Westerbeke Diesel 82b Four Parts Manual

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rWESTERBEKE MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 1008 WMDW 1298 AdobeUCSfor Overhaul and Limits mm mm Liters Liters AdobeUCS3 3 3 3 3 1 5 1 114 TAN rMIELDED JJ r tl2 RED 12 REI247JlilLG EMERGENcy if 20A ClBCUII fJllltE MEMEB 114 8RN or 1 112 RED J 4 PUR i7 f1S is 14 RED E 0 lIZ c i 0 E r1 1I L1t AdobeUCSBED GENERATOR WIRING SCHEMATIC 039422 WITH DUAL RELAYS BATTERY SWITCH 120 AMP ICIRCUIT jBREAKER 1 EMERGENCY I STOP r SWITCH I r I I L j L HOURMETER START SWITCH L I II PREHEAT SWITCH j PREHEAT SOLENOID rI I I I I L I STARTER STARTER SOLENOID rI M I I I I I I L I IT 110 AMP 870 ICIRCUIT KI L jBREAKER 30 START 0 KI 86 85 K2 30 87 OIL PRESS EXH TEMP WATER TEMP SW SW SW o Engines Generators 74 GLOWPLUGS ALTERNATOR T823 0 FUEL PUMP FUEL SOLENOID 86 AdobeUCSBED GENERATOR WIRING DIAGRAM 039422 AL TRNATOR 51 A liFT PUMP 1 PO NOTE 2 An onoff switch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat Twelve volt diesel engine starters typically draw 200 to 300 amps when cranking A switClz with a continuous ratingo17Samps at 12 VDC will normally serve this function but a switch must never be used to make Ihe starter circuit FUEL SOLENOID WATER TEMP SENDER u 225 ARM z 225 AWNT Jr T82672 W Je REMOVE THIS 110 t JUMPER WHEN 6l r 256 Ii A OIL PRESSURE SW OIL PRESS SENDER T EXHAUST SW 225 1020 I CONNECTING A M 0 rurLL 267267fOil 1 IIn K IllIti I 225 225225225 nlt r1 i 225 i I EJ I IJ STOP I SWITCH I I I L J 73 STANDARD INSTRUMENT PANEL AdobeUCSJ AdobeUCSshore power THE ELECTRONIC GOVERNOR Problem Probable Cause System appears dead 1 Low battery voltage at controller 1 Check wiring for cause Check battery state of charge Engine runs at idle2 Stuck linkage 2 Lubricate free up linkage between controller and throttle arm 3 No signal or weak signal from sensor 3 Check for improperly installed or damaged sensor in flywheel Measure AC voltage from sensor while housing Replace or adjust engine is running at idle Voltage should be 25 volts or greater 4 Check Actuator depress PREHEAT and check for battery voltage between negative black lead at terminal block a Purple lead to black 4 Replace controller if battery voltage is not present at both leads b Second purple to black 5 Perform the following check between terminals at the actuator and the negative DC lead at the controller terminal block Preheat depresseda Low voltage 12020 VDCat either a Broken actuator lead actuator connection b Battery voltage at both actuator b Broken actuator lead connections c Battery voltage at one actuator lead c Replace the actuator but not the other Actuator fully extends when PREHEAT 1 Check controller Lift one of the purple is depressed and stays extended actuator leads from the terminal block Depress PREHEAT a Actuator fully extends a Short in lead to actuator b Actuator does not fully extend and b Replace controller connections NOTE Release PREHEAT and reconnect the purple lead Actuator hunts oscillatesand 1 Linkage between actuator and throttle 1 engine running binding 2 Improper adjustment of GAIN on 2 Lessen GAIN adjustment Recalibrate the 3 Inadequate DC power supply to controller complete the following tests Connect a DC voltmeter across the plus and negative leads at the controller terminal block Lift both purple leads from the terminal block Connect one purple lead to the C plus terminal and the other to the DC negative Momentarily depress PREHEAT If actuator does not fully extend check the actuator leads The actuator should fully extend 3 If the voltage is less than specified check for loose or poor connections low battery voltage voltage drop in DC circuit due to remote panel installation and small wire sizes making connections DC voltage registering on the meter should be 12 VDC System 96 VDC or higher 24 VDC System 192 VDC or higher NOTE Reconnect actuator leads properly after making this test 3a Sensor positioned marginally too far 3a Check the position of the sensor away from flywheel teeth giving erratic signal voltage to controller Engines Generators 70 adjust the v v 1 2 a engine the underspeed AC VOLTAGE CONNECTIONS AC VOLTAGE CONNECTIONS NOlE The frame ground wire whitegreenmust be prop255erly positioned when changing the AC output configuration of the AC terminal block For making connections to the AC terminal block use terminal ends267for 114 inch studs that will accept multi strand copper wire siW1 for the amperage rating from the hot lead connection The frame ground wire is white or white with a green strip It connects between the neutral stud and the generator frame Generator Frequency 1 Frequency is a direct result of speed 1800 rpm 60 hertz 1500 rmp 50 hertz 2 To change generator frequency follow the steps below Configure the AC terminal block for the desired voltage frequency as shown Ensure that the case ground wire is connected to the correct terminal block neutral ground stud NOTE The whitegreen ground wire may be removed in those installations where the AC circuit has a separate neutral and ground circuit This will prevent the unit from being a ground source in the vessel 120240V o 0 120V60Hz 230V50Hz 115V 50Hz o 0 L1 L1 L2 I N L1 A JUMPER IS REQUIRED BETWEEN LOAD CONNECTIONS 0 1Jt4 256 Engines Generators 64 0 L1 N 0 ILLUSTRATION SHOWS 230V50Hz CONNECTIONS with L L L N L L L N L L L N L L N L L L L duce AC automatically disconnect reading is GENERATOR CONTROL PANEL SWITCHES DESCRIPTION This manually controlled series ofWESTERBEKE marine diesel generators is equipped with toggle switches on the engine control panel and optionally at remote panels The following instructions and methods of correcting minor prob255lems apply only to such toggle switch controls All three switches are momentary contact type and serve the following functions 1 PREHEAT The PREHEAT toggle switch is a double pole single throw switch The switch serves two purposes pre255heating the engine for easy starting and defeating of bypassing the engine oil pressure switch The defeat func255tion turns on the fuel solenoid instrument power and alternator excitation When the PREHEAT switch is depressed the voltmeter panel lights gauges and meters and fuel solenoid will activate The PREHEAT switch should be depressed for twenty seconds 2 STOP The STOP toggle switch is a single pole single throw normally closed switch The switch provides power to the fuel solenoid instrument cluster and alterna255tor excitation after the oil pressure switch has closed upon starting Opening of this switch opens the power circuit to the fuel solenoid stopping the flow of fuel to the engine and shuts down the engine To stop the engine depress the STOP switch When the STOP switch is depressed the power feed to the fuel solenoid is opened and the fuel flow to the engine is stopped The STOP switch should be depressed until the generator stops rotating 1 2 3 CONTROL PANEL 3 START The START toggle switch is a double pole single throw switch The switch serves two purposes starting the engine and defeating of bypassing the engine oil pres255sure switch The defeat function turns on the fuel sole255noid instrument power and alternator excitation While the PREHEAT switch is still depressed depressing the START switch engages the start solenoid Panel power and the fuel solenoid will be activated When the engine begins to fire the START switch should be released The PREHEAT switch should not be released until the oil pressure reaches alarm stops NOTE When the engine is shut down the water tempera255ture gauge and the oil pressure gauge will continue to register the last temperature and oil pressure readings displayed They will return to zero once electrical power is restored 4 EMERGENCY STOP The EMERGENCY stop switch at the rear of the control box is normally closed When depressed it will open the DC circuit to the control panel and shut the engine down As the switch is not toggled it can be used when performing maintenance REMOTE PANEL For remote operation of the generator system the same three switches are used The PREHEAT and START switches are connected in parallel with the gauge panels switches and serve the same functions as in the gauge panel The STOP switch is in series with the gauge panels STOP switch and serves the same function 0 0 STOP RElEASE STAHlER START PRESS 2ND FIRST GENERATOR 0 0 0 REMOTE PANEL Generators 60 required cause major the problem STANDARD HARDWARE BOLT HEAD MARKINGS Bolt strength classes are embossed on the head of each bolt Customary inchbolts are identifed by markings two to grade eight strongestThe marks correspond to two marks less than the actual grade ie a grade seven bolt will display five embossed marks Metric bolt class numbers identify bolts by their strength with 109 the strongest NOTES 1 Use the torque values listed below when specific torque values are not available 2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used 3 Reduce torques by 30 or more when threading capscrews into aluminum STANDARD BOLT NUT TORQUE SPECIFICATIONS METRIC BOLT NUT TORQUE SPECIFICATIONS SAE Grade 5 SAE Grade 62677 SAE Grade 8 Capsrew Body Size Torque Torque Torque Boll Grade 46 Grade 48 Grade B8 9B Grade 109 Inches225 ThreadRLb Wrench Size ALbNmALb NmFtLb NmFILbNm14 20 8 1110 1412 1628 10 1414 19M3 55mm 03 0505 071 1315 2511618 17 2319 26243324 19 2627 37M4 7mm 08 111 152 33 45M5 8mm 15 25 2 345 665 931816 31 4234 4644 6024 35 4749 66M8 10mm 3 44 5575 1011 15M9 13mm 7 95101318 2535 267116 14 49 6655 7570 95Ml0 16mm 14 1918 2537 5055 7520 55 7578 10612 13 75 10285 115105 14220 85 115120 163M12 18mm 26 3533 4563 8597 130M14 21 mm 37 5055 75103 140151 205M16 24mm 59 8085 115159 215232 31591612 110 149120 163155 21018 120 163170 231M18 27mm 81 110118 