SERVICE MANUAL 44A-44B-44C-FOUR 35C-35D-35E-THREE MARINE DIESEL ENGINES 8.0KW - GOHz . 6.0KW - 50Hz BTDA 10.0KW-GOHz 7.5KW - 50Hz BTDA 11.5KW - GOHz 9.2KW - 50Hz BTD (elec) 12.5KW -G6OHz 9.4KW - 50Hz BTDB 12.6KW - 60Hz 10.4KW - 50Hz BTD (elec) 15.0KW - 60Hz 12.0KW - 50Hz BTDC ~ Single and Three Phase ~ MARINE DIESEL GENERATORS PUBLICATION NO.45100 REVISION 2 ‘APRIL 2010 . NESTERSeEKE CoMPoRATION ‘iva erantisy NOUGTAIAL PARK TA - ticaorre wmv.wesrencexe coCALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some are known to the Stats of Calfornia to cause cancer, birth defects, and other reproductive harm. A warnine: Exhaust gasses contain Catbon Monoxide, an odorless and colorless gas, Carbon Monoxide is polsonows and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can Include: Dizziness ‘Throbbing In Temples Nausea ‘¢Auscular Twitehing Headache Vomiting ‘* Weakness and Sleepiness» Inability to Think Coharontly {IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, ‘seek modtoal attention, Shut down the cult and do hot restart ‘unt It has heen Inspected and repaired. They ara inexpensive obtainable at your focal marine store,SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamencal rules and precau- tions. Knaw when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK AX WARNING: Bo n0t touch Ac electrical connections utile engine Is running, oF when connected to shore ‘ower Lethal vollag is present at these connections! Do not operate this machinery without electrical enclosures and covers in place. 'm Shut off electrical power before accessing electical equipment. ‘m Use insulated mats whenever working on electrical ‘equipment. ‘Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment. 1m Remove wristwatch and all jewelry when working on electrical equipment. 1m Do not connsct utility shore power to veséel’s AC circuits, except through a ship-to-shore double throw transfor switch. Damage to vessel's AC generator may result if this procedure is not followed. Electrical shock results from handling a charged capaci tor, Discharge capacitor by shorting tecminals together, PREVENT BURNS — HOT ENGINE AA WARKING: Do n0t touch hot engine parts oF exhaust system components. A runing engine gets very hot! 1m Always check the engine coolant level atthe coolant recovery tank AA WARNING: steam can cause injory or death! Incase of en engine overheat, allow the engine to cool before touching the engine or checking the coolant. PREVENT BURNS — FIRE AA WARING: Fire can cause ijary or destht wm Prevent lash fires. Do not smoke or permit flames or sparks to o2cur near the carburetor, fel Tne, filter, fuel pump, or other potential sources of spilled fue] or fuel ‘vapors, Use a suitable container to catch all fuel when removing the foel line, carburetor, or fuel filters. 1 Do not operate with a Coast Guar Approved flame sarester removed. Backfire can cause severe injury or death. = Do not operate withthe sir cleane/sitencer removed. Backfire can cause severe injury or death 1% Do not smoke or permit flames or sparks to oceur nest the fuel system. Keop the compartment andthe engine/generator lean and free of debis to minimize the chances of fire. Wipe up al spilled fuel and engine il Be aware — diesel fuel will burn, PREVENT BURNS — EXPLOSION AX WARNING: Exposions fom tue! vapors can cause injary or death! i Follow rofueling safety instructions. Keep the vessels hatches closed when fueling, Open and ventilate cabio aftr fueling, Check below for fumes/vapor before run- ning the blower. Run the blower forfour minutes before starting your engine. 1 All fue vapors ae highly explosive, Use exteme care ‘ven handling and storing fuels. Store fel in a wel-ven tated area away fom spk producing equipment and cout ofthe each of chien, Do not fil the fuel tanks) while the engine is runing. 1 Shutoff the fuel service valve a the engine when servicing the fuel sytem. Take care in cetching any fuel that might spi. DO NOT allow any smoking, open flames, cr other ‘ures of ire near the fuel system or engine when servc- ing. Ensure proper ventilation exists when servicing the fuel system. Do notalter or modify the fuel system, i Be sure all fuel supplies have a positive shutoff valve Be certain fut fine fitngs are adoqutey tightened and five of leaks. Wt Make suo a fire extinguisher is installed nearby and is propery maintained, Be fasiliar with its proper use. Extinguishers rated ABC by the NEPA are appropriate forall applications encountered inthis environment. |WESTERBEKE. CAR WESTERBEKESAFETY INSTRUCTIONS ACCIDENTAL STARTING ‘TOXIC EXHAUST GASES A WARNING: Accidente starting an cause Injory or death! 'm Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect ‘last ‘Make certain all personnel are clear of the engine before starting. 8 Make certain all covers, guards, and hatches are re- installed before starting the engine, BATTERY EXPLOSION AA WARNING: Battery oxplosin can cause injury or death! Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, & highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shutoff al electrical equipment in the vicinity to prevent electical arcing dur- ing servicing. Never connect the negative (~) battery cable othe pos sive (# conneetion termina! of the starter solenoid. Do sot test the battery condition by shorting te terminals together Sparks could ignite batery gases or fuel vapors. ‘Ventilate any compartment containing batteries to prevent sccumulation of explsive gases. To avoid sparks, donot dsb the battery charger connections while the batery is boing charged f= Avoid contacting the terminals with tool, et. to prevent tums or sparks that could cause an explosion, Remove wristwatch, rings, and any other jevelry before handing the battery. 1m Alvays tum th battery charger off before disconnecting the battery connections. Remove the negative lead fist ‘and reconnect it last when disconnecting the battery. BATTERY ACID AA WARKING: suturic acid in batteries ean cause severe injury or death! & When servicing the battery or checking the electrolyte level, wear rubber gloves, « rubber apron, and eye protec- tion. Batteries contain sulfuric acid which is destructive. fic comes in contact with your skin, wesh it off at once with water, Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps, AX WARNING: cordon monoxide (60) is a deadly gos! ‘Ensure thatthe exhaust system is adequate to expel gases ‘discharged from the engine, Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close attention to the manifold, water injection elbow, and ‘exhaust pipe nipple. Be sure the unit and its surroundings are well ventilated '& In addition to routine inspection of the exhaust system, install a carbon monoxide detector. Consult your boat builder or dealer for installation of approved detectors, 1m For additional information refer to ABYC 22 (educa- tional information on Carbon Monoxide). AA WARNING: carton monoxide (C0) 5 an inisible odorless gas. Inhalation produces flu-like symptoms, nausea or death! 