the top AdobeUCSthe top I ASSEMBLY Alternator Drive Pulley 1 Lock the flywheel in place 2 Remove the crankshaft screw 3 Draw out the drive pulley When to 2746 N267m Tightening torque Crankshaft screw 260 to 280 kgf267m 1881 to 2025 ft267lbs Alternator Drive Fan Pulley RADIATOR MODELS 1 Lock the flywheel in place 2 Remove the crankshaft screw 3 Draw out the drive fan pulley Water Pump and Oil Cooler Water Pump 1 Remove the pipe band and the water pipe 2 Remove the water pump When When mounting the water pump take care not to forget mounting the Oring and not to let it out of position Oil Cooler 1 Remove the water pipe 2 Remove the oil filter cartridge 2and the oil cooler joint screw 3 Remove the oil cooler 392 to 441 N267m Tightening torque Oil cooler joint screw 40 to 45 kgf267m 289 to 325 ft267lbs COOLER OIL FILTER 2 Generators 26 WATER PIPE ORIVE PULLEY CRANKSHAFT SCREW 01 WATER PUMP AdobeUCShand tighten Fuel Camshaft and Governor Weight ContinuedWhen Fix the fuel camshaft with lock bolts as the key way of fuel camshaft 10is upward 225 Install the injection pump assembly to the injection pump housing 225 Attach the Oring and the cover and tighten the cover mounting screws 225 Install the governor sleeve to the fuel camshaft 225 Check the movement of the governor sleeve 225 NOTE 225 Be careful not to damage the Oring 225 Be careful the direction of the governor sleeve 225 When reassembling inner parts oil each part slightly Fuel camshaft stopper 79 to 93 N267m 080 to 095 kgf267m mounting screw 58 to 69 nIbs Tightening torque Governor weight 628 to 726 N267m 64 to 74 kgf267m mounting nut 463 to 535 n267lbs Replacing Injection Pump Assembly IIf necessary225 The Injection pump can be replaced with the crankshaft in whatever position 1 Disconnect all injection pipes 2 Disconnect the fuel pipe 2and fuel overflow pipe 3 Disconnect the connector 3from the stop solenoid Then remove the stop solenoid 4 Detach the sight cover 5from the injection pump unit 5 Unhook the starter spring 6and remove the control rod nut 6 Slide off the governor connecting rod 7from the rock pin of injection pump assembly 7 Remove the injection pump mounting screws and nuts and take out the injection pump assembly 225 NOTE 225 Be careful not to drop the antirotation nut 225 Be careful not to deform the start spring CAMSHAFT KEY WAY 10225 When taking out the injection pump assembly be careful not to hit it against the governor connecting rod CONNECTING ROD When Install the new injection pump according to the installing procedure WESTERBEKE Engines Generators 24 STARTER SPRING 6CONNECTING ROD I ASSEMBLY Fuel Camshaft and Governor Weight 1 Separate the governor housing assembly from the injection pump unit See the Injection Pump Unit2 Remove the governor sleeve 3 Remove the injection pump assembly 4 Remove the cover 5 Remove the fuel camshaft lock screws 6 Fix the fuel camshaft with open end wrench 4and remove the governor weight mounting nut and the governor weight 57 Loosen the fuel camshaft stopper mounting screws and remove the fuel camshaft stopper 68 Pull out the fuel camshaft 7and bearings 8together 9 After removing the bearings circlip 9press out the bearings 225 NOTE 225 Do not use the fuel camshaft lock bolts when removing the governor weight mounting nut Otherwise the lock bolts or injection pump housing might get damage When Press the bearings into the fuel camshaft 225 Set the circlip at the gear sides bearing 225 Install the fuel camshaft and bearings to the injection pump housing 225 Attach the fuel camshaft stopper and tighten the fuel camshaft stopper mounting screws with the specified torque 225 Attach the governor weight to the fuel camshaft and tighten the governor weight mounting nut with specified torque Injection pump 23510 275 N267m 24 10 2B kgf267m mounting screw 174 to 203 ftIbs Tigntening torque Injection pump 17710206 N267m IB 10 21 kgf267m mounting nut 13010152 ftIbs BEARINGS B WESTERBEKE Engines Generators 23 COVER GOVERNOR WEIGHT the Remove the I ASSEMBLY Governor Fork Lever Assembly 1 Pull off the governor fork lever shaft 1with the extra screw Dia 4 mm Pitch 07 mm Length more than 25 mm2 Unhook the governor spring 3at the governor fork lever 4side 3 Remove the governor fork lever assembly from the governor housing 5When After