160225 305321 43551811 150 203167 226210 285M20 30mm 118160166 225321 435457 62018 170 231240 325M22 33mm 159 215225 305435 590620 840314 10 270 366280 380375 50816 295 400420 569M24 36mm 203 275288 390553 750789 1070789 395 536440 597605 82014 435 590675 915M27 41 mm 295 400417 565811 11001154 1565M30 46mm 402 545568 7701103 14951571 213018 590 800660 895910 123414 660 895990 1342M33 51 mm 546 740774 10501500 20352139 2900M36 55mm 700 950992 13451925 26102744 3720NOTE Formula to convert FtLbs to Nm Newton Metersmultiply FtLb x 1356 SEALANTS LUBRICANTS Oil based PERMATEX 2 and its HIGH TACK equivalent are excellent all purpose sealers They are effective in just about any joint in contact with coolant raw water oil or fuel A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets and Orings LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil filter assembly Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When installing gaskets that seal around water coat both sides with WHITE SILICONE grease Highcopper ADHESIVE SPRAYS are useful for holding gaskets in position dur255ing assembly Specialized gasket sealers such as HYLOMAR work well in applications requir255ing nonhardening properties HYLOMAR is particlarly effective on copper cylinderhead gaskets as it resists fuel oil and water Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolant passages Do not use tape sealants BOLTS Lightly oil head bolts and other fasteners as you assemble them Bolts and plugs that penetrate the water jacket should be sealed with PERMATEX 2 or HIGH TACK When assembling the flywheel coat the bolt threads with LOCTITE blue Antiseize compounds and thread locking adhesives such as LOCTITE protect threaded components yet allows them to came apart when necessary LOCTITE offers levels of locking according to the job LITHIUM based grease is waterproof ideal for water pump bearings and stuff255ing boxes Heavily oil all sliding and reCiprocating components when assembling Always use clean engine oil Engines Generators 58 9 9 9 9 6 9 6 9 2 3 2 3 8 SERVICE DATA I STANDARDS AND LIMITS 225 828 FOUR MARINE ENGINE Component CONNECTING ROD Small End Bore Piston Pin and Specified Value Standard Repair Limit End Bushing 0005 00015 0012 003900020 005Bend and Twist 0002 in 4 005 in 100Side Clearance 00094 00134 0239 034000157 040Small End Bore 11816 11824 30012 ROD BEARING Oil Clearance 00014 00030 0036 0076 0039 010Available Undersize 001 002 003 0255 0508 0762PISTON Diameter 37381 37399 94967 94993Piston Ring Hole Bore 11809 11814 29996 30008Ring Groove Width Top 00958 0966 2433 2453Second 00954 0962 2423 2443Oil 01887 01895 4793 4813PISTON RINGS PistonLiner Clearance O0017 00028 0032 0083Width Top 00958 00954 00962 2423 2443Oil 01887 01895 4793 4813Thickness Top 00930 0938 2363 2383Second 00930 0938 2363 2383Oil 01867 01875 4743 4763Side Clearance Top 00020 00070 0050 0180 0118 030Second 00016 00031 0040 0080Oil 00012 00028 0030 0070End Gap 0Q157 00240 040 060 00591 15PISTON PIN Diameter 11809 11811 29994 30000Pin to Piston Clearance 0 0006 0 0016CRANKSHAFT Main Joumal diameter29848 29853 75812 75825Grinding Limit 2955 7505Crankpin Diameter 24060 24065 61112 Diameter 0030 0762End Play 00055 00154 0140 0390 00157 040Runout 00020 005Component MAIN BEARING Specified Value Standard inchesmmRepair Limit 00020 00037 0059 0090 00047 012Available Undersize 001 002 003 0254 0508 0762CYlINDER BLOCK Warpage Iimit 0004 010Cylinder Liner Inner Diameter 37412 37422 95025 95050 00079 020Protrusion 00040 00000 0101 0000Flywheel to Crankshaft Runout 00079 020FUEL SYSTEM Idle Speed 600 650 rpm Fuel Injection Pump Plunger diameter 0393 100Gam Lift 008 22Injection Timing O TDC Injector Nozzle Diameter 0031 080Injection Order 1 3 4 2 Injection Pressure 1920 710 psi 135 50 kgcm LUBRICATION SYSTEM Oil Pressure 54 psi 38 kgcmMin Safe pressure idle 43 261 14 psi 03 261 01 kgcmOil Capacity sump 63 Qts 60 LOil Pump Outer Rotor and Body Clearance 00055 00100 014 025 00118 030Rotor Lobe Clearance 00016 00059 004 015 00118 030Rotor End Float 00016 00039 004 010 00059 015Pump Shaft and Body Clearance 00024 00079 006 015 00039 010STARTER MOTOR Depth of Brush Undercut 0019 05 0008 02Height of Brush 0669 17 0236 6Spring Pressure 43 IbM 3 kgcmCommutator 0D 1523 387 0039 10Pinion Shaft End Play 00197 05Engines Generators 56 1 5 1 AdobeUCSI I llilllU NOTE An onoff switch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat Twelve volt diesel engine starters typically draw 200 to 300 amps when cranking A switch with a continuous rating of 175 amps at 12 VDC will normally serve this junction but a switch must never be used to make the starter circuit r828 FOUR MARINE ENGINE WIRING DIAGRAM 039144 I o 0 liED 110 It D t ALARM C eUZlnt L 11 au ADMIRAL PANEL CAPTAIN PANEL lIeu 11 au l I Engines Generators 52 TESTING e Now check the voltage between the alternator output tenninal Band ground If the circuit is good the voltage at the alternator should be the same as the bat255tery or if an isolator is in the circuit the alternator volt255age will be zero If not a problem exists in the circuit between the alternator and the battery Check all the connections look for an opening in the charging cir255cuit TESTING THE STARTING BATTERY267 ALTERNATOR ENGINE RUNNINGMU LTIMETER WITCH RID G COM 1ENGIN E GROUND f Start the engine again Check the voltage between the alternator output and ground The voltage reading for a properly operating alternator should be between 135 and 145 volts If your alterna255tor is overor undercharging have it repaired at a reli255able service shop NOTE Before removing the alternator for repair use a voltmeter to ensure that 12 volts DC excitation is pre255sent at the EXC terminal if the previous test showed only battery voltage at the B output terminal If 12 volts are not present at the EXC terminal trace the wiring looking for breaks and poor connections Jump the 12 V to the Exc terminal from a known 12V source and operate the alternator If the voltage output is 1314 volts the alternator is ok Trace the cause for 12 volts not present at the Exc terminal Alternator is Working 4 Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself mID MULTIMETER G COM SERVICE BATIERY TESTING THE SERVICE BATTERY ENGINE RUNNINGA CAUTION When perfonning tests on the alter255nator charging circuit do not use a high voltage tester ie MeggerYou can damage the altemator diodes ALTERNATOR INSPECTION When rebuilding the engine the alternator should be cleaned and inspected The housing can be wiped off with a solvent and the alternator tenninal studs should be cleaned with a wire brush Make certain the studs are tight and clean the wiring connections that connect to the wiring harness Turn the rotor pulley by hand It should tum smoothly Depending on when the alternator was last serviced the brushes may need replacing If the alternator is at all suspect send it to a service shop for testing and overhaul Engines Generators 51 AdobeUCS4 o MULTIMETER COM 14 to Fuel Solenoid Fuel Lin Pump 14 BROWN 14 PINK to Tachomel8r 51 AMP ALTERNATOR x GENERATOR 110RED GROUND A WARNING A failed alternator can become very hot Do not touch until the altemator has cooled down This section is to determine if a problem exists with the charging circuit or with the alternator If it is determined that the alternator AdobeUCSthe tach AdobeUCSan adjusting Sliding portion MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between terminals S and body No continuity should be found between S and M Continuity should be found between S and the body and M and the body Inspecting The Armature 1 Check the armature with a growler tester If its short circuited replace the armature Also check for insulation between the commutator and its shaft If poorly insulated replace the armature ARMATURE ARMATURE CHECK 2 Measure the commutator OD and the depth of undercut Repair or replace it if the service limit is exceeded Also check the commutator outside surface for dirtiness and roughness If rough polish the commutator with fine crocus cloth COMMUTATOR 00 Commutator Outside Diameter Standard Commutator Outside Diameter Limit 1523 in 387 mm0039 in 10 mmBrush and Brush Holder Inspection 1 Check the brushes If worn out beyond the service limit replace the brushes BRUSHES NEW USED Brush Height Standard 0669 in 17 mmBrush Height Limit 02363 in 6 mm2 Check the brush spring tension A weak or defective spring will cause excessive brush wear replace the springs if suspect BRUSH HOLDER ASSEMBLY 3 Check for insulation between the positive brush holder and holder base If poorly insulated replace the holder assembly Also check the brush holders for proper staking Engines Generators 47 AdobeUCS5 Remove MOTOR DESCRIPTION The starter can be roughly divided into the following sections 225 A motor section which generates a drive power 225 An overrunning clutch section which transmits an arma255ture torque preventing motor overrun after starting 225 A switch section solenoidwhich is operated when actu255ating the overrunning clutch through a lever and which supplies load current to the motor The starter is a new type small lightweight and is called a highspeed starter The pinion shaft is sep255arate from the motor shaft the pinion slides only on the pin255ion shaft A reduction gear is installed between the motor shaft and a pinion shaft The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease The motor shaft is supported at both ends on ball bearings The lever mechanism switch and overrunning clutch inner circuit are identical to conventional ones ADJUSTMENT AND REPAIR If any abnormality is found by the following tests the starter should be disassembled and repaired Pinion Gap Inspection 1 Connect a battery 12Vbetween the starter terminal S and