1m Donot use copper tubing in diesel exhaust systems, Diesel fumes can rpidly destroy copper tubing in exhaust sys- tems, Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust/water leakage. 1m Do not install exhaust outlet where exhaust can be drawn through portholes, vets, or air conditioners. Ifthe engine exhaust discharge out is nea the waterline, water could center th exhaust discharge outlet and close or restrict the flow of exhaust. Avoid overloading the craft Although diesel engine exhmust gases are not as toxic as exhaust fumes from gasoline engines, carbon monoxide {ass present in diesel exhanst fumes, Some of the symp- toms or signs of eabon monoxide inhelation ot poisoning Vomiting ‘Muscular twiteting Dizziness Intense headache ‘Throbbing in temples Weakness and sleepiness AVOID MOVING PARTS AX WARNING: Rotating parts can cause injury or death! Do not service the engine while it is running. If asitua- tion arises in which it is absolutely necessary to make ‘operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components. CRESTS BENESAFETY INSTRUCTIONS Do not wear loose clothing or jewelry when servicing. equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracclets that could be caught in moving pats. Make sure all attaching hardware is property tightened. ‘Keep protective shields and guards in their respective places at all times. Do not check fluid levels or the drive belt's tension while tho engine is operating. Stay clear of the drive shaft andthe trensmission coupling. ‘when the engine is running; hair and clothing can easily be caught in these rotating pars. AA WARNING: High noise ieves can cause hearing Joss! w Never operate an engine without its muffier installed. ‘Do notrun an engine with the air intake (silencer) removed. 1m Do not run engines for long periods with their enclosures open. AA WARNING: D0 not work on wachinory when you are mentally or physically incapacitated by fatigue! OPERATORS MANUAL Many of the preceding safty tips and warnings are repeated in your Operators Mancal 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 ould begin with athor- cough examination ofthe American Boet and Yacht Counct’s (ABYC) standards, These standards are a combination of sources including the USCG and the NFPA. ‘Sestons of the ABYC standards of particular interes ae 112 Ventilation Pt Exhaust systems 4 Inboard engines 9 DC Electrical systoms All installations must comply with the Federal Code of, Regulations (FCR). ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC, NFPA and USCG publications {or safety codes and standards. Follow their recomamenda~ tions when installing your engine. ABYC (American Boat end Yacht Council) “Safety Standards for Small Craft” Order from: ABYC 3069 Solomon's Island Rd. Edgewater, MD 21037 [NEPA (National Fire Protection Association) “Fire Protection Standard for Motor Craft” Order from: NEPA 11 Tracy Drive ‘Avon Industrial Park ‘Avon, MA 02322 USCG (United States Coast Guard) “USCG 33CFRI83” Onder from: USS. Government Printing Office ‘Washington, D.C. 20404 Engines & GeneratorsINSTALLATION “When installing WESTERBEKE engines sitd generators itis important that strict tention be paid tothe following information: CODES AND REGULATIONS ‘Strict federal regulations, ABYC guidelines, and safety codes must be complied with ‘when installing engines and generator in 2 marine environment. ‘SIPHON-BREAK For installations where the exhaust manifold/water injected exhaust elbow is close to ‘or will be below the vessel's waterline, provisions must be made to install a siphon- break in the raw water supply hose to the exhaust clbow: This hose must be looped a minimum of 20” above the vessel's waterline. Failure to use a siphon-break when the exhaust manifold injection port is at or below the load waterline will result in ‘raw water damage to the engine and possible flooding of the boat, Ifyou have any doubt about the position of the water injected exhaust elbow relative to the vessel's waterline under the vesse!’s various operating conditions, install a siphon-break. NOTE: A siphon-break requires periodic inspection and cleaning 10 ensure proper ‘operation. Failure to property maintain a siphon-break can result in catastrophic ‘engine damage. Consult the siphon-break manufacturer for proper maintenance. AVAILABLE FROM "YOUR WeSTERDEKE EXHAUST SYSTEM DeMER ‘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 Marine installation Manual covering gasoline and diesel engines and generators is supplied with every unit sold. This manual fs also available in pat format on our website to download Website: www. westerbeke.com CESPWESTERBE % Generators WVTABLE OF CONTENTS Parts Identitication/Engines.. Parts kientification/Generators. Specifications - 44-Four Models. Introduction Specifications - 35-Three Models. Engine Troubleshooting. . . DG Electrical System (aerator) Testing for Overhaul. Mando Alternator Servic Engine Disassembly Wiring Diagram - Generators. Wiring Schematic - Engines. Specifications - Generators BT Generator Single/Three Phas 12 Stud Internal Wising Schematic ‘Component Resistance Values. Internal Wiring Schematic 6 Stud. BT Generator Troubleshooting Lee Bsa [AC Terminal Board (12 Stud). BB Internat Wiring (Three Phase BT Troubleshooting (Three Phase). BT Voltage Regulator Adjustments (Three Phase) Wiring Diagram - Generator (Electranis Governor) Wiring Schematic - Generator (Electronic Governor). Erectronic Governor (Optional Electronic Governor (Adjustments) Linear Actuator Troubleshooting ‘Special Tools - Generator . Standard Hardware. Matric Conversion Data Index, Drive Belt Adjustment. ‘Adjusting Idle Speed. Service Data-Standards and Limits.. Special Tools - Engines. Torque Specifications, Wiring Diagram - Engines. ]ESTERBEIEPARTS IDENTIFICATION/PROPULSION [COOLANT PRESSURE CAP ‘waven maecrED ‘EXHAUST EO ‘THERMOSTAT 2oncmcuiT BREAKER \WATER HEATER ‘CONNECTION REAR FRONT ‘SIDE OU. FILL FRONT ‘Dc ALTERNATOR. ‘wit LD. PLATEPARTS IDENTIFICATION/GENERATORSINTRODUCTION PRODUCT SOFTWARE Product software, (technical data, parts lists, manuals, ‘brochures and catalogs), provided fom sources other than WESTERBEKE are not within WESTERBERE’S contro, ‘WESTERBEKE CANNOT BE RESPONSIBLE FOR THE, CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMELINESS OR ‘COMPLETENESS THEREOF AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY {INCURRED IN CONNECTION WITH OR ARISING OUT (OF THE FURNISHING OR USE OF SUCH SOFTWARE. WESTERBEKE customers should keep in mind the time span between printings of WESTERBEKE, product sofware and the unavoidable existence of earlier WESTERBEKE product software. The product software provided with WESTERBEKE products, whether from WESTERBEKE or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product. Itnot only makes good sense bat is imperative that appropriate representatives of WESTERBEKE or the supplier in question be consulted to determine the accuracy ‘and curentness ofthe product software being consulted by ‘the customer. NOTES, CAUTIONS AND WARNINGS As this manual takes