reassembling the governor housing assembly check the movement of the governor fork lever assembly the speed control lever and the stop lever 225 NOTE 225 When assembling the inside parts put the oil on each Inside part slightly 225 Be careful not to deform the start spring Boost Arms III equipped Boost Compensator1 Remove the boost actuator 12 Remove the circlip 23 Remove the boost arms 3and the boost spring 4from the pin fi392 to 451 N267m Tightening torque Boost actuator 40 to 46 kgf267m 289 to 333 ftIbs J IIOOiHACTUATOR 1I 267ClIP 2 BOIOST ARMS 3nrRnlnT SPRING 4PIN 5WESTERBEKE Engines Generators 21 GOVERNOR PIN 5 4HOUSING 5GOVERNOR FORK LEVER 4FORK LEVER t SHAFT I GOVERNOR SPRING REMOVING THE CRCLIP BOOST ARMS AND SPRING I ASSEMBLY Thermostat Thermostat Assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 2 Remove the thermostat assembly When Apply a liquid gasket Three Bond 1215 or equivalentonly at the thermostat cover side of the gasket 225 Install the thermostai with its bleed hole facing towards the discharge opening of the thermostat housing ReAssemble and Test THERMOSTAT THERMOSTAT HOUSING COVER Turn the cover back into place and tighten the three screws Do nol overtightenl Tighten the hose clamp and close the drains Top off the coolant and run the engine CHeck for normal temperature and for any leaks around the thermostat assembly TEMPERATURE267 SENSOR Injection Nozzle Nozzle Holder THERMOSTAT ASSEMBLY SENSOR 1 Secure the nozzle retaining nut 7with a vise 2 Remove thehozzle holder 1and take out parts inside When Assemble the nozzle in clean fuel oil 225 Install the push rod 4noting its direction 225 After assembling the nozzle be sure to adjust the fuel injection pressure 343 to 392 N267m Nozzle holder 35 to 40 kgf267m 253 to 289 253267Ibs NOZZLE HOLDER ADJUSTING ROO 4PIECE tNOZZLE PIECE t96 to 245 N267m Tightening torque Overflow pipe nut 20 to 25 kgf267m 145 to 181 253267Ibs NUT 7490 to 686 N267m Nozzle holder assembly 50 to 70 kgf267m 362 to 506 253267Ibs Engines Generators 20 I ASSEMBLY Injection Pump Unit Removing the fuel injection pump unit1 Detach the gear cover for the fuel injection pump unit from the gearcase 2 Place the piston of the 4th cylinder at the top dead center in the compression stroke Lock the flywheel in place 225 IMPORTANT SUPPORT 225 look for the align mark on the idle gear 2 Using a white marking pen or the like put an align mark on the engaged tooth of the idle gear This helps to reassemble these gears in mesh later 225 NOTE 225 When the already existing align marks align with each other there is no need to put another align mark 3 Unscrew the two plugs 1off the injection pump unit 4 Tighten the upper fuel cam shaft lock screw until it comes into contact with the fuel cam shaft Make sure the cam shaft does not move any longer 5 Tighten the lower fuel cam shaft lock screw 2until it comes into contact with the fuel cam shaft 225 NOTE 225 Never overtighten the lock screws when they have come into contact with the cam shaft Otherwise the injection pump unit itself may get damaged 225 Use of a socket set screw dog point typein recommended for best results Such screw can be constructed as shown in figure a6 loosen the injection pump gear mounting nut Using the specific gear puller take out the gear 5 225 NOTE 225 Be careful not to drop the key 7 Disconnect the lubricating oil pipe 8 Loosen the three injection pump unit mounting nut 9 Remove the injection pump unit support 6and take out the injection pump unit Injection Pump Unit Reassembling the fuel injection pump unit1 Place the piston of the 4th cylinder at the top dead center in the compression stroke Lock the flywheel in place 2 Place the injection pump gear 5back into the gear case position Make sure of aligning the align marks of the injection pump gear 5and the idle gear 2 3 install the injection pump unit to the injection pump gear 5 225 NOTE 225 When installing the injection pump unit to the injection pump gear make sure that the key is fit in the keyway of injection pump gear WESTERBEKE Engines Generators 19 a1B c D A M8 x Pilch 125 B 5 mm dia 0 I 97 in diaC 4 mm 0157 inD 45 mm 1772 inE 10 mm 039 in Conspicuously Painted I ASSEMBLY 4 Temporarily tighten the injection pump gear mounting nut by hand 5 Fix the injection pump