the starter body and the pinion drive should rotate out and stop A CAUTION Never apply battery voltage for over 10 seconds continuously 2 Lightly push the pinion back and measure the return stroke called pinion gap3 If the pinion gap is not within the standard range 00197 00788in 05 to 2Ommadjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the number of shims increases DS2DMM PINION GAP NoLoad Test 1 Connect the ammeter voltmeter and battery to the starter as illustrated 2 When the switch is closed the pinion must protrude and the starter must run smoothly at 3000 rpm or moreIf the current or starter speed is out of specification disas255semble the starter and repair it A CAUTION Use thick wires as much as possible and tighten every tenninal securely This is a solenoid shift255type starter which makes a rotating sound louder than that of a directdrive type starter When detecting starter rotation at the pinion tip be careful not to come in contact with the pinion gear when it protrudes SOLENOID Perform the following tests If any test result is not satisfactory replace the solenoid assembly 1 Inspect the solenoid for continuity between terminals and and between terminals S and the body and M and the body There should be no continuity found between terminals S and M Continuity will be found between ter255minals S and the body and terminal M and the body MULTIMETER NOTE Disconnect the wire from terminal M 2 Connect a battery to the solenoids terminal S for and M for Have a switch in the lead and close it The pinion drive should extend fully out A CAUTION Do not apply battery current for more than 10 seconds when testing the solenoid Engines Generators 45 RAW WATER PUMP PUMP OVERHAUL NOTE Since completely rebuilding a damaged or worn pump from individually purchased parts would almost match the price of a new pump WESTERBEKE recommends that a new pump be purchased Before disassembling the raw water pump inspect the pump by rotating the drive shaft If it is rough frozen or seems to have excessive play replace the entire pump Disassembly The pump as removed from the engine will have hose attachment nipples threaded into its inlet and outlet port They may be left in place or removed if they interfere with the pump disassembly Note the port location and positioning if removed 1 Loosen the set screw with an allen wrench and remove the water pump pulley from the shaft Taking care not to lose the key 2 Remove the four cover screws the cover and the cover gasket NOTE Replacement of the cover gasket is recommended however it you are going to reuse it keep the gasket well lubricated until the pump is reassembled If its allowed to dry the gasket will shrink and not be reusable 3 Pull out the impeller with long nose pliers or a pair screwdrivers 4 Remove the cam screw and cam HOUSING GASKET 5 Remove the housing assembly releasing the shaft bearing and seal assembly This will allow the bearing and seal to be disassembled for inspection NOTE It may be necessary to use a drift and arbor press to press the bearing and seal assembly from the shaft 6 Inspect all parts and replace those showing wear or erosion 7 Use the illustration to assist in reassembling the raw water pump a Apply a small amount of petroleum jelly to the seals inner race and to the impeller shaft at reassembly b When positioning the cam in the housing use a small amount of Pennatex 1 on the inner cam surface and cam screw head remove any excess from the impeller housing c Apply a light film of silicon or petroleum jelly to the inner surface of the housing for the impeller 8 When the pump is assembled reposition and tighten the hose nipples into the pump housing use Teflon sealant on the nipple thread Assemble the pump to the engine and attach the hoses and the belt RAW WATER PUMP Engines Generators 44 For additional 9 AdobeUCS6 9 CIRCULATING PUMP REMOVING THE PUMP Remove in the following order coolant drain as neededVbelt water hoses water pump attaching nuts and water pump DISASSEMBLY 1 Remove the pump pulley boss by using a support and press 2 Remove the bearing shaft from the impeller and bearing housing by using a support block and press 3 Remove the snap ring with snap ring pliers and press out the water pump shaft from the bearings TUBULAR SUPPORT INSPECTION Inspect the shaft bearings and impeller Look for cracks and damage Check the housing gasket and inspect the rear seals and small end gaskets Replace any parts that show wear ASSEMBLY Assemble the water pump in the reverse order of disassembly using the following procedure 1 Fill lithium grease lithium base NLGI No2into the following positions 225 Ball bearings 225 Approximately 113 space between both ball bearings 225 Space between the ball bearing and water baffle plate 2 Apply a thin coat of engine oil to the press fit surface of the water seal and press the larger end into the proper aperture of the pump using a tubular mandrel Mazda tool 490636 145SPRING LOADED SEAL BEARINGS RETAINING RING COLLAR TOOL SEAL NOTE Do not allow oilor grease to contaminate the surfaces of the ceramic ring or the graphite small endof the springloaded seal 3 After the water pump has been assembled check if the pump shaft rotates smoothly INSTALLING THE PUMP 1 Install in the reverse order of removal NOTE Use a new gasket 2 After installing the pump fill the system with coolant and operate the engine to check for leaks Engines Generators 41 ENGINE ADJUSTMENTS Abnonnally high readings on all cylinders indicates heavy carbon accumulations a condition that might be accompanied by high pressures and noise NOTE In case of severe vibrations and detonation noise have the injectors checked and overhauled by an authorized fuel injection service center Poor fuel quality contaminates and loss of positive fuel pressure to the injection pump will result in injector faults When reinstalling the glow plugs use antiseize compound SEnlNG THE IDLE SPEED PROPULSION ENGINE1 Warm the engine to nonnal operating temperature 2 Stick a piece of suitable reflecting tape on the crankshaft pulley 3 Idle the engine 4 Use the light of a photoelectric strobe type tachometer on the reflecting tape and compare with the readings on the electric tachometer Nonnal idle speed 650 950 rpm NOTE The idle speed may vary according to the transmission and propeller 5 To adjust the engine idle speed loosen the lock nut of the idle adjustment bolt and turn the bolt clockwise to increase idle speed and to reduce NOTE Should the engine rpm be in question verify the tachometer readings as shown at the instrument panel See TACHOMETER IDLE ADJUSTMENT rY OLT ADJUSTING IDLE SPEED SPEED ADJUSTMENT GENERATORNOTE Speed adjustment of the generator hertzis controlled by the electronic governor see ELECTRONIC GOVERNOR for speed and gain adjustments Early Models Without Electronic Governing Engine speed is maintained by the governor mechanism inside the fuel injection pump 615 620 hertz at noload and 585 590 hertz at full rated generator outputEngine noload speed is adjusted by positioning the throttle lever against the adjustable throttle stop screw lock wiring it at that position and tensioning the throttle stop screw against the throttle lever and securing it with its lock nut When servicing the injection pump the service shop must be advised if the pump is to be used in a generator application The service shop will have to remove and replace the gover255nor spring with a propulsion spring Once the pump is set to propulsion specifications the generator spring is reinstalled in theinjection pump and the pump remounted on the engine The throttle is then set for the proper engine noload speed hertzFor disassembly inspection reassembly and internal adjustments of the injection pump it is recommended the pump be taken to a qualified injection service shop authorized to service Diesel KiKi injection equipment ENGINE STOP SOLENOID267 This solenoid is installed on the top rear of the injection pump and is activated by 12 VDC electrical current NOTE To service generator applications refer to the GENERATOR section of this manual 1 The solenoid does not operate when the keys witch is turned ON Preheat depresseda Are the engine batteries turned ON b Is the 20 amp circuit breaker set c Is 12 VDC present at the solenoid connection 2 The solenoid does not stop the engine when the keyswitch is switched OFF Stop switch depresseda Check to see if 12 VDC is still present at the solenoid electrical lead with the key off Stop switch depressedb Remove solenoid from injection pump and ensure plunger and spring in the solenoid are not sticking FROM START MOTOR SOLENOID SOLENOID i SPRING rPLUNGER INJECTION PUMP Engines Generators 40 AdobeUCSrocker arm 2 3 adapter and AdobeUCSglow plug 9 Reinstall the FUEL SYSTEM PROBLEM PROBABLE CAUSE Engine output and performance poor 1 Contaminated or inferior fuel 1 Purge fuel system and replace with quality fuel 2 Fuel filter obstructed 2 Remove and replace filter element 3 Air in fuel system 3 Bleed and check for source 4 Injection pump timing incorrect 4 Check the timing and adjust pump as needed 5 Injector high pressure lines leaking 5 Loosen and then retighten injector line attachment nut or replace the complete line 6 Injectors not operating properly 6 Remove injectors and adjust spray pressure to proper setting 7 Shaft stuffing box too tight 7 Check shaft free movement and for heat 8 Valves improperly adjusted 8 Check valve adjustment and maintain Large amount of black exhaust smoke 1 Clogged fuel filter 1 Replace the fuel filter and bleed the system 2 Restricted air intake 2 Remove air obstruction 3 Engine overloaded 3 Check engine propeller size and engine performance no load through fully loaded 4 Injection timing 4 Check the injection pump timing