you through the operating procedures, ‘maintenance schedules, and troubleshooting of your marine ‘engine, critical information will be highlighted by NOTES, ‘CAUTIONS, and WARNINGS. An explanation follows: NOTE: An operating procedure essential 10 note. A CAUTION: Procedores which, itnotstrcty ‘bserved, can result athe damage or destruction of ‘your engine. AA WARNING: Procedures which, it not properly followed, can result in personal injury or loss of life. ‘ORDERING PARTS Whenever replacement parts are needed, always provide the engine model number and serial nurnber as they appear on the silver and black nameplate located on the manifold. You must provide us with tis information so we may properly identify your engine. In addition, include a complete part description and part umber for each part needed (see the separately furnished Parts List, Insist upon WESTERBEKE packaged parts because will fit or generic pants are frequently not made tothe same specifications as original equipment. Customer Identification Card CRS WESTERBEKE ‘Customer Hentifiction ‘MR. GENERATOR OWNER MAIN STREET HOMETOWN, USA ‘Model 11.5 EDT Expires: 8/5/2013, ‘Sex. #U0000-E811 ‘The WESTERBEKE engine serial number was an alphanumeric number that can assist one in determining the date of manufacture, A manufacturing date code is placed atthe end of the engine serial number. It consisted of a character followed by three numbers. Today it consists of two characters, Previous date code. The character indicated the decade E=2000s. The frst mumbec represented the year in the decade, and the second and thir, the month ofthat year, ‘Beginning in May 2008, the two characters HE. represented 2008 and the E the month of May and so on HF 2008 Fuly, HG 2008 July. ‘SERIAL NUMBER LOCATION ‘The engine's serial number can be found stamped into the engine block just above the injection purmp. An identification plate on the engine manifold also displays the engine model and serial number, “The generator serial number is stamped onthe Let side of the generator housing and on the flat surface above the rotary cariorbeaing-e NGI SERIAL ueéR ‘The following sections contain detailed information telating tothe proper operation characteristics of the major components and systems ofthe engine. Included are «disassembly, inspection and reassembly instructions for the ‘guidance of suitable equipped and staffed marine engine service and rebuilding facilities. The necessary procedures should be taken only by such facilities. ‘Additional detailed information and specifications are pro- vided in other sections of this manual, covering the generator, alternator, starter motor, engine adjustments, cooling pumps, efc. tore‘The following troubleshooting chart describes certain probloms relating to engine service, the probable causes of ENGINE TROUBLESHOOTING MOTE: The engine’s electrical sytem is protected by a 20- ‘ampere manual reset circuit breaker. The preheat solenoid is these problems, and the recommendations to overcome ‘mounted on the same bracket. these problems’This chart may be of assistance in determin- ing the need for an engine overhaul. PROBLEM ‘PROBABLE CAUSE ‘VERIFICATION REMEDY HARD STARTING ‘LOW CRANIAW SPEED 1, Engina of viscosity t00 tg. 41, Replace engine of wth ess viscous ait 2, Rundown battery, 2. Recharge bttory, 8. Wom batty 8, Roplace battery, 4, Batty terminal loosely connected, 4, Olean terminals and correct cables. 5, Defective start 5, Repl or roplace starter. 6, Defective main dive section. 6. Chak cut for dsengagerent DEFECTIVE INJECTION SYSTEM 1. A frapned infu! passage. 2, Clogged fuel Me 8. Low injection pressure 4 Inadequate pray 6. ination pump defvetng suflat ta, 6. Injection to ery. 1. Bleed ar rom fuel syste. 2, Clean ot replace fit. 8. Agus inti pressure. 4, lean or replace nazi. ', Repar or replace inaction pump. 6, Adjust inaction timing, MAIN ENGINE TROUBLES 1, Low compression. Incorrect va claranc, », Inadaquats contact of ve seat. ©, Valve str sia. 4, Broken valve sring. «8. Compression leas through cinder head gasket f. Piston rng sete. 1. Wor piston ing and cinder. 2. Burnt glow pug. 3, Fauly glow plug operation 4. Incorrect governor ver pesto. 2. Adjust vab clearance, Lap vale Replace vaive and vahe guide, 4. Replace valve sping. Replace gasket. 1. Replace piston ad piston rng 8. Overhaul engine. 2, Replace glow pug 8. Core lad wir coneeton. 4. Satlverto starting poston. ‘8 Contaminated tu! tark 8, Govemar spring out of POSITION Correct spring ‘Low OUTPUT LOW COMPRESSION See HARD STARTING INJECTION SYSTEM OUT OF ADJUSTINENT 4. Incorect injection timing. 4. Aust injection ining. 2, Insufcient injection. 2 Repair or replace Icon pump. 3. Low injetion pressure. 3. Check injection nazae and adjust pressure, INSUFFICIENT FUEL 4. Ar trapped in fuel system, 1. Chuck and retghtn connector. 2, Clogged titer. 2, Glean or repaes er 3, Clan tank, INSUFFICIENT INTAKE AIR 1, Clogged air ceane. 4. Clean or rope ar lene. (continued) ee 5ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE ‘VERIFICATIONREMEDY, LOW OUTPUT (eont,) | OVERHEATING 1. Low coolant val 41 Add eooiant 2, Loose V-belt 2. Adjust o opace V-belt. 3, Incorrect injection timing. 3, Adjust inztion timing 4, Low engine ol ove 8. Add engine ol EXCESSIVE Oil OIL LEAKAGE ‘CONSUMPTION 1. Defective ol seals. 1. Replace o seas 2, Broken gear case geet. 2, Replace gasket. 3. Loose gear case attaching bol. 2, Rotighten bots. 4, Loose drain plug. 4. Retighten plug. 5, Loose oll pipe connector. 8. Ratighten oll connections. ‘Brolen rocker cover gasket. 6, Replace gasket 7, Loose rocker cover attaching bols. 7. Retighten attaching bots OW LEVEL RisitiG 1. Wor piston ring. 1. Replace rng. 2. Worn piston or onder. 2, Replace piston and rebore,eyinder. ‘3. Incorrectly positioned psten ring gop. ‘3. Correct ing gap postions. 4, Displaced or twisted connecting rod. 4, Replace connecting red, ‘OWL LEVEL FALLING 4. Defective stom sel 1. Replace stom seal, 2, Worn valve and valve guide. 4, Replace a vahe and valve guide. EXCESSIVE FUEL ENGINE BODY TROUBLES ‘CONSUMPTION 1. Noisy rocking. 1. 808 KNOCKING. 2. Smoky exhaust. 2, Soe SMOKY EXHAUST. ‘8, Moving parts nealyselzed or excessively worn, |. Repair orrelane, 4, Poor compression. 4. See LOW COMPRESSION; HARD STARTING. 8, Improper vale ining 5, Adjust. 8, Improper valve clearance. 8, Adjust, INSUFFICIENT INTAKE AIR 1. Aira obstructed. 4, Remove obstruction. NOZZLE TROUBLES 1. Seized noze. 1. Replace. 2. Worn nozle, 2, Replace, IMPROPER FUEL Replace with proper ful FUEL LEAKS. Find fuel eas. ‘SMOKY EXHAUST ‘WHITISH OR PURPLISH 1. Excessive engine ol. 4. Correct olive. 2, Excessive ise of ol into combustion chamber. «a. Poor piston contact a, Check b. Setzad piston ring. b, Replace ocean, «. Excessive pston-o-cyinder clearance. 6, Replace or correct (continued) j pester ‘Generators 6ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION AEMEDY ‘SMOKY EXHAUST (cant,) | WHITISH OR PURPLISH (con) «Worn valve stem and valve guide. 4. Replace. 