unit and tighten the injection pump gear mounting nut to the specified torque S Take off the fuel cam shaft lock screws 2and tighten the plugs 1for plugging INJECTION PUMP GEAR 57 Loose the injection pump unit mounting nuts 4for aligning the injection timing 8 Moving the injection pump unit clockwise viewed from gear case sidealign the injection timing marks Son the injection pump unit and on the gear case 9 Tighten the injection pump unit mounting nut 4to the specified torque 10 Reconnect the lubricating oil pipe 3and replace the injection pump unit support and the gear cover of the injection pump unit 11 Remove the flywheel lock 12 Check the injection timing See the Injection Timing13lf the injection timing is not within the specification repeat 7to 12again Injection pump gear 736 to 834 N267m 75 to 85 kgf267m mounting nut 542 to 6t5 hIbs TIghtening torque Injection pump unit 177 to 206 Nm t8 to 21 kgf267m mounting nut 130 to 152 hIbs Governor Housing Assembly 1 Remove the injection pump unit from the engine See the Injection Pump Unit2 Remove the governor lubricating pipe 3 Remove the stop solenoid 4 Detach the sight cover 3from the injection pump unit 5 Unhook the start spring 4from the rack pin 5of injection pump assembly S Remove the nut NOTE 225 Be careful not to drop the nut inside Engines Generators 18 6 NUTS 4 I ASSEMBLY 7 Slide off the governor connecting rod 7from the rack pin of injection pump assembly GOVERNOR CONNECTING ROD 78 For convenient sake temporarily hook the start spring on the rack pin hole of the governor connecting rod PIN 51 9 Remove the governor housing mounting screws 10 Detach the governor housing assembly 8from the injection pump unit When When reassembling the inside parts put the oil on each inside part slightly 225 After sliding on the governor connecting roa to the rack pin tighten the nut with the specified torque with using the jig for keeping the governor connecting rod horizontal See the Replacing Injection Pump Assembly225 After tightening the nut hook the start spring on the rack pin 225 Check the movement of control rack of injection pump assembly by the stop lever 225 NOTE 225 When installing the governor housing assembly to the injection pump unit be careful not to damage Oring 225 When linking the governor connecting rod to the rack pin of injection pump use the jig for keeping the governor connecting rod horizontal Otherwise the control rack may be stuck and causes to be difficult to start the engine or hunting of governor See the Replacing Injection Pump housing 9B to 113 N267m 100 to 115 kgf267m mounting screw 723 to B32 ft267lbs Tightening torque 2B to 40 N267m Antirotation nut 029 to 041 kgf267m 21 to 30 ft267lbs GOVERNOR HOUSING ASSEMBLY 81 Engines Generators 17 11 GOVERNOR CONNECTING ROD 71 O267RING CONNECTING ROD 7START SPRING I ASSEMBLY Selecting Cylinder Head Gasket 225 Replacing the Cylinder head Gasket 1 Make sure to note the notch abor cof cylinder head gasket 2 Replace the same notch abor cas the original cylinder head gasket 225 Selecting the Cylinder Head Gasket 225 Select the cylinder head gasket thickness to meet with the top clearance when replacing the piston piston pin bush connecting rod or crankpin bearing 1 Measure the piston heads protrusion or recessing from the crankcase cylinder face 4 spots per each piston average of four pistonsusing the dial Jauge as shown 2 Select the suitable cylinder head gasket refer to the table below Piston Heads protrusion or Notch 01 Thickness of cylinder recessing from the level of Cylinder head gasket crankcase cylinder face Head average of 4 pistonsGasket Before After tightening tightening V3300267E2B 267007 to 267027 to 2 notches 090mm 080mm 0049 mm 2670151mm a00354 in 00315 in 26700028 to 26700110 to 00019 in 26700059 in 0050 to 267015 to 1 notch 100mm 090mm 0149 mm 2670051 mm b00394 in 00354 in 00020 to 26700059 to 00058 in 26700020 in 0150 to wnhout 105mm 095 mm 020 mm 00510 Dmm notch c00413 in 00374 in 00059 to 26700019 to 00078 in a in 1 Remove the valve cap 1and the valve spring collets 2compressing the valve spring 4with the valve spring retaine 3When Install the intake valve spring with its smallpitch end downward at the head side225 Wash the valve stem and valve guide hole and apply engine oil sufficiently 225 