and adjust as needed 5 Fuel injectors not operating properly 5 Check nozzle spray Abnormal noise from engine 1 Poor quality andor incorrect fuel 1 Use No2 diesel fuel 2 Incorrect injection timing Timing too advanced 2 Check injection timing 3 Fuel injector stuck open 3 Locate and remove faulty injector Replace or rebuild Engines Generators 37 FUEL SYSTEM PROBLEM PROBABLE CAUSE Engine hard to start or fails to start 1 No fuel at injectors 1 Check causes a through e a No fuel in fuel tank andor fuel shut off a Fill tank Open shutoff and bleed system b Fuel filter clogged b Replace filter and bleed c Fuel filter clogged c Bleed pump Check fittings for suction leak on fuel supply d Fuel shutoff solenoid not working d Trouble shoot as described in previous section e Injection pump faulty e Inspect pump Repair or replace pump as needed 2 Fuel injectors faulty 2 Remove and test nozzles Repair nozzles as needed 3 Water andor air in fuel filters 3 Remove water andor bleed air from system Check system for leaks and fuel tank for water contamination 4 Injection timing incorrect 4 Check and adjust the timing 5 Glow plugs not working 5 Check glow plug circuit and repair as needed Engine idling too low 1 Idle speed too low 1 Adjust idle stop as needed 2 Fuel filter clogged 2 Replace filter and bleed fuel system 3 Incorrect injection pump timing 3 Check timing and adjust as needed 4 High pressure injection line leaking 4 Slacken attaching nut and retighten 5 Fuel injector leaking at sealing gasket in head 5 Retighten injector andor replace sealing washer 6 Injection nozzle not operating properly 6 Check nozzle and adjust as needed 7 Engine air intake obstructed 7 Check air flow intake silencer and air flow into engine compartment Fuel consumption too high 1 Idle speed too high 1 Check engine speed 2 Engine air intake restricted 2 Check intake and correct 3 Injection timing incorrect 3 Check timing and readjust pump as needed 4 Injector nozzle leaking 4 Tighten nozzle or replace sealing gasket 5 Injector not operating properly 5 Remove injector and adjust nozzle spray pressure 6 Engine overloaded 6 Check propeller size and engine performance Generators 36 FUEL INJECTORS INSPECTING SPRAY PAnERN 1 Operate the hand lever of the nozzle tester at intervals of one stroke per second to check if the fuel is injected cor255rectly in its axial direction A nozzle is defective if it injects fuel in an oblique direction or in several separate strips Also a spray in the form of particles indicates a defect These defects may sometimes be caused by clog255ging with dust and therefore all parts should be carefully cleaned before reassembly FAULTY ANGLE FAULTY DIRECTION 2 Operate the hand lever to raise the pressure up to 1635 psi 115 kglcm2which is 280 psi 20 kglcm2lower than the starting pressure If with pressure applied fuel does not drip from the nozzle oil tightness is satisfactory Dripping of fuel with pressure applied is indicative of damage to the needle valve or valve body or poor contact between both In that event both needle valve and valve body should be considered defective and replaced M CORRECTM AFTER IlUP TEST WRONG DISASSEMBLY AND INSPECTION 1 Clamp the nozzle holder in a vise remove the nozzle nut and disassemble the nozzle body spring and needle 2 Clean the disassembled parts with clean diesel fuel NOTE Greatest possible care should be taken in handling the nozzles as they are precisely machined The nozzle and the needle valve are matched parts Do not mix their original combinations Disassemble and wash each noz255zle assembly separately Carbon deposits on the nozzle body must be removed with a piece of hard wood However it would be advis255able not to clean the surrounding area of the nozzle ori255fice to avoid possible damage to the orifice Iron dust on the magnetic filter top must be removed completely 5 Assure the needle valve when it is pushed in the nozzle body comes down into the valve seat by its weight about 07092in 18mmIf it does not replace the assembly If any defect is found always replace the needle valve and the nozzle body as a unit 6 Check that there is no flaw or other damage on mating surfaces and sliding surfaces of the nozzle body and the needle valve and if present replace the nozzle assembly ASSEMBLING THE INJECTOR 1 Assemble in the reverse order of 4isassembly NOTE After assembling the injector test it 2 Tighten the nozzle body on the nozzle holder to the speci255fied torque Nozzle Body Torque 24 mm socket80 10 IMt 58 72 kgmINSTALLING 1 Install in the reverse order of removal NOTE The copper washers should not be reused Replace with new washers 2 TIghten the nozzle on the cylinder head to the specified torque Nozzle Torque 27 mm socket43 511bft 60 70 kgmINJECTOR RETURN lINE WASHER ADJUSTING SHIM SPRING NOZZLE NOZZLE lNUT WASHERS Engines Generators 35 AdobeUCSFUEL INJECTORS REMOVING THE INJECTORS NOTE Injector must be serviced in a clean room environ255ment 1 Disconnect the high pressure lines from the injectors and loosen the lines at their attachment to the injection pump and move them out of the way of the injectors Avoid bending the lines 2 Remove the fuel return line in its entirety from the top of the injectors Take care not to lose the two sealing wash255ers and banjo bolt that attaches the fuel return line to each injector 3 Unscrew the injector from the cylinder head using a suit255able 27 mm deep socket NOTE Clean the area around the base of the injector prior to lifting it out of the cylinder head to help prevent any rust or debris from falling down into the injector hole If the injector will not lift out easily and is held in by carbon build up or the like work the injector side to side with the aid of the socket wrench to free it and then lift it out 4 The injector seats in the cylinder head on a copper seal255ing washer This washer should be removed with the injector and replaced with a new washer when the injec255tor is reinstalled INJECTION 1 Using the nozzle tester check the spray pattern and injec255tion starting pressure of nozzle and if it exceeds the limit adjust or replace the nozzle When using nozzle tester take the following precautions A CAUTION The spray injected from the nozzle is of such velocity that it may penetrate deeply into the skin of fingers and hands destroying tissue If it enters the bloodstream it may cause blood pOisoning a If the diesel fuel of the nozzle tester is discolored replace it At the same time clean or replace the filter b Set the nozzle tester in a clean place where there is no dust or dirt INJECTION PRESSURE TEST c Mount the nozzle and nozzle holder on the nozzle tester d Use the fuel at the approximate temperature of 68260 F 200 Ce Operate the hand lever of nozzle tester several times to bleed the air in the nozzle line then move the hand lever at intervals of one stroke per second while read255ing the injection starting pressure Injector Starting Pressure 1920 Ibin 135 kgemf If the fuel injection starting pressure is not within the specification it can be adjusted by removing or adding shims in the injector body to achieve proper pressure NOTE The shims are available in 27 kinds ranging from 05 mm to 154 mm at 002 increments An incre255ment of 04 mm causes the starting pressure to rise by approximately 68 Ibin2 48 kgcm2SHIM SHIM THICKNESS 01 mm 02mm 03mm 05mm When replacing the shim grip the retaining nut in a vise and remove the body with a wrench Tighten the retaining nut to the specified torque INJECTOR Engines Generators 34 AdobeUCSFUEL INJECTION PUMP I FUEL LIFT PUMP CHECKING CAM LIFT 1 Turn the crankshaft in the direction of normal engine rotation and read the maximum value which the dial indicator pointer on the measuring device shows This value is cam lift Amount of Cam Lin 008 in 22 mm2 After this check remove the measuring device and install the plug and sealing washer 3 Reinstall the 0032 inch thick timing washer in the injec255tion pump BLEEDING THE INJECTION PUMP 1 The injector pump and injector high pressure lines will have to be bled of air after the lines have been reinstalled To bleed the injection pump first loosen the return con255nection aThen by priming with the lever on the engine mounted fuel filter supply fuel to the injection pump to remove the air from the injection pump Continue until fuel clear of air passes out of the loosened return connec255tion 2 Next bleed the high pressure lines by loosening them at their attachment to the fuel injectors Loosen the attach255ing nuts one to two turnson all four fuel lines Tum the key on and crank the engine with the starter until fuel spurts by the loosened connections Stop cranking the engine Tighten the attaching nuts and start the engine in the usual manner FUEL INJECTION PUMP FUEL LIFT PUMP EARLY MODELSThe fuel lift pump should be cleaned and repainted Install a new filter as illustrated and clean the ground wire terminal FUEL FILTER FUEL LIFT PUMP MAGNET This pump operates during the start sequence when preheat is pressed Simulate a start and depress preheat the pump should produce a clicking sound indicating the pumping piston in the pump is working If no clicking is heard check that 12 volts are present at the pump connection and the pump is properly grounded 1 Test the pump by connecting a battery and fuel line as illustrated Fuel delivery must be 05 pints 225 ccor more every fifteen seconds FUEL LIFT t SUCTION HEAD APPROX 500 mmi THE FUEL PUMP MEASURING CYLINDER NOTE Later model WESTERBEKE engines and genera tors use a solid state fuel lift pump that requires no maintenance The above tests can be performed on these models FUEL LIFT PUMP WESTERBEICE Engines Generators 33 AdobeUCSFUEL INJECTION PUMP TESTING INJECTION TIMING 1 Remove the air intakesilencer assembly 2 