2, Low engine ol visoosty. , Replana, 1, Brcassive ol pressure. t. Correct. 8. Injcton timing is too tat 3. Adjust. 4. Insufficient compression. 4 See LOW COMPRESSION; HARD STARTING. BLACKISH OR DARK GRAYISH 4. Engine body troubles. oor compression. «8. See LOW COMPRESSION HARD STARTING. Improper valve cerance. . Adust, 2, Insufficient intake air (ar leaner logged). 2, Clean ar cleaner. 8. Improper fue 3, Roplace with proper ue ABNORMAL SOUND (CRANKSHAFT AND MAIN BEARING (OR NOISE 4. Badly worn bearing. 4. Roplac bearing and grind crankshatt. 2. Badly wor crankshaft 2. Grind rankshatt. 3. Maited bearing. ‘3. Replace bearing and check iubrcation system. ‘CONNECTING ROD AND CONNECTING ROD BEARING 1. Worn connecting rd big end bearing, 1, Replace bearing. 2. Worn cranipin. 2, Grind erankshat. 3, Bent connecting rod. ‘8. Correct bend or replace. PISTON, PISTON PIN, AND PISTON FING 4. Wom eying. 1, Reto cylinder to oversize and replace piston, 2, Wom piston pin, 2. Replace piston 3, Piston seed. 3, Replace piston and reborecynder 4, Pston selzed and ring worn or damaged. 4 Replace piston and rings. ‘VALVE MECHANISM 1. Worn camshatt 4. Replace, 2, Excessive valve clearance. 2. Adjust. | 8, Worn timing gear 3, Replace. 4, Worn fan pulley beating. 4 Replace. ROUGH OPERATION INJECTION PUMP SYSTEM 1. Uneven injection, 1. Adjust inotion or replace parts. 2. Control rack mattunctioning. 3, Wor dalvery valve, 4. Inadequate injection naz spay. 2, Disassemble, check and correct injection pur. ‘3 Replace, 4, Replace injetion nazz. (GOVERNING SYSTEM 4. Governor lever mafunctioning. 2, Fatigued goveinor spring, 1. Check governor shaft and caret operation. 2, Replace. (continued) ‘Engines & GeneratorsENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE ‘VERIFICATION/REMEDY. wovocKINe ENGINE KNOCKS WITHOUT MUCH SMOKE 4, Main engine troubles. 8. Overhaated cylinder. ‘a, See OVERHEATING; LOW OUTPUT. ', Garbon deposits in cylinder. 1. Glan, 2, Too early ition timing. 2. Correct 8. Too high injection pressure. 3, Correct. 4, Improper ful 4, Replace with proper fuel KNOCKING WITH DARK SMOKE 1. Poor compression, 1. See LOW COMPRESSION; HARD STARTING. 2, Injcton pump matfunetioning. 2. AdjustRapair 8, Improper nozzle ‘8, Poor spray. ‘a. Clean or replace nozzle, Poor chattering. bs, Repair ar replace nazi. «. Afterinjection crip. «. Repair or replace naz. 4. Nozale needle vaive seizd, 4, Ropate, INTERMITTENT. 1. Fuel iter logged. 4. Clean or replane. [EXHAUST SOUND 2. Fuel pipe sucks ait 2, Raightan pipe Joints or replace pip. 8 Wator moc in fuel 3. Replae fel. ‘OVERHEATING 4. Vel slackening or slippery with o. 1, Adis, replaos or clean. 2. Damaged water pump. 2, Replace. 8. Lack of coolant. 3. Add, 4, Low ol vel or poor ol quay. 4, Add or change. 5. Knocking, 5, See KNOCKING. 6. Moving parts sized or damaged. 6. Replace, 7. Defective thermostat 7. Replaco, LOW OIL PRESSURE —] 1. Wom Bearings. 1. Engine ovealreplace bearings. 2, Ralf valve malluncton 2, Overhaul ol pump. 3. Clogged ol coor. 8, Repalt. 4, Diesel tution ofthe ol 4, Injection pump repair. WESTERBENETESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD ‘Cause of Low Compression Generally, the time at which an engine should be overhauled {s determined by various conditions such as lowered engine power output, decreased compression pressure, and increased fuel and oil consurmption. The lowered engine power output isnot necessarily due to touble with the engine itself, but is sometimes cansed by injector nozzle wear or injection pamp ‘wear. The decrease in compression pressure is caused by many factors. Its, therefore, nezessary to determine a cause ‘or causes on the bass of data produced by petioic {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 cour 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 injec- ‘ion timing, and wear of the injectors. They are cansed also by defective electrical devices such asthe battery, altemator, starter and glow plugs. Therefore it is desirable to judge the ‘optimum engine overheul time by the lowered compression pressure caused by worn eylinders and pistons plus increased ‘il 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 pars ofthe engine are operating properly, To determine the period of engine overhaul, {important to measure the engine compression pressure regu larly. At the same time, the engine speed at which the mea- surement of compression pressure is made should be checked because the compression pressure varies with engine rpm. ‘The engine rpm can be measured atthe front end of the cranks, NOTE: To test engine compression see the ENGINE ADJUSTMENT section ofthis manual. ASSEMBLY 41, Wash all parts, except for oll seals, O-rings, rubber sheets, te, with cleaning solvent and dry them with pressure ait. 2 Always use tools that are in good condition and be sure ‘you understand how to use them before performing any job, 3. Use only good quality ubricants. Be sure to apply a coat of oil, grease or sealant to parts as specified.. 4, Be sure to use a torque wrench to tighten parts for which torques are specified. S. Ant time the engine is assembled, new gaskets and O-rings must be installed. OVERHAUL CONDITIONS Compression pressure tends to increase a litte in a new cngine until piston rings and valve seats have been broken in. ‘Thereafter, it decreases gradusly withthe progress of wear ofthese pats. ‘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, end compression values are at minimum or below. Engine compression should be 30 ke/on?, 427 psi at 290 rpm, The maximum difference between cylinders must not exceed 10%. DISASSEMBLY ‘Before disassembly and cleaning, carfilly check for defects which cannot be found after disassembly and leaning. 2. Drain water, fuel and oil before disassembly. ‘Clean or wash the engin exterior Do not remove or disassemble the prs that require no disassembly. Perform disassembly in a proper order using proper tools Keep disassembled parts in order Apoly oil when neces- sary, Take special care to keep the fuel system parts from intrusion of dust and dirt 6, arts must be restored otheirrespectve components fam, ‘which they were removed at disassembly. This means ta all arts must beset aside separately in groups, each marked for ‘is component, so thatthe same combination or set ean be reproduced at assembly. 