After installing the valve spring collets lightly tap the stem to assure proper fit with a plastic hammer Engines Generators 16 a2 Notches b1 Notch cWithout Notch Flywheel Side MEASURING PISTON PROTRUSION RECESS SPOTS II I 2 1Valve Cap J1 J1 2Valve Spring Collet OlTh 3Valve Spring Retainer 4Valve Spring 5Valve Stem Seal 6Valve 7Arm Bridge LARGE PITCH SMALL PITCH t INSTALL WITH SMALL 10PITCH END DOWN I ASSEMBLY Rocker Arm and Push Rod 1 Remove the rocker arm 1as a unit 2 Remove the push rods 3 Detach the bridge arm When When putting the push rods onto the tappets check to see if their ends are properly engaged with the tappet recess 225 IMPORTANT 225 After reassembling the rocker arm be sure to adjust the valve clearance Rocker arm bracket 490 to 559 N267m Tightening torque 50 to 57 kgf267m screw 362 to 412 ftIbs Cyfinder Head and Tappet 1 Loosen the hose clamp and remove the bypass hose 2 Disconnect the fuel pipe 3first and then the fuel filter 3 Remove ttie IN EX Manifold 4 Remove the cylinder head screw in the order of 18to 1and remove the cylinder head 5 Remove the cylinder head gasket 6 Remove the tappets from the crank case When Replace the head gasket with a new one 225 Before installing the tappets apply engine oil thinly around them 225 When mounting the gasket set it to the knock pin hole Take care not to mount it reversely 225 The cylinder head should be free of scratches and dust 225 Take care for handling the gasket not to damage it 225 Install the cylinder head 225 Tighten the cylinder head screw gradually in the orderof 1to 18aiter applying engine oil 225 Be sure to adjust the valve clearance See the Valve Clearance 225 It is not necessary to retighten the cylinder head screw aiter running the engine for 30 minutes 225 IMPORTANT 225 When replace the piston piston pin bush connecting rod or crankpin bearing select the cylinder head gasket thickness to meet with the top clearance refer to the Selecting Cylinder Head Gasket 225 NOTE 225 Mark the cylinder number to the tappets to prevent interchanging Cylinder head mounting 981 to 1079 N267m Tightening torque 100 to 110 kgf267m screw 723 to 796 ItIbs Engines Generators 15 LVli PUSH RODS TAPPET 014 06 03 Om 018 010 02 07 0 no no 00 00 15 017 ocloo d 0 0800 0013 005 004 0012 16 CYLINDER HEAD TIGHTENING SEQUENCE DISASSEMBLY I ASSEMBLY Cylinder Head and Valves Cylinder Head Cover and Nozzle Holder 1 Remove the injection pipes 1and overflow pipes 2 Remove the glow plugs 3 Remove the nozzle holder assembly 4and copper gaskets 4 Remove the heat seal 5 Remove the head cover When Check to see that the cylinder head cover gasket is not defective 225 Be sure to replace the heat seal 225 TIghten the head cover mounting bolts to specified torque 225 Mount the return fuel check valve with the I mark in the direction of flow back to the taok t Cylinder head cover 69 to 113 N267m 07 to 115 kgf267m mounting screw 51 to 832 ItIbs Injection pipe retaining 226 to 363 N267m 23 to 37 kgf267m nut 166 to 268 ItIbs 490 to 686 N267m Tightening torque NOlzle holder assembly 50 to 70 kgf267m 362 to 506 ItIbs Overflow pipe assembly 196 to 245 N267m 20 to 25 kgf267m retaining nut 145 to 181 ItIbs 196 to 245 N267m Glow Plug 20 to 25 kgfm 145 to 181 ItIbs Nozzle Heat Seal Service Removal Procedure 225 IMPORTANT 225 Use a plug that has a dia which is bigger than the heat seal hole Approx 6 mm 14 in1 Drive screw driver lightly into the heat seal hole 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal out together with the injection nozzle gasket If the heat seal drops repeat the above procedure Hmit seal 4and injection nozzle gasket 3must be changed when the injection nozzle is removed for cleaning or for service LIFTING EYE CAUTION IF THERE IS REASON TO REMOVE THE ENGINES LIFTING EYE 00 NOT ATTEMPT TO TAKE OUT THIS STUO SIMPLY REMOVE THE NUT AND THE BOTTOM BOLT THE STUD IS PERMANENTLY ASSEMBLED THRU THE WATER JACKET o GLOW NOZZLE COPPER GASKETS HEAT SEAL HEAD COVER Engines Generators 14 PHilLIPS INJEClrION PIPE PIPE INJECTION NOZZLE GASKET 3r3sLHEAT SEAL 4the alternator 114 112 ASSEMBLY PROCEDURES GENERAl INFORMATION Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces using a gasket scraper or wire brush Check to ensure that the surfaces to which the silicone gasket is to be applied is