Remove the four high pressure injector lines that connect between the injection pump and injectors 3 Remove the bolt and gasket installed on the distributor head of the injection pump 4 Remove the valve rocker cover S Rotate the crankshaft in normal direction of rotation using the front crankshaft pulley nut and place the No 1 piston at IDe of its compression stroke No1 piston is first from the front of the engineNOTE To verify the rocker arms of No4 cylinder should be rocking one opening one closing 6 Remove the snap ring from the end of the rocker shaft at cylinder No 1 along with the retaining washer 7 Loosen the rocker arm adjusting bolt so as to allow the arm to be removed from the push rod and slide it off the rocker shaft 8 Press down on the valve and spring assembly and ensure the valve is hitting the top of the No 1 piston Then remove the cap keepers and valve springs from the No 1 valve NOTE Ensure the valve moves freely in its guide Take care to not drop the keepers down the push rod hole 9 Position a dial indicator gauge on the valve stem and using the front crankshaft pulley nut rock the crankshaft and clockwise to to locate the exact IDe of the compression stroke for the No 1 piston Then zero the indicator gauge to the valve stem the gauge should be able to measure up to 03 inch of valve movement mm BTDC r0205 int 10 Slowly turn the crankshaft in the opposite direction of normal rotation until the indicator reads 0180 261 005 inches BIDe It is advisable to go slightly more than 0180 inches and then return to that figure to remove gear lash The No1 piston is now at 30260 BIDe Verify the scribe mark on the injection pump outboard mounting flange is properly aligned with the scribe mark on the engine mounting case At the six oclock position on the outboard side of the injection pump is a semioval cover with two screws Remove this cover and locate the sealing Oring and timing washer 0032 inches in thickness 11 Remove the plug and sealing washer from the aft center of the injection pump The plug is centrally located where the four high pressure injector lines attach to the pump In place of the plug install the Mazda tool 49 9140 074 measuring device Ensure the measuring device rod con255tacts the plunger inside the pump and then zero the gauge PLUG AND vmIN WASHER FUEL INJECTION PUMP 0 NOTE When setting the dial gauge confirm that the dial gauge pointer does not deviate from the scale make of zero by slightly turning the engine crankshaft from left to right Turn the engine crankshaft in the normal direction of rotation to bring the No 1 piston up to IDe The dial indicator on the valve stem should zero and the indicator on the injection pump should show 0039 inches 1 mmof movement ADJUSTING INJECTION TIMING 1 Loosen the nuts holding the injection pump to the engine The high pressure injector lines should not be attached to the injection pump2 Make the adjustment by moving by moving the injection pump itself When the amount of movement of the mea255suring device indicator on the injection pump is too large first tum the injection pump in the reverse direction of the engine rotation so that the dial gauge pointer indicates less than the scale mark of 0039 inches 1 mmThese adjustments are to tighten the gear backlash Injection Pump Gear Lock Nut Torque 29 51 ftIb 40 74 mkgWhen the amount of the measuring device indicator on the injection pump is too small tum the injection pump in the direction of normal engine rotation so that the measur255ing device indicator points to the scale mark of 0039 inches 1 mm3 After the adjustment tighten the injection pump hold255down nuts and then confirm again that the adjustment has been done correctly Remove this washer and replace the cover WESTERBEKE Engines Generators 32 head ENGINE ASSEMBLY MARINE 59 Assemble the damper plate to the flywheel Damper Plate Torque 1426720 ft267lb 17 27 mkg60 Reinstall the marine transmission and fill with ATF DextronIII NOTE Some transmissions such as the Borg Warner Velvet Drive require oil coolers Oil coolers should be cleaned pressure tested and repainted at engine over255haul The transmission oil cooler hoses should also be inspected Refer to the text on Heat Exchangers 61 Fill the engine cooling system with premixed coolant 5050 good quality antifreeze and distilled waterFill the engine oil sump to the mark on the dipstick with lube oil API spec CF or CG4The engine should be test run under load prior to At this time readjust the valve clearances on the hot engine Allow the engine to cool to room temperature and retorque the cylinder head bolts and recheck the valve clearances See ENGINE ADJUSTMENTS TYPICAL TRANSMISSION OIL COOLERS GENERATOR 59 Mount the generator back end assembly with its control panel Reconnect all DC wiring and reconnect all AC connections A CAUTION Check all AC and DC wiring connections to WESTERBEKE wiring schematics and diagrams 60 Fill the engine cooling system with premixed coolant 5050 good quality antifreeze and distilled waterFill the engine oil sump to the mark on the dipstick with lube oil API spec CF or CG 4The engine should be test run under load prior to At this time readjust the valve clearances on the hot engine Allow the engine to cool to room temperature and retorque the cylinder head bolts and recheck the valve clearances See ENGINE ADJUSTMENTS Engines Generators 30 ENGINE ASSEMBLY 43 Install the fuel injection nozzles and return lines Use new sealing washers throughout in the same order as were the old washers Injector To Head BoH 27mm deep socket43 51 f1lb 60 70 mkgSee FUEL INJECTORS for more details 44 Install the glow plugs and connectors Use antiseize compound on the threads Glow Plug Torque 72 108 f1lb 10 15 mkgTo test the glow plugs see GLOW PLUGS 45 Connect the fuel line to the engine mounted fuel filter and the injection pump Use new sealing washers 46 Connect the high pressure injector lines from the injection pump to injectors Reinstall the line clamp Attaching Nuts Torque 18 22 f1lb 25 30 mkg47 Install the bellhousing 48 Install the air intake silencer 49 Mount the engine heat exchanger The heat exchanger should be serviced when the engine is overhauled Refer to HEAT EXCHANGER for service and inspection 49 Mount the fuel filter assembly Attaching Nuts Torque 33 49 f1lb 46 68 mkg50 Install the alternator and drive belt A CAUTION Connect the alternator properly Should the polarity be reversed a powerful current would flow from the battery into the alternator damaging the diodes and wiring harness a Install the alternator support bolt through the alternator leg undersideinto the engine casting b Swing the alternator into position on the adjusting bracket and fasten Lightly tighten c Adjust belt tension d Tighten both bolts and recheck belt tension Support bolt Torque 27 38 f1lbs 38 53 mkgAdjusting bracket bolt Torque 9 10 f1lbs 12 18 mkgNOTE Make certain the belts are perfectly aligned with the alternator and engine pulleys If not insert or remove spacers as needed to align the alternator See ALTERNATOR for testing 51 Install the raw water pump and drive belt Insure it is in proper alignment with the crankshaft pulley Check the belt tension Refer to RAW WATER PUMP for pump breakdown 52 Install the oil and water sender and switch 53 Install the starter motor 54 Install the breaker panel and the preheat solenoid 55 Reinstall the engine electrical harness 56 Mount the complete exhaust manifold and the expansion tank to the cylinder head Man Hold Mounting Bolts Torque 1217 f1lb 16 24 mkgSee EXHAUST MANIFOW for service and inspection 57 Assemble the wiring harness and ground wires 58 Reconnect all DC wiring harness terminals to their engines components A CAUTION Check all AC and DC wiring connections to WESTERBEKE wiring schematics and diagrams Engines Generators 29 1 8 3 complete breakdown 2 3 AdobeUCSthe tappet AdobeUCSgears on AdobeUCSthe main AdobeUCStorque sequences AdobeUCSENGINE INSPECTION TIMING GEAR COVER OIL SEAL 1 Inspecting timing gear cover oil seal Check the timing gear cover and the lip of the oil seal for any damage If necessary replace the cover or oil seal 2 Oil seal replacement To remove the oil seal use the oil seal puller and installer and pull out the oil seal To install apply engine oil on the outside of a new oil seal then press fit the oil seal with oil seal puller and installer until the installer comes in contact with the cover REAR OIL SEAL OIL SEAL INSTALLER TOOL 1 Inspecting oil seal Check the oil seal lip for wear fraying or other damage and if necessary replace it 2 Oil seal replacement a Strike out the old rear oil seal with a suitable mandrel b Apply engine oil onto the outside of a new seal and press fit the seal in the rear oil seal cap equally NOTE In case the crankshaft is worn the oil seal must be fitted on the oil seal cap with its fitting position moved by approximately O1I81in 3mmso that the seal does not touch the worn down portion of the crankshaft INSTALLATION REMOVAL OIL PAN 1 Scrape and clean any dirt or metal particles from the inside of the oil pan 2 Check the oil pan for cracks and damaged drain plug threads 3 Inspect for damage uneven surfaceat the bolt holes caused by the over torquing of the bolts surfaces as required Repair or replace the oil pan OIL JET UPPER BLOCK1 Make certain the oil passage is not clogged 2 OIL JET VALVE OIL SEAL Engines Geneators 23 ENGINE INSPECTION CHECKING CLEARANCE BETWEEN TUI Ifoi BUSHING AND SPINDLE CHECKING THE GEARS 1 Visual Inspection Check each gear idler gears injection pump drive gear crankshaft gear camshaft gearfor cracks or other damage If necessary replace as required 2 Inspecting end play of idler gear Check the end play of the idler gear with a dial indicator as shown If it exceeds the specified