7, Pay stention to marks on assemblies, components and pars for their positions or directions. Put on mars, if necessary, i aid assembly. (Carefully check each pat or component fore any sign of faulty condition during removal orclaaing. The part will tell You how it ated or what was abnocnal about it more scourtely during removal or cleaning. ALTERNATOR INSPECTION ‘When rebuilding the engine, the altemator should be cleaned and inspected. The housing can be wiped off with a solvent and the alternator terminal 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. ‘Tum 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, For additional information on alternators refer to the ALTERNATOR TROUBLESHOOTING and MANDO ‘SERVICE in this manual. |WESTERBEKE CR MESTEREEIEENGINE DISASSEMBLY GENERATOR Disconnect the AC wiring and unplug the engine’s DC wiring harness at the generator control panel. Remove the battery cables from the engine and tape over the terminals. NOTE: Label any lines, hoses or cables as you separate therm, ‘Separate the exhaust hose at the water injected elbow and disconnect the fuel supply and retum lines, Drain the engine oil and the coolant from the engine. (Carefully support and then unbolt the generator backend from the engine. See SPECTAL TOOLS in this manual. Additional generator information will be found in the GENERATOR section of this manual. PROPULSION ENGINE ‘Switch off the batteries and disconnect the battery cables. from the engine and tape over the terminals. Drain or pump out all the engine oil and drain the coolant from the engine and engine hoses. ‘Unplug the instrument panel wiring harness. Drain the transmission fluid and the transmission oil cooler hoses, Detach the ojl cooler hoses and unbolt the transmission from the engine. NOTE: Label any lines, hoses or cables ds you separate them. sock. Coolant DRAIN PLUG. NOTE: A coolant fase may ben is ‘oss inv one pl mare the bas. TRANSMISSION 1 the transmission is not being rebuilt shoul be visually inspected. Flush out and pressure test the ofl cooler and replace the coolant hoses. Inspect and lubricate the gearshift linkage andthe propeller shaft coupling. Clean and repaint the transmission and change the transmission fluid Por transmission service end maintenance refer to your teansmission manual. To rebuild a transmission contact you WESTERBERE dealer or an authorized transmission service center ENGINE DISASSEMBLY ‘Take the following precautions 1M Clean the exterior of the engine of any deposits of dirt and oil. Be careful not to damage the disassembled parts. im Arrange parts inthe order of disassembly. Mark or Tabel parts as needed to insure proper mating and reassembly. Keep parts clean, 1M Mount the engine on a suitable engine stand for disassembly. ‘With the transmission separated from the engine, begin the fellowing step by step procedure to disassemble the engin. 1.Remove the transmission damper plate from the engine flywheel 2.Remove the engine ol cooler and ol hoses. Note oil hose connections from the oil cooler to the engine. '3.Remove the engine heat exchanger If possible, leave ‘ono end ofeach hose connected tothe part being removed 4,Remove the bell housing and the circuit breaker! proheat solenoid mounting bracket. 5. Remove the engine back plate. 6, Remove the start motor, drive belt and the alternator. Label the wires anc cables 7. Remove the engine mounted raw water pump, complete with its adapter mounting plate. See RAW WATER PUMP for parts breakdown. 8. With the hoses disconnected, remove the thermostat ‘housing and housing gasket, leaving the emperatare sender in place. 9. Remove the coolant cireulating pump. Refer to COOLANT CIRCULATING PUMP ASSEMBLY. 10.Remove the air intake slencer and the intake manifold. 4.Remove the ofl iter and the mounting bracket from the ‘engine block. 12.Unbolt the elbows and remove the exhaust manifold in its entirety. 1Remove the fue injection pump. Disconnect the fuel injection pipes and fuel leak-off pipe from the fuel injection pump and nozzes. NOTE: Put plugs or caps on the openings of the injection pump and nozzle connectors. Gol tees work well as plugs. 14zRemove the fuel injection nozzle. Loosen the ful injection nozzes with a wrench, Remove the nozzles and sgaskets from the cylinder head. NOTE: Remove the gaskets from the cylinder head with a gasket scraper. Discard the gaskets. WESTERBEKE ‘Engines & Generators 10ENGINE DISASSEMBLY 15, Remove governor assembly. 1. Remove the tie rod cover. 'b Remove the spring from the tie rod with pliers 10 disconnect the te Tod from the fuel injection pump. «¢. Remove the governor assembly. 16. Remove governor weight. a. Remove the sliding sleeve. 1b. Remove the sliding sleeve shaft and governor weights. 17, Fuel injection pomp removal. ‘a, Remove the tie rod cover. 'b, Remove the spring from the tie rod with pliers to disconnect the tie rod from the fuel injection pump. 418, Remove the fuel injection pump. NOTE: Keep a record ofthe thickness ofthe shims for installation. 19, Remove the presure elie valve frm the elinder block. 20, Remove the rocker shaft assembly. . 1, Remove the bolts that hold the rocker stays in position ‘and remove the rocker shaft assembly. bb, Remove the valve caps. 21, Disassemble the rocker shaft assembly. Put identifica- tion on each rocker arm as to its location on the rocker shaft. 22, Remove the eylinder head bolt. Loosen the cylinder ‘head bolts in two or thee steps inthe sequence shown, NOTE: If any parts on the eylinder head are faulty, check the cylinder head bolts for tightness with a torque wrench before loosening them. FRONT ‘CYLINDER " f ‘CYLINDER HEAD BOLT LOOSENING 23, Remove the cylinder head assembly. Lift the cylinder ‘ead straight up with a hoist. NOTE: If the gasket is seized and the cylinder head cannot be separated from the cylinder black, tap around the thick side portion of the cylinder head with a plastic hammer. sae Cezjwesrenpexe. Engines & GeneratorsENGINE DISASSEMBLY ‘VALVE SPRING 24, Remove the valve and valve spring, ‘a Compress the valve spring with a valve lifter and remove the valve lock. 'b, Remove the retainer, spring and vale. NOTE: The valves, retainers, springs and valve locks must be set aside separately in groups, each tagged for ojlinder munber for correct installation. 25, Remove the valve stem seals with pliers. NOTE: Do not reuse the valve stem seals. 26, Remove the flywheel. a, Haye someone hold the crankshaft pulley wi ‘wrench to prevent the flywheel from rotaing, 1b. Remove one of the bolts that hold the flywheel in position. Install a safety bar (M12 x 1.25) into the threadod hole in the flywheel from which the bolt was removed. Remove the remaining bolts Hold the flywheel by hand and withdraw it from the ‘crankshaft. Joggling the flywheel back and forth will litte removal. ORDER OF DISASSEMBLY 27. Remove the rear plate-The rear plate is doweled in position. Pull the plate as straight as possible when removing it 28, Remove the oll seal case. Remove the bots that hold the oll seal case in position. Remove the case from the cylinder block with 2 screwdrive:. AX CAUTION: Do not cause damage tothe oi! sea, 29, Remove the tappet, Remove the tappets from the ‘eylinder block with a valve push rod. NOTE: The tappets will fll ito the ol pan ifthe camshaft is removed before the tappets are remaved. REMOVING THE ©, (CRANKSHAFT PULLEY y S54 ge OW, SAFETY BARS 30, Remove the crankshaft pales. a Tall two safety brs (M2 x 1.25) into the threaded holes in the rear end ofthe crankshaft, Put a bar between the safety bars to old the crankshaft to prevent i from rotating. bb, Remove the crankshaft pulley. AA WARNING: inhen removing the crankshatt ‘pulley, be prepared to stop the Job in case the bar ‘slips off the crankshaft to prevent injury. (OF CRANKSHAFTENGINE DISASSEMBLY TIMING GEARS ORDER OF DISASSEMBLY 12 Fuel mueeniow PUMP CAMSHAFT GEAR ‘Qimter GEAR “7 TIMING GEAR CASE Ceyjwesr G eee 13ENGINE DISASSEMBLY 31. Remove the timing gear case, Remove the bolts that ‘hold the timing gear casein position and remove the case. AR WARNING: the trontpiato is botted inside the timing gear case. Do not attempt to remove this late along with the timing gear case by tapping. 