flat Make sure that there are no oils greases and foreign substances deposited on the application surfaces Do not forget to remove the old sealant that remains in the bolt holes ASSEMBLY 225 Wash all parts except for oil seals Orings rubber sheets etc with cleaning solvent and dry them with air pressure 225 Always use tools that are in good condition and be sure you understand how to use them before performing any job 225 Use only good quality lubricants Be sure to apply a coat of oil grease or sealant to parts as specified 225 Be sure to use a torque wrench to tighten parts for which torques are specified 225 When the engine is assembled new gaskets and Orings must be installed Be aware of these common problems that can occur during assembly Insufticlent Lubrication Heavily oil sliding and reciprocating parts lightly oil head bolts and other fasteners except those that penetrate into the water jacket These fasteners should be sealed with Pennatex No Z or the hightech equivalent Reversed orientation Most gaskets many bolt washers and all thermostats are asymmetrical Mechanical damage Run fasteners down in approved torque sequences and in three stepsIZ 23 and 111 torque Exceptions are torquetoyield bolts and rocker arm shaft fasteners The former are torqued as indicated The lattermcker shaft fasteners should be brought down in very small increments working from the center bolts out Gaskets especially head gaskets might also be damaged during assembly they should be positioned with great care GREASE INTERNAL SNAP RING EXTERNAL SNAP RING PLACE THE SHARP EDGE AGAINST THE DIRECTION aFFORCE When reassembling external or internal snap rings position them so that the sharp edge faces against the direction from which force is applied GASKET INFORMATION The engine has several areas where forminplace RTV silicone gaskets are used such as LOCTITE 598 or GE RTV 100 To ensure that the gasket fully serves its purpose it is necessary to observe some precaution when applying the gasket Bead size continuity and location are very important Too thin a bead could cause leaks and too thick a bead could be squeezed out of location causing blocking or narrowing of the fluid feed lines To eliminate the possibility of leaks from a joint it is necessary to apply the gasket evenly without a break while observing the correct bead size The gasket material used in the engine is a room temperature vulcanization RTVtype and is supplied in a 140z 400 The RTV hardens as it reacts with the moisture in the atmospheric air and can be used for sealing both engine oil and coolant assemblies Engines Generators 12 begin the by step tell you DESCRIPTION FORK LEVER 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 ranges from idling to maximum speedby utilizing the balance between the flyweights centrifugal force and spring tension A governor shaft for monitoring engine speed is independent of the injection pump shaft and rotates at twice the speed of conventional types providing better response to load fluctuation and delivering greater engine output At Start The stop solenoid energized to run typeis powered to release the stop lever As no centrifugal force is applied to the flyweight 1low tension of the start spring 2 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 3clockwise to idle the engine It tensions the governor spring 4to pull the fork lever 2 When the fork lever 2 is pulled it moves the torque spring pin 6and fork lever 1 7in 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 225 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 weight decreases Then the torque spring moves the fork lever 1 in the direction of arrow A The control rack moves in the direction that increases fuel supply to increase the output It is balanced with the centrifugal force of the flywheel weight to produce low255speed output torque outputSPRING PIN SPEEO LEVER FORK LEVER 1 7IDLE ADJUSTING FLYWEIGH1l1 NO267LOAD ROTATION OUTPUT LIMITING BOLT TORQUE LIMITING BOLT SPEEO CONTROL LEVER 131Hl 225 To stop engine GOVERNOR SPRING 4llllwJCONTROL RACK When the stop solenoid is turned off the spring tension of the solenoid is released the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine To stop the engine manually move the external stop lever to the left 9Y WESTERBEKE