limit replace the thrust plate or idler gear JIJNOTE Measure the end play after tightening the idler gear attaching nuts to the specified torque value Thrust plate torque 1fl socket17 231tlb 23 32 kgmStandard end play 00059 00118 in 015 030 mm3 Check backlash between gears Check the backlash between each gear with a dial indicator NOTE Check the backlash after assuring that the idler gear end play and the clearance between the idle gear bushing and spindle are within the standard Backlash Standard 00039 00079 in 010267020 mmBacklash Limit 00118 in 030 mmTAPPET 1 Visual inspection Check the tappet for cracks and other damage and if damaged replace the tappet Check for abnormal wear of the portion of the tappets that contact with the cam and if anyone is abnormally worn replace the tappet 2 Inspecting Clearance Between Tappet and Tappet Bore Check the clearance between the tappet and tappet bore and if the clearance is greater than the limit replace the tappet or cylinder block Clearance Limit 00039 in 010 mmTAPPET CLEARANCE PUSH RODS 1 Visual Inspection Check each push rod for damage to eithfr end If damage is severe replace the push rod 2 Bend Inspection Check the push rod for bend and if it exceeds the limit replace it Place the push rod on a flat surface and measure the clearance between the center of the push rod and the flat surface Replace the push rod if the wear limit is exceeded Bend limit 00075 in 019 mmTESTING THE PUSH ROD PUSH RODS Engines Generators 22 AdobeUCSENGINE INSPECTION 4 Inspecting crankshaft end play Check the end play of the crankshaft and if the end play exceeds the limit replace the thrust washer with 0007 in 0178 mmover255size Crankshaft end play is measured by setting a dial gauge on the rear end of the crankshaft and moving the crankshaft in the axial direction Crankshaft End Play Standard 00055 00154 in 014 039 mmCrankshaft End play limit 00157 in 040 mmMAIN BEARING 1 Inspecting main bearing Check the main bearing for peeling seizure or fusion and if necessary replace the bearing 2 Inspecting main bearing Using the plastigauge measure the oil clearance and if it exceeds the limit replace the main bearing PLASTIGAUGE Oil Clearance Standard 00023 00035 in 0059 0090 mmOil Clearance Limit 0005 in 012 mmCAMSHAFT 1 Visual Inspection Check the camshaft for cracks and damage If necessary replace the camshaft NOTE If the damage is slight you may be able to correct the camshaft with an oil soaked fine emery grindstone Take special care to not damage the original cam form 2 Inspecting cam height Measure the cam height and if it is less than the limit replace the camshaft Cam height limit 16724 in 42478 mmINTAKE AND EXHAUST CAM CAM ElGKT rwINSPECTING THE CAMSHAFT 3 Inspecting camshaft journal Check the camshaft journal and if wearing exceeds the limit replace the camshaft No1 No2 NO3 No4 Diameter of Joumal 20437 20449 in 51910 51940 mm20339 20350 in 51660 51690 mm20240 20252 in 51410 51440 mm20142 20154 in 51160 51190 mmWear Limit 0008mm 00003 in4 Inspecting camshaft oil clearance Check the clearance between the camshaft journal and the camshaft support bore as follows a Measure the camshaft journal diameter and the camshaft support bore b Calculate the clearance and replace the camshaft or cylinder block if the clearance exceeds the limit Oil clearance limit 00057 in 0145 mm5 Checking camshaft alignment and if it exceeds the limit replace the camshaft Maximum allowable runout 00031 in 008 mm6 Inspecting camshaft end play a Install the thrust plate camshaft gear lock plate and camshaft gear lock bolt on the camshaft b Tighten the lock bolt to the specified torque Lock Bolt Torque 19mm socket46 691bft 64 95 kgmc Measure the clearance between the thrust plate and camshaft gear If it exceeds the limit replace the thrust plate End play limit 00118 in 03 mmCAMSHAFT GEAR IDLER GEAR BUSHING AND IDLER GEAR SPINDLE 1 Visual inspection Check for damage on the bushing inner surface of the idler gear and the spindle sliding sur255face and if necessary replace the idler gear or spindle Check the oil passage for clogging and if necessary clean the passage with compressed air or wire 2 Inspecting clearance between bushing and spindle Check the clearance between the idler gear bushing and the spindle and if it exceeds the limit replace the idler gear or spindle Clearance Standard 00013 00033 in 0034 0084 mmClearance Limit 0006 in 015 mmEngines Generators 21 AdobeUCSENGINE INSPECTION 6 Inspecting connecting rod bearing Check the connect255ing rod bearing for peeling and thennal damage If it is severe replace the bearing 7 Inspecting connecting rod bearing clearance Using the plastigauge measure the oil clearance of the connecting rod bearing and if it exceeds the limit replace the connecting rod bearing Connecting Rod Cap Torque 56415786 ftIb 78 80 mkgConnecting Rod Bearing Clearance Standard 00005 00012 in 0012 0031 mmLimit 00020 in 005mmUndersize Bearing 0010 in 0254 mm0020 in 0508 mm0030 in 0762 mmINSPECTING BEARING CLEARANCE 0 CRANKSHAFT 1 Visual Inspection Check the crankshaft for cracks or other damage If cracking is suspected thoroughly clean the crankshaft and perfonn a magnafiux check of the crankshaft If any cracks are detected replace the crank255shaft MAGNAFLUX TEST CRANKSHAFt Check for clogging of oil passages and if clogged remove with compressed air or a wire 2 Runout inspection Check the crankshaft runout and if it exceeds the limit replace the crankshaft Runout Limit 00020 in 005 mmCRANKSHAFT RUNOUT INSPECTION RUNOUT 3 Inspecting crank pin and journal Support the crank255shaft on both ends using Vblocks Measure the diameter of each crank pin and crankshaft main journal and if the diameter is less than the limit refinish the crank pin and main journal to size for the next undersize bearing Crank pin diameter Standard 240601 24065 in 6111261125 mmWear limit 0002 in 005 mmMain journal diameter Standard 29848 29853 in 75812 75825 mmWear limit 0002 in 005 mma For the measurement on both the crank pin and the main journal measure them at vertical and horizontal directions on front and rear places b When refinishing the crankshaft its finish to Rlmm as shown in the diagram c Refer to the chart for refinishing dimensions of the crankshaft where an undersize bearing is used REFINISHING DIMENSIONS Undersize bearing 001 in 0254 mm002 in 0508 mm0D3 in 0762 mmUndersize bearing 0D1 in 0254 mm0D2 in 0508 mm0D3 in 0762 mmMain journal diameter 29748 29753 in 75558 75571 mm29648 29675 in 7530475317 mm29578 29554 in 75050 225 675063 mmCrankpin diameter 23964 23965 in 6086826760871 mm2387423865 in 60604 60617 in 6035026760363 THE CRANKSHAFT Engines Generators 20 AdobeUCSobtain the AdobeUCSENGINE INSPECTION 2 Cylinder Liner Replacement Hydraulic press or similar device is needed a Attach the cylinder liner puller and installer to the lower rim of the cylinder liner then press out the liner h Check for scratches on the cylinder block side and if any remove them by using extremely fine emery paper with engine oil c To install the liner apply engine oil on the cylinder block bore and the liner exterior then set the liner on the cylinder block Using the cylinder liner puller and installer press the liner into the cylinder block NOTE Press the liner in straight When press fitting the liner keep the pressure within a range of22006600lb Measure the liner protrusion and correct it if necessary Protrusion Limits 00040 0 in 0101 0 mmLINER PISTON AND PISTON RING 1 Visual Inspection Check the sliding surface and ring groove of the piston for wear scratches or any other damage a Inspecting the clearance between the piston and the cylinder liner h Check the clearance between the piston and the cylin255der liner by measuring the cylinder bore and the piston diameter and if the clearance exceeds the limit replace the cylinder liner and the piston DIAL INDICATOR GAUGE Side Clearance 00017 00028 in 0032 0083 mmc Measure the piston diameter at 90260 the pin bore axis and 0866in 22mmbelow the piston top SUB COMBUSTION CHAMBER Standard Piston Diameter 37381 37399 in 94967 94993mm2 Piston Ring Inspection Check the piston ring for breaks seizure and wear and if any of these conditions exist replace the ring Check the clearance between the piston ring and the ring groove and if it exceeds the limit replace the ring PISTON RING Side Clearance Limit 0012 in O30mm3 Inspecting the piston ring end gap Position the piston ring into the bottom of the cylinder liner Measure the piston ring end gap and if it exceeds the limit replace the ring Be sure to position the piston ring below the ring sliding surface of the cylinder liner Piston Ring End Gap Limit 0591 in 15mmEngines Generators 18 component part AdobeUCSthe valve the valve the valve AdobeUCS1 5 AdobeUCSthe valve the valve AdobeUCSENGINE DISASSEMBLY REMOVING THE TIMING GEAR CASE REAR OIL SEAL b Remove the wrist pin snap rings c Using a nylon drift drive the wrist pin from the piston and rod d Protecting your eyes with safety glasses disengage and withdraw the snap rings Although mechanics generally press out and sometimes hammer outpistons pins these practices should be discouraged Instead take the time to heat the pistons either with a heat gun or on a hot plate Pins will almost fallout e While the piston is still warm check for bore integrity Insert the pin from each side If the pin binds at the center the bore might be tapered if the bore is misaligned the pin will click or bind as it enters the far boss NOTE The number stamped on the rod shank and cap should correspond to the cylinder number Sometimes these numbers are scrambled or missing and the mechanic must supply them Stamp the correct num255berson the pads provided and to prevent confusion deface the originals PISTON