32. Timing gear backlash measurement. Measure the back- lash of each gear and keep a record for correct measure- rent. Reolace the gears ifthe backdash exceeds the limit —F NN Ser ‘TIM GEA BACILASH (CRANKSHAFT GEAR AND YOLER GEAR. DLER GEAR AND ‘CARISHAFT GEAR - IDLER ‘GEAR AUD FUEL NECTION PUMP CANSHAFT GEAR CAMSHAFT GEAR/-.0. GEAR wt Boitain (030mm) o.rt8 in (6.30) a.tt8in ) 9. «0.0078 0 or m) FUEL INJECTION PUIKP CAMSHAFT 0.0028 - 0.0079 In GEAR AND OIL PUMP GEAR (0.7-0.20mm) (0. 33, Remove the idler gear: To remove the idler gear, rotate the gear in direction ofthe helix of the teeth to pull it ‘out of mesh. 34, Remove the camshaft. a Remove the bolts that hold the thrust plate. », Pull the camshaft out ofthe eylinder block, AX CAUTION: Do not cause damage tothe lobes ‘or bearing Journals when removing the camshaft 38. Remove the fuel injection pump camshaft, 1a, Remove the stopper bolt, ', Tap tho rear end of the camshaft with a copper bar to ‘push it out ofthe front side ofthe cylinder block. 36, Remove the gear ( when required). To remove the ~ gears from the camshaft and fuel injection pump camshaft, use an arbor press. 37. Remove the oil pump. Remove the bolts that hold the oi pur tothe cylinder block and remove the pump. 38, Remove the front plate, Remove four bolts that hold the font plate in position. Tap the plate ighcly with aplastic Jammer to seperate tho aoske, 39. Remove the oil pan. 1. Tur the engine upside down, .Tap the boitom comers ofthe oit pan with a plastic Thane to remove the oft pan AX CAUTION: Do not attempt to pry off the ot ‘pan by inserting a screwdriver or 2 chisel between the olf pan and the cylinder block. Damage to the oll pan can be the result. 40, Remove the oil screen. Loosen the nut that holds the oil ‘screen in position and remove the screen. 7 ORDER OF DISASSEMBLY 8. 16: 9. 1" ~ 4 3 $ 1 eeeENGINE DISASSEMBLY 41. Thrust clearance measurement for connecting rod big ‘end, Install the connecting rod to its crankpin and tighten the cap nuts to the specified torque. Measure the thrust clearance wih afeler gauge. Ifthe clearance exceeds the limit, replace the connecting rod THRUST CLEARANCE ‘STANDARD: 0.990.088 in(0.10-0:26mm) UT: 0.9187 (som) MEASURING THRUST CLEARANCE FOR CONNECTING ROD BiG END 42. Remove the connecting rod eap. a, Lay the cylinder block on its side, 1b. Pur identification on each connecting rod and cap ‘combination as to its Tocation in the engine. ce Remove the caps. 43, Remove the piston. ‘a. Tar the crankshaft until the piston is at top center. 'b Pash the pistcin and connecting rod away from the crankshaft with the handle of a hammer uatl the piston rings are above the cylinder. Remove the piston ‘and connecting rod, Repeat steps a and b for the removal of the other pistons. 44, Measuring the crankshaft end play. Seta dial indicator so that it will touch the end of the crankshaft and measure the end play. Ifthe end play exceeds the limit, replace the flanged bearing. ‘CRANKSHAFT END PLAY STARDARD: 0.00197 - 0.00688 in (850-017) Ua: 0401969 1n( 00 mm) 45. Remove the main bearing exp. a. Lay the cylinder block with its bottom (il pan) sido up. b, Remove the bolts that hold the main bearing caps in position. Remove the caps c. Remove he front and rear bearing caps with a sliding tammer 46. Remove the crankshaft. AX CAUTION: bo not causo damage to the bearings. MOTE: Pur identification on each main bearing as 10 its Location in the engine ES 447. Separate the piston from the connecting rod. 2. Use Piston Pin Setting Too! to separate te piston from the connecting rod. ‘Insert the push rod of the tot into the bore in the piston for the piston pin and, using an arbor press, remove the piston pia, ¢. Also use the Piston Pin Setting Teo! to install he ‘connecting rod to the piston. AX CAUTION: 20 not attempt to remove the ‘piston pin by tapping. Replace any piston pin which ‘requires a greater force for removal. ARROW, PISTON. aa 15INSPECTION CYLINDER HEAD AND VALVE MECHANISM 1. Cylinder head. Using a heavy ecourate straight edge and afecler gauge, check the bottom face for warpage in three cHEoK positions, lengthwise, two crosswise and two wiithwise a3 THREADS shown inthe illustration. If warpage exceeds the limit, reface the bottom face with a surface grinder. \WARPAGE - CYLINDER HEAD BOTTOM FACE ‘STANDARD 0.0020 in (0.0Sram) sUAKINUIA usr ‘.gosaie (010mm) CHECK ON. HOLES FOR CLOSING Rocker arms and rocker shaft. Measure the bore in the rocker arm for the rocker shaft and the diameter of the rocker shaft to find the clearance between the arm and the shaft, If the clearance has reached the limit, replace the rocker arm. If it exceeds the limit, eplace both arm and. shaft. BORE IN ROCKER ARM FOR SHAFT ‘STANDARD 0.74449 0.74527 in (1,810 18,830) DIAMETER OF SHAFT FOR ARM ‘STANDARD 0.74331 - 0.74401 in (18.280 -18.898mm) ‘CLEARANCE BETWEEN ROCKER ARM AND SHAFT SPECT FOR CRAOKS, Ol ‘STANDARD 0.00047 - 0.00187 in (0.012 - 0.050mm) ‘OR COOLANT LEAKS. CLEAN sir .00787 (0.200mm) g ‘OFF SCALE ANID CARBOH 9 INSPECT AND on TEST SPRING -OHECK FOR GALLING “AND WEAR INSPECT FOR RIDGES (OF DAMAGE twsnecr fo WEAR ANC conmacT (MEASURING ARMS ‘AND ROGKER SHAFT ‘CHECK ENDS FOR WEAR “INSPECT FOR BEND ‘AND DAMAGEINSPECTION 3. Valve springs, Check the squareness and free length. If the aquareness andor fre length exceeds the limit, replace the spring. VALE Senin Fe Lena SIAMDAND 1.85 97am) in intienm} spn sauanEness : 'STRIOARD 9° MANAUS SPRING TEST FORCE - LENGTH UNDER TET FORCE (Sts G2) SiOMD "hos 21508 wat 15% (MEASURIG DIRECTIONS. CHECKING VALVE STEM WEAR 5, Valves, valve guides and valve seats. ‘a, Measure the diameter of the valve stem as shown in the illustration. Ifthe stem is wom beyond the limit, or itis abnormally worn, replace the valve. YALE STEM DIAMETER (NORMAL SIZE 0.280 in (6.6num) WLET AND EXHAUST) LET VALVE: STANDARD 0.25846 - 0.25005 in (6.566 -6.580mm) ‘LirT 0.25581 in (6.S00mm) EAHAUST: STANDARD 0.25709. 