Engines Generators 10 DESCRIPTION PISTON AND PISTON RINGS This engine employs the ETVCS VERSIONII so that the improved combustion surface at the top of the piston enables more complete com255bustion efficiency than the conventional models 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 heat load of the piston TOP RING I I r I OILRING PISTON Three rings are installed in grooves in the piston The top ring is made of nitrizing steel to get more reliability than the chrome plated ring 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 chromeplated on the peripheral surface and it is an undercut ring to prevent the holding of oil DEPRESSION The oil ring 3has 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 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 balanced weight on the crankcase to absorb the second inertia mentioned above and reduce vibration v WESTERBEKE Engines Generators 9 PISTON TOPLAND BALANCER SHAFT AdobeUCSI 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 assem255ble and disassemble it The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance HALFFLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 05 mm or so off the cylinder head This arrangement helps reduce noise coming from the cylinder head RUBBER PACKING CYLINDER HEAD CYLINDER HEAD COVER 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 Englnes Generators 8 UOIL PAN insufficient air ENGINE PROBLEM PROBABLE CAUSE KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles aOverheated cylinder a See OVERHEATING LOW OUTPUT bCarbon 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 Afterinjection 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 Vbelt 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 pumps 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 blockcylinder head flawed 2 Replace Generators 6 ENGINE PROBLEM PROBABLE CAUSE 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 clogged2 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 continuedMJI WESTERBEKE Engines Generators 5 ENGINE PROBLEM PROBABLE CAUSE LOW OUTPUT cnIOVERHEATING 1 Low coolant level 1 Add coolant 2 Loose V267belt 2 Adjust or replace V267belt 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 Loose267oil 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 6Adjust 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 225225 Check b Seized piston ring b Replace or clean c Excessive clearance c Replace or correct Generators 4 in fuel FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Generally the time at which an engine should be overhauled is determined by various conditions such as lowered engine power output decreased compression pressure and increased fuel and oil consumption The lowered engine power output is not necessarily due to trouble with the engine itself but is sometimes caused by injector nozzle wear or injection pump wear The decrease in compression pressure is caused by many factors It is therefore necessary to determine a cause or causes on the basis of data produced by periodic inspection and maintenance Oil analysis on a seasonal basis is a good means of monitoring engine internal wear When caused by worn cylinders or piston rings the following symptoms will occur 1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption 4 Hard engine starting 5 Noisy engine operation These symptoms often appear together Symptoms 2 and 4 can result also from excessive fuel injection improper injection timing and wear of the injectors They are caused also by defective electrical devices such as the battery alternator starter and glow plugs Therefore it is desirable to judge the optimum engine overhaul time by the lowered compression pressure caused by worn cylinders and pistons plus increased oil consumption Satisfactory combustion is obtained only under sufficient compression pressure If an engine lacks compression pressure incomplete combustion of fuel will take place even if other parts of the engine are operating properly To determine the period of engine overhaul it is important to measure the engine compression pressure regularly At the same time the engine speed at which the measurement of compression pressure is made should be checked because the compression pressure varies with engine rpm The engine rpm can be measured at the front end of the crankshaft 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 The engine requires overhaul when oil consumption is high blowby evident and compression valves are at minimum or below ENGINE COMPRESSION Check the compression pressure To do this warm the engine remove all fuel injectorsor glow plugs disconnect the fuel shutoff solenoid wire and install a compression adapter in the injector hole or glow plug hole Connect a compression tester on the adapter and crank the engine with the starter motor until the pressure reaches a maximum value Repeat this process for each cylinder Look for cylinders with dramatically lower compression than the average of the others COMPRESSION PRESSURE Faclary Specat 250 RPM 626 PSI 44 Kglcm 432 MPa ALLOWABLE LIMIT al250 RPM 472 PSI 332 Kglcm 326 MPa If a weak cylinder is flanked by healthy cylinders the problem is either valve or pistonrelated Check the valve elearances for the weak cylinder adjust as needed and test again If the cylinder is still low apply a small amount of oil into the cylinder to seal the rings and repeat the test If the compression comes up the rings are faulty Abnormally high readings on all cylinders indicate heavy carbon accumulation a condition that might be accompanied by high pressures and noise NOTE In case of severe vibrations and detonation noise the cause may be fuel injector problems see FUEL INJECTORS Poor fuel quality contaminants and loss of po sitive fuel pressure to the injection pump will result in faults TESTING ENGINE COMPRESSION When reinstalling the glow use antiseize compound 343 to 392 N267m Nozzle holder 35 to 40 kgf267m 253 to 2B9 ftIbs t96 to 245 N267m Tightening torque Over1low pipe nut 20 to 25 kgf267m 145 to tBt ft267lbs 490 to 6B6 N267m Nozzle holder assembly 50 to 70 kgl267m 362 to 506 ft267lbs Engines Generators 2 3 7 AdobeUCSSAFETY INSTRUCTIONS 225 Do not wear loose clothing or jewelry when servicing equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in moving parts 225 Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at all times 225 Do not check fluid levels or the drive belts tension while the engine is operating 225 Stay clear of the drive shaft and the transmission coupling when the engine is running hair and clothing can easily be caught in these rotating parts HAZARDOUS NOISE A WARIIIING High nIl IBvels can cau hBaring oss1 225 Never operate an engine without its muffler installed 225 Do not run an engine with the air intake 225 Do not run engines for long periods with their enclosures open 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 thor255ough examination of the American Boat and Yacht Councils ABYCstandards These standards are a combination of sources including the USCG and the NFPA Sections of the ABYC standards of particular interest are H2 Ventilation PI Exhaust systems P4 Inboard engines E9 DC Electrical systems All installations must comply with the Federal Code of Regulations FCRABYC NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their when installing your engine ABYC American Boat and Yacht CouncilSafety Standards for Small Craft Order from ABYC 15 East 26th Street New York NY 10010 NFPA National Fire Protection Protection Standard for Motor Craft Order from National Fire Protection Association II Tracy Drive Avon Industrial Park Avon MA 02322 USCG United States Coast GuardUSCG 33CFR183 Order from US Government Printing Office Washington DC 20404 v WESJERBEKE EngInes Generstors iii symptoms or wristwatch and PROPOSITION 65 WARNING Exhaust gas from diesel and gasoline engines and some of its 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 and death Symptoms of Carbon Monoxide exposure can include Dizziness Nausea Headache Weakness and Sleepiness Throbbing in Temple Muscular Twitching Vomiting 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 livingsleeping quarters of your vessel They are inexpensive and easily obtainable at your local marine store Engines Generators i SERVICE MANUAL 65AFOUR MARINE ENGINE 260 AND 200KW EDER NET GENERATORS 3285 and 255KW EDE DNET ARINE GENERATORS PUBLICATION 053017 SECOND EDITION APRIL 2009 WESTERBEKE F WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD IL MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE AdobeUCS