RING MAl CRANKSHAFT PULLEY BEARING CRANKSHAFT GEAR SPRING WASHER SLiNGE MAIN BEARINGS 36 Remove the rear oil seal by striking out the old seal with a suitable mandrel 37 Disassemble the connecting rod caps and line up the main bearing caps and bearings according to the order of bearing numbers Also properly arrange the thrust wash255ers taking care not to change the combination 38 Remove the piston and connecting rod assemblies Temporarily install the connecting rod cap on the con255necting rod so as to not mix the rods and caps 39 Disassemble the piston assembly a Using the piston ring remover remove the piston rings While removing the piston rings note the order they are removed and which side of the ring faces the piston crown 40 Remove the main bearing caps 41 Remove the main bearings and thrust bearings 42 Remove the crankshaft 43 Remove the tappets NOTE After removing the main bearings and bearing caps arrange them in order of removal Do not mix caps After removing the thrust bearings note their positioning for proper reinstallation Engines Generators 13 AdobeUCSENGINE DISASSEMBLY CRANKSHAFT PULLEY 27 Remove the crankshaft pulley bolt with the aid of a 38 mm socket and draw the pulley off the front crankshaft TIMING GEAR COVER TIMING GEAR CASE INJECTION PUMP DRIVE GEAR Remove the timing gear cover and remove the injec255tion pump washer injection pump friction gear and the injection pump drive gear 29 Remove the camshaft gear a Wedge a clean cloth between the camshaft gear and the idler gear remove the retaining bolt b Remove the retaining plate friction gear and using a suitable bearing puller the camshaft gear 30 Remove the idler gear a Remove the attaching nuts thrust plate idler gear and idler gear hub TIMING GEAR DIAGRAM TIMING GEAR CASE REMOVING THE CAMSHAFT GEAR 31 Remove the crankshaft gear a Remove the wave washer the friction gear and using a suitable puller remove the crankshaft gear and its key 32 Tum the engine over and remove the oil pan 33 Loosen the oil pump assembly set screw at the side of the block Remove the oil pump For oil pump details see OIL PUMP 34 Remove the timing gear case from the front of the engine block Discard the old gasket 35 Remove the camshaft Keep the engine turned over when removing the camshaft This allows the valve lifters to seat on the block bosses away from the cam lobes Engines Generators 12 ENGINE DISASSEMBLY Engine Block Disassembly Disassemble the engine in the following order 21 Remove the cylinder head rocker cover and gasket ROCKER 256 COVER 22 Remove the cylinder head GASKET NOTE Loosen the cylinder head bolts equally and gradually and in the order shown 5 9 13 17 16 12 8 6 10 14 18 15 11 7 23 Remove the rocker arm assembly a Remove the valve stem caps so as not to lose them when removing the cylinder head Label each cap as to which valve it belongs b Remove the push rods Label each rod as to which valve it belongs ROCKER ARM ASSEMBLY 3 24 Lift the cylinder head off the engine and remove the cylinder head gasket HEAD 25 Disassemble the rocker arm assembly 26 Remove each valve from the cylinder head assembly Use an appropriate valve spring compressor to aid in disassembly Arrange or label the valves so as to replace them in the cylinder and guide from which they were removed TAPER PIN RECESS 256 TAPER PIN HOLE 256 JAM NUT SPRING WASHER ROCKER 245 t SPRING VALVE SPRING RETAINER OTAPPET Engines Generators 11 VALVE SPRING REMOVAL AdobeUCSENGINE DISASSEMBLY 16 Remove the fuel injectors dust seals and sealing washers from the cylinder head using a 27mm deep socket 17 Remove the glow plugs 18 Remove the crankcase breather hose and rocker arm cover 19 Remove the engine mounted fuel filter and fuel line to the injection pump Note the arrangement of the seal255ing washers on the banjo bolts at fuel filter and the injec255tion pump20 Remove the injection pump Scribe the mating marks on the pump body flange and the timing gear case before a Remove the cover and the locknuts h Loosen the two injection pump holddown nuts Do not remove entirely The holddown nut on the engine side of the pump can be loosened by using a 114 universal socket and extension with ratchet c Remove the nut and lockwasher from the injection pump shaft NOTE Take care not to drop the nut and the washer into the timing gear case d Place the keyway on the injection pump shaft in the 1200 position with the aid of the front crankshaft pulley bolt before attempting to remove the injection pump e With the use of extractor Mazda tool 49 SE 01 157 apply sufficient pressure to loosen the pump from the keyed gear The loose holddown nuts will prevent the pump from falling from the engine f Once loosened remove the holddown nuts and wash255ers and carefully withdraw the pump from the drive gear and engine so as to avoid losing the injection pump drive key inside the timing case NOTE If an extractor is not available replace the nut on the injection pump shaft loosely and with a nylon drift and hammer gently tap the injection pump shaft to dislodge it from the keyed drive gear Injection Pump If the injection pump requires servicing it should be sent to an injection service shop that can properly service a type injection pump If the injection pump does not require servicing it should be wiped clean covered and set aside until reassembly Adjustments to timing if needed can be performed after assembly See FUEL INJECTION PUMP Engines Generators 10 ENGINE DISASSEMBLY DISASSEMBLING THE MAIN ENGINE With the transmissionor generator separated from the engine begin the following step by step procedure to disassemble the engine NOTE Mount the engine on a suitable stand or work bench 1 Remove the transmission damper plate from the engine flywheel C o 0 DAMPER PLATE BOLTS 2 Remove the engine oil cooler and oil hoses Note oil hose connections from the oil cooler to the engine 3 Remove the engine heat exchanger If possible leave one end of each hose connected to the part being removed 4 Remove the bell housing propulsion engineand the circuit breakerpreheat solenoid mounting bracket 5 Loosen the front crankshaft pulley bolt and remove the flywheel WHEN REMOVING THE MOUNTING BOLTS LOCK THE FLYWHEEL WITH A RING GEAR BREAK TOOL 6 Remove the engine back plate ONE BOLT DEVIATES J FROM THE 6J SET UP 7 Remove the start motor drive belt and the alternator Label the wires and cables 8 Remove the engine mounted raw water pump adap255tor mounting plate and drive from the front cover The drive is removed by turning in a counter clockwise direction See RAW WATER PUMP for parts breakdown 9 With the hoses disconnected remove the thermostat housing and housing gasket leaving the temperature sender in place 10 Remove the coolant recirculating pump See COOLANT RECIRCULATING PUMP for parts break255down 11 Remove the air intake silencer and the intake manifold 12 Remove the oil filter and the oil cooler mounting bracket from the engine block PLUNGER 3 SPRING ORING PLUG 13 Unbolt the elbows and remove the exhaust manifold in its entirety Injection Pumpnnjectors Disassembly OIL FILTER 14 Detach aU the high pressure injection lines from the injection pump to the injectors Leave the two upper line clamps in place NOTE Cap the ends of the lines and the connections at the injection pump and at the injectors to prevent entry of foreign material 15 Remove the fuel return line from the top of the injec255tors and from the fuel injection pump by removing the four 12 mm attaching bolts Note the washer arrange255ment on fuel return line banjo bolts Cap all the openings on the fuel return line injectors and injection pumpEngines Generators 9 DISASSEMBLY PROPULSION ENGINE Unplug the instrument panel wiring harness Drain the fluid and the transmission oil cooler hoses Detach the oil cooler hoses and unbolt the transmission from the engine Drain or pump out all the engine oil and drain the coolant from the engine and engine hoses For transmission service and maintenance refer to your transmission manual To rebuild a transmission contact your WESTERBEKE dealer or an authorized transmission service shop TRANSMISSION If the transmission is not being rebuilt it should be visually inspected Flush out and pressure test the oil cooler and replace the coolant hoses Inspect and lubricate the gear shift linkage and the propeller shaft coupling Clean and repaint the transmission and change the transmission fluid Refer to TRANSMISSIONS in this manual MARINE ENGINE GENERATOR Disconnect the AC wiring and unplug the engines DC wiring harness at the generator control panel Disconnect the battery cable connections and the engine ground cables Separate the exhaust hose at the water injected elbow and disconnect the fuel supply and return lines NOTE Label any lines hoses or cables as you separate them Drain the engine oil and the coolant from the engine Carefully support and then unbolt the generator backend from the engine See SPECIAL TOOLS GENERATOR in this manual Additional generator information will be found in the GENERATOR section of this manual TABWASHER LABEL THE TERMINAL CONNECTIONS AS YOU DISCONNECT THE WIRING HARNESS Engines Generators 8 THE ENGINE SHOULD BE SECURELY MOUNTED ON A SUITABLE ENGINE STAND TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Generally the time at which an engine should be overhauled is detennined 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 inspec255tion 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 injec255tion timing and wear of plugs and nozzles They are caused also by defective electrical devices such as the battery alter255nator 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 over255haul it is important to measure the engine compression pres255sure 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 NOTE To test engine compression see the ENGINE ADJUSTMENT section of this manual 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 should be 30 kgcm2 427 psi at 200 rpm Cylinder compression should not vary by more than 427 psi 30 kgCm2J DISASSEMBLY 1 Before disassembly and cleaning carefully check for defects which cannot be found after disassembly and cleaning 2 Drain water fuel and oil before disassembly 3 Clean or wash the engine exterior 4 Do not remove or disassemble the parts that require no disassembly 5 Perform disassembly in a proper order using proper tools Keep disassembled parts in order Apply oil when neces255sary Take special care to keep the fuel system parts from intrusion of dust and dirt 6 Carefully check gaskets packings and oil seals even if check255ing is not specified Replace with new ones if defective Engines Generators 7 ENGINE PROBLEM PROBABLE CAUSE KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles a Overheated cylinder a See OVERHEATING LOW OUTPUT b Carbon deposits in cylinder b Clean 2 Too early injection timing 2 Correct 3 Too high injection pressure 3 Correct 4 Improper fuel 4 Replace with proper fuel KNOCKING WITH DARK SMOKE 1 Poor compression 1 See LOW COMPRESSION HARD STARTING 2 Injection pump malfunctioning a Check valve wornsticking a Replace check valve 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 INTERMITIENT 1 Fuel filter clogged 1 Clean or replace EXHAUST SOUND 2 Air leak in fuel supply side of system 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 B Moving parts seized or damaged B Replace 7 Defective thermostat 7 Replace LOW OIL PRESSURE 1 Wom Bearings 1 Engine overhaul replace bearings 2 Relief valve malfunction 2 Overhaul oil pump 3 Clogged oil cooler 3 Repair 4 Diesel dilution of the oil 4 Injection pump repair Engines Generators 6 ENGINE PROBLEM PROBABLE CAUSE SMOKY EXHAUST coniWHITISH OR PURPLISH conid Worn valve stem and valve guide d Replace e Low engine oil viscosity e Replace r Excessive oil pressure r 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 2 Clear intake 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 ROD 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 Rebore 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 Worn delivery valve 2 Replace 3 Inadequate injection nozzle spray 3 Replace injection nozzle Generators 5 ENGINE PROBLEM PROBABLE CAUSE LOW OUTPUT 1 Low coolant level 1 Add coolant 2 Loose Vbelt 2 Adjust or replace Vbelt 3 Incorrect injection timing 3 Adjust injection timing 4 Low engine oillevel 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 Retighten bolts 4 Loose drain hose attachment 4 Retighten banjo bolt and secure 5 Loose oil pipe connector 5 Retighten oil connections 6 Broken rocker cover gasket 6 Replace gasket 7 Loose rocker cover attaching bolts 7 Retighten attaching bolts OIL LEVEL RISING 1 Dead cylinder 1 Check compression 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 Defective valve stem seal 1 Replace valve 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 EXHAUST 3 Moving parts nearly seized or excessively worn 3 Repair or replace 4 Poor compression 4 See LOW COMPRESSION HARD STARTING 5 Improper valve timing 5 Adjust 6 Improper valve clearance 6 Adjust INSUFFICIENT INTAKE AIR 1 Air intake obstructed 1 Remove obstruction NOZZLE TROUBLES 1 Seized nozzle 1 Replace 2 Worn nozzle 2 Replace IMPROPER FUEL Replace with proper fuel FUEL LEAKS Find fuel leaks SMOKY EXHAUST WHITISH OR PURPLISH 1 Excessive engine oil 1 Correct oil level 2 Excessive rise of oil into combustion chamber a Poor piston contact a Check b Seized piston ring b Replace or clean c Excessive clearance c Replace or correct Generators 4 Adjust injection Adjust injection Adjust injection software provided TABLE OF CONTENTS Introduction 2 Engine Torque Specifications 57 Engine Chart 3 Standard Hardware Torques 58 Testing for Overhaul 7 Generator Information 59 Engine I Generator Disassembly 8 Generator Control Panel SWitches 60 Engine Disassembly 9 Control Panel 61 Engine Inspection 14 BE Generator 62 Engine Assembly 24 Generator AC Voltage Connections 63 Exhaust ManifoldlHeat Exchanger 31 Voltage Regulator Adjustments 65 Fuel Injection Pump 32 Internal Wiring Schematics 66 Fuel Injection PumpFuellift pump 33 Internal Wiring Schematics 67 Fuel Injectors 34 BE 68 Fuel System 36 Electronic Governor 69 Glow Plugs 38 the Electronic Governor 70 Engine Adjustments 39 Shore Power Transfer Switch 71 Coolant Circulating Pump 41 BED Generator Wiring Schematic 72 Lubricating Oil Pump 42 Remote StartStop Panel Wiring Diagram 72 Oil Pressure 43 BED Generator Wiring Diagram 73 Starter Motor 45 BED Generator Wiring Diagram 74 Tachometer 49 BED Generator Wiring Schematic 75 Alternator Testing 50 Generator Specifications 76 Engine Wiring Diagram 52 Special Tools267 Generator 78 Engine Wiring Schematic 53 Metric Conversions 79 Engine Specifications 54 Index 80 Engine Standards and Limits 55 Engines Generators 1 When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information CODES AND REGULATIONS Strict federal regulations ABYC guidelines and safety codes must be complied with when installing engines and generators in a marine environment SIPHONBREAK For installations where the exhaust manifoldwater injected exhaust elbow is close to or will be below the vessels waterline provisions must be made to install a siphon255break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 20 above the vessels waterline Failure to use a siphonbreak when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and posswle flooding of the boat EXHAUST SYSTEM The exhaust hose must be certified for marine use The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of the vessels hull A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv engine with air intake before starting from gasoline SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully Most accidents are caused byfailure to follow fundamental rules and precau255tions Know when dangerous conditions exist and take the necessary precautions to protect yourself your and your machinery The following safety instructions are in compliance with the American Boat and Yacht Council ABYCstandards PREVENT ELECTRIC SHOCK A WARNING Do not touch AC electrical connections while engine is running or when connected to shore power Lethal voltage is present at these connections 225 Do not operate this machinery without electrical enclosures and covers in place 225 Shut off electrical power before accessing electrical equipment 225 Use insulated mats whenever working on electrical equipment 225 Make sure your clothing and skin are dry not damp particularly shoeswhen handling electrical equipment 225 Remove wristwatch and all jewelry when working on electrical equipment 225 Do not connect utility shore power to vessels AC circuits except through a shiptoshore double throw transfer switch Damage to vessels AC generator may result if this procedure is not followed 225 Electrical shock results from handling a charged capaci255tor Discharge capacitor by shorting terminals together PREVENT BURNS HOT ENGINE A WARNING Do not touch hot engine parts or exhaust system components A running engine gets very hot 225 Always check the engine coolant level at the coolant recovery tank A WARNING Steam can cause injury or death 225 In case of an engine overheat allow the engine to cool before touching the engine or checking the coolant PREVENT BURNS FIRE A WARNING Fire can cause injury or death 225 Prevent flash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters 225 Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death 225 Do not operate with the air removed Backfire can cause severe injury or death 225 Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the clean and free of debris to minimize the chances of fire Wipe up all spilled fuel and engine oil 225 Be aware diesel fuel will bum PREVENT BURNS EXPLOSION A WARNING Explosions from fuel vapors can cause injury or death 225 Follow refueling safety instructions Keep the vessels hatches closed when fueling Open and ventilate cabin after fueling Check below for fumesvapor before run255ning the blower Run the blower for four minutes before starting your engine 225 All fuel vapors are highly explosive Use extreme care when handling and storing fuels Store fuel in a area away from sparkproducing equipment and out of the reach of children 225 Do not fill the fuel tankswhile the engine is running 225 Shut off the fuel service valve at the engine when servicing the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other sources of fire near the fuel system or engine when servic255ing Ensure proper ventilation exists when servicing the fuel system 225 Do not alter or modify the fuel system 225 Be sure all fuel supplies have a positive shutoff valve 225 Be certain fuel line fittings are adequately tightened and free of leaks 225 Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment Engines Generators PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNING Exhaust gasses contain Carbon Monoxide an odorless and colorless gas Carbon Monoxide is poisonous and can cause and death Symptoms of Carbon Monoxide exposure can include Dizziness Nausea Headache Weakness and Sleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the unit and do not restart until it has been inspected and repaired I It Ii 1ft o q SERVICE MANUAL FOR THE 82B FOUR MARINE DIESEL ENGINE AND THE 25KW60Hz BED 20KW50Hz BED MARINE DIESEL GENERATORS SINGLE PHASE THREE PHASE PUBLICATION NO 040485 EDITION ONE NOVEMBER 1998 WESTERBEKE MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 Member NmioMl Marine Manufacture Associatwn 225 AdobeUCS

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