0.28767 In (6.590 -6.550mm) Luni 0.25594 (6.600mm) 7 \VALVE SPRING ( TESTER (MEASURING 1.0. OF Pressing” THE VALVE GUIDE 4, Valve push rods. Using V-blocks and a dial indicator, Hee tarot a tand cecads thant enlace te. The valve guide wears more rapidly atts both ends than any other parts. Measure the bore inthe guide for posh rod. oe the stom at its ends with an inside micrometer caliper bart mr tea at aaa to find the clearance between the stem and guide, Ifthe clearance exceeds the limit, replace the guide or valve ‘whichever is badly worn, ‘CLEARANCE BETWEEN THE VALVE STEM AND VALVE GUIDE INSPECTING THE MET VALVE: AHOARD Ud -.428 1 (0.20.05) ‘BEND OF THE PUSH (e.A0eF) ROD [nMUSTYYE MONRO 1020-0 (0.08.48) eur 080i (16m) q Hi ( \ IWESTERBEKE ‘Engines & GeneratorsINSPECTION in (i0=05 mm) aaaeey HEIGHT TO THE TOP OF THE VALVE NORMAL SIZE 0.39 in (10mm) «. Valve guide replacement. (1) Remove the guide from the cylinder head by poshing it with a tool and an arbor press from the bottom side ofthe head. (2) Install a new guide into the cylinder head by ‘pushing it with an erbor press from the upperside of the head unt the specified height tothe top of the guide is obtained. (G) Insert a new valve into the guide and make sure the valve slides in the guide freely. (6 After the valve guide has been replaced, check the valve contact with its seat. (6) Puta small amount of Prussian blue or read lead on the valve face. Hold the valve with a valve lapping tool (commercially available) and press it against the seat to check its contact ‘LAPPING THE VALVE IN THE SEAT t e ee2. oS rh ‘oF ew erse ¢ (© The width of contact must be uniform all the way around both seat and valve. If the contact is bad, reface the valve and seat. (7) Ifthe valve margin (valve lip thickness) exceeds the Timit, replace the valve. VALVE MARGIN (LIP) THICKNESS SURUDARD 0.03910 (1.0mm) tna 0.020 in (0.6mm) (8) I the valve sinkago (the dimension from the top of ‘closed valve to the face of cylinder head) ‘exceeds the limit, recondition the valve seat or replace the cylinder head assembly. ‘VALVE SRKARE STANDARD 0.020 = 0.00081 (0.5 +: 0.25mm) is 0.059 in (1.5mm) ‘aPPING ‘coMPouND 000 BAD CONTACT MUST BE UNIFORM ‘AROUND THE COMPLETE, CIRCUMIFERENCE ‘VALUE AND VALVE SEAT CONTACT = Ss — VaWE. ‘ VALVE SIAC ‘MARGIN 6. Valve refacing. a. Sot the vale eficer at an angle of 45° and grind the valve ‘The valve margin most not be tess than the limit. Lf the ‘margin seems tobe less than the limit when the valve isrefaced, replace the valve. 7, Valve seat refacing, a, Before reftcing the valve sea, check the clearance between the valve and guide, and replace the guide if necessary. b.Cuvthe valve seat with a valve seat cuter (commercially availabe), or grind it with a valve seat grinder, and finish the width of valve seat and the angle ‘of seat face tothe comect valves. AUGLE OF SEAT FACE: STANDARD 48" |WOTH OF VALVE SEAT ‘STANOARD 0,081 -0.071 n (1.8 -1.8mm) UNIT 6.098 in (Sem) TUESTERBENE 18. After refacing the valve seat, put lapping compound on the valve face and lap the valve in the valve seat. 8, Valve lapping, Be sure to lap the valves in the seats after refacing oF replacing the valves or valve seats. ‘a Put a small amount of lapping compound on the valve seal, ea ye 0.051 - 0.071 IN {1.8 - 1.86) aS NOTE: Do not put lapping compound on the valve stem. Use a lapping compound of 120 10 150 mesh for intial lapping and a compound of finer than 200 mesh for finish lapping. ‘Mixing the compound with a smal amount of engine oil will, ‘help put the compound an the vaive face uniformly. 1. Using a lapping tool, bold the valve against the seat and rotate it only a part of a tur, then raise the valve off its ‘seat, rotating it to a new position. ress the valve ‘against the seal for another part of a turn. Repeat this operation uni the compound wears and loses is cutting property. «. Wash the valve and valve seat with dry cleaning solvent. 4. Apply engine oll tothe valve and lap it in the seat ©, Check the valve face for contact. INSPECTION COMBUSTION JET ‘9. Combustion jet replacement. Replace the combustion jets only when they are cracked or defective. ‘To remove the jet, insert a 6mm (0:2Sin) diameter ‘round bar tarough the bore in the cylinder head for the ‘glow plug and tap around the jet. ‘. To install a new jet, put the jet in position in the head. ‘with its tangentil orifice in alignment with the center of the main chamber and tap it with a plastic hammer. ‘COMBUSTION JT, 8 a9)ENGINE INSPECTION TIMING GEARS AND FLYWHEEL - INSPECTION POINTS ‘oasKer REPLACE, JWECTION PUUP CAMSHAFT BEARING (GHECICFOR woIsE (sPHING) AND WEAR SHAFT ‘CHECK FOR BEXD OR DAMAGE TO THE LOBES rma gan case INSPECT FOR CRACKS/DISTORTION Ly | crmuswarr pouty = ISPEGT BELT GROOVE FOR WEAR OL SEAL INSPECT FOR DAMABEGING WEE, Gyeax cowTAcT Face FoR scoRING ew On mses oveokceanrononiace——__ : oi etre —3 ey WESTERBEKE Engines & Genoratore 20INSPECTION 10. Camshaft 1. Messure the diameter ofthe journal and the bore in the ‘hashing for the shaft to find the clearance as shown in the illustration. Ifthe clearance exceeds the limit, replace the bushing. (CLEARANCE BETWEEN TE CAMSHAFT JOURRAL AND BUSHING ‘STANDARD 0.0069 In (016mm) ‘MEASURING THE CAMSHAFT SSOURMAL ’, Use Camshaft Bushing Installer special tool) for camsha bushing replacement. (1) Remove the ofl pan. Using a “remover” end of the cylinder, push out the bushing int the eylinder block, Crush’and take out the bushing from the block, FRONT OF ‘CAMSHAFT CYUNDE BUSHING = BLOCK CamsHaeT INSTALLER. BUSHING REMOVING CAMSHAFT BUSHING. (@) Install a new bushing in position with its oif holes in aligament with those of the oi gallery, NoTcH iH BUSHING (@ Measure the lobe height and base circle as shown {in the illustration, Subtract the base circle from the lobe beight to find the lobe lift. Ifthe lobe lift exceeds the limit, replace the camshafl. LOBE HEIGHT OF CAMSHAFT ‘STANDARD » 1.4063 in (98.72) Lim 1.886810 (34-72mm) easunins econ — AY (MEASURING THE ‘LOBE HEIGHT OF | | THE CAMSHAFT 111, Fue injection pump camshaft. Measure the lobe height ‘and base circle as shown in the illustration. Subtract the. ‘base circle from the lobe height to find the lobe lift: IF the lobe lift exceeds the limit, replace the camshaft ‘LOBE HEIGHT OF FUEL MWJECTION PUMP CAMSHAFT ‘STANDARD 1.73 in (mm) ul unr | 1.6910 (43mm) LOBE HEIGHT OF THE FUEL INJECTION PUMP ui MEASURING DinEcTION ¥ 12. Tappets. 1. Check the cam contact face of each tappet for abnormal ‘wear. Replace the tappet ifthe face is defective, 'b. Measure the diameter of the tappet andthe bore in the ‘oylinder block for the tappet to find the clearance. If the cloarance exceeds the limit, replace the tappet, (CLEARANCE BETWEEN THE TAPPET AIUD THE CYLINDER BLOCK ‘STANDARD 0.0059 (0.tSmm) GO 000 BAD BAD (CAM CONTACT FACE OF THE TAPPET oa 21INSPECTION 13. Idler gear. ‘a. Measure the bore in the idler gear forthe sbaft and the diameter of the shalt to find the clearance. Ifthe Clearance exceeds the limit, replace the gear or shaft whichever is badly wor, ‘CLEARANCE BETWEEN THE IDLER GEAR AND THE SHAFT ‘STANDARD 0.0012. 0.0028 in (0.03 -6.07mm) unr 0.0079 in (020mm) Install a now idler sbaft to the cylinder block so that its dimension from the face of the block is 1.030.020 in (26540.5mm). [DIMENSION OF THE IDLER SHAFT FROM ‘THE BLOCK FACE 14, Flywheel and ring gear ‘a Put the flywheel on the surface plate. Seta dial indicator at one side of te frition (clutch contact) face ‘and move it over tothe opposite side of the face as shown in the Mustration to find flatness. If fatness ‘exoceds the limit, grind the face. FLATWESS OF THE FLYWHEEL, ‘STANDARD 0.0069 in (018mm) MAXIMUM AiMrT 0197 (0.500m} (MEASURING FLYWHEEL FLATHESS 'b. Check the ring gear and replace it if its teeth are ‘abnormally worn oc chipped. (1) Removal : Heat the rng gear evenly with an acetylene torch, “Tp the sing gear all the way around with a bar and ‘a hammer as shown in the illustration to remove it ‘rom the fywhee (2) Installation leat a new sing upto a temperature of 302°F (150°C) with a piston heater and instal it to the flywheel with ts unchamfered side foremost 15, Pistons, piston rings and piston pins. ‘& Measure the diameter ofthe piston atts skirt in a direction transverse tothe piston pin with a micrometee as shown in th illustration. Ifthe diameter exceeds the limit, replace the piston. Selecta now piston so thatthe difference between average weight ofall piston in one engine does not exceed the standard. DIAMETER OF PISTON STANOARD ut ‘STANDARD (NOMINAL STE 3.0681- 2.060010 3.06210 4.8 in (8.850) (7rs8-7786em) (77-60) versie 072810 1.0088 in 2.2mm) e.ssmm ((OMIMAL Siz 3.088712 jazsmm) versie 3.e27in {rien m0) {7a.36mm) (OMIA Size 8.08050 mason) ‘MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN AVERAGE WEIGHT OF ‘ALL PISTONS IN ONE ENGINE, (az) STANDARD 0.4810 (6mm) @ easuntNe DIRECTION 'b. Measure the cleerance between the groove and piston with a straight edge and a feeler gauge. If the clearance ‘exceeds the limit, replace the ring. ‘COMPRESSION RING CLEARANCE STANDARD uum 0.1 COMPRESSION .0024~0.0088 in 0.611810 ig (.08-0.107m) (0.30019) 0.2 COMPRESSION ‘8.0878 in iis (020mm) mL RING 0.0012 - 0.0028 ia 0.0079 in (0.08-0.6tmm) (0-200) «¢. I the clearance sill exceeds the limit after new piston, tings havo been installed, replace the piston. . coMagpi ra cesice | No.2 compression mune + FOLEARANCE LAD MEASURING THE CLEARANCE BETWEEN ‘THE PISTON RING AND GROOVEENGINE INSPECTION CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN - INSPECTION POINTS moronANEs enpcsnance Co) fo sect Fone fee ‘CYLINDER BLOCK reo Wane en Tae re Inspec fon PLusten of. sto ——— ‘HOLES, CHECK FOR DAMAGE TnSPE07 Foe Wea, TOLUGS OR DONELS. ‘SOORING, CRACKS, Overneansan — & EXCESSIVE WIDENING ‘OFF GROOVES, comeerne nos —— onal ‘CHECK FOR BEND OF THnsT (HECK B15 END THRUST (GHECK JOURNALS AND cRARUCPINS CLEARANCE. FDR WEAR, CRACKS, AND BENDS. INSPECT FOR CLEAR OL HOLES. ‘00 NOT USE THIS CRANKSHAFT 6 TF THERE is EVIDENCE OF ‘CRANKSHAFT GEAR. OVERHEATINGBURWING. INSPECT GEAR TEETH FOR DAMAGE. [MAIN BEARINGS INSPECT FOR LOSS OF OVERLAY INSPEC FOR DETERIORATION LNSPECT FOR SCRATCHES OSE! [SPECT FOR DETERIORATION. AND RUST. REPRINT IF HEGESSARY.INSPECTION 4. Put the piston rng in a gauge or inthe bore in anew f. Check the connecting rod for bend or twist as follows: cylinder block and measure te clearance between the ge eal sean rum ads of the ring with afeler gauge ws shown If he pruners ieteert anita clearance exceeds the limit, replace all the rings. the connecting rod with a press. NSE DMT FOU) sevoms o rms oF consecrate ROD ‘STANDARD 0.0020 in 3.64 maximem (0.05/100mm) mires ney LIMIT 0.0068 in 3.88 maximum (0.15/100%n) (@) Generally, a connecting rod aligneris used to check. the connecting rod for bend or twist. NOTE: To check the rod for bend, install the cap to the connecting rad and tighten the cap nuts to the specified torque. ‘QVERSIZE 9.09 in (78.50 mm) 0.0197 in (2.501) NOTE: Put the piston ring inthe gauge or cylinder squarely with the piston. L > ae s renew’ “2 Tat zr (CLEARANCE BETWEEN THE ENDS OF THE PISTON RINGS ‘STANDARD No.1 RING 0.9959- 0.0118 in (048 -0.30m0) um (3) To check the connecting rod fited tothe piston for bend, put te connecting rod and piston on the surface plate as shown, inert a round bar having a diameter equal to that ofthe crenkpin into the bore in the big end of the rod and measure “A” and “B” with a dial indicator. Subtract “A” from “B” to find the bend (*C"). B the piston forthe pinto find the clearance. If the c . clearance exceeds the limit, replace the piston ot pin, ‘al whichever is badly worn. DIAMETER OF THE PISTON PIN (NOMINAL SIZE 0,01 tn (23mm) 4 ‘STANDARD 0.60577 0.90551 in (22.994 -23.0000m) ‘CLEARANCE BETWEEN THE PISTON PIN AND PISTON STANDARD 0.00024 0.0071 in (0.008- 0.018mm) Liar 0.00197 in (0.050mm) cece ‘ CONNECTING ‘ROD BENDINSPECTION 16. Crankshaft 1, Clearance between crankpin and connecting rod beating. (J) Install the bearing (upper and lower halves) and cap to the ig end ofthe connecting rod and tighton the cap nus tothe specified torque. Measure the bore in the bearing for erankpin as shown, (2) Measure the diameter of the erankpin to find the clearance between the crankpin and connecting rod. bearing. t im fl sosimne | T DiRecTiOn (MEASURING THE DIAMETER OF ‘THE CRANKPINL DIAMETER OF CRANKPIH (WORMMAL SIZE 1.69 n (48mm) STANDARD 1.05779 1.88838 in (47.950 -47.865mm) CCLEARAUCE BETWEEN THE CRAUKPIN AND THE CONNECTING ROD BEARING ‘STRUDARD 0.00098 0.00288 In (0.025 -0.072mm) tar ‘0.00591 in (0:1600m) (3) Ifthe clearance exceeds the limit, install a new ‘bearing and check the clearance agai (@) Ifthe clearance still exceeds the limit, erind the cerankpin to 0.25mm (0.0098 in), 0.50mm (0.0197 in) ‘oF 075mm (0.0295 in) undersize and use a undersize ‘connecting rod bearing. CCRANKPIN UNDERSIZES (0.250 (0.0088 in) FINISH 47.75°° wm (1.8789 **™ in) 0.50 (0.0197 In) AMISH A7.50-**¢ mm (1.8701 3 7 hom tf oF soooNozte =—§ ——— _RECONDITOH/REPLAGE If the diesel fue! of the nozzle tester is discolored, replace it, Atthe same time, clean or replace the fuel filter. b. Mount the nozzle and nozzle holder on the nore tester © Operate the hand lever of nozzle tester several times to bleed the air inthe nozzle line, then move the hand lever at intervals of one stroke per second while reading the injection staring pressure. ‘WiECTOR STARTING PRESSURE 1991“ (140 gta) .1f th fue injection stating pressure is not within the specification, ican be adjusted by removing or adding shims in the injector body to achieve proper pressure, NOTE: An increase or decrease ofshima thickness by (0.004 in (0. Imm) will vary the injection pressure by 142 psi (10 kgf-om), Ten shims are available in thickness from 1.25 mm to 170 mm (0.0492 in to 0.0669 in) in Increments of 0.0020 in (0.05 mn). ‘e When replacing the shi, grip the retaining mut in vise and remove the body with a wrench. Tighten the retaining nut tothe specified torque. sant sertan Tames came Ste INJECTOR = & — xcox ron wenn ai oneaee ‘CHECK FOR CARBON——_, 3 on une —, eae one Toni 4 DISASSEMBLY AND INSPECTION 1, Clamp the nozale holder in a vise, remove the nozale aut ‘and disassemble the nozzle body, spring,and needle. 2. Clean the disessembled parts with clean diesel fue. INSTALLING 1L. 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 402 41ENGS = 05tahm) C FWESTERBEKE 40GLOW PLUG TESTING GLOW PLUGS ‘To inspect the plug, remove the electical terminal connections, then unscrew or unclamp each plug from the cylinder head. ‘Thoroughly clean each piug's tip and threads with a so brush sand cleaning solution fo remove all the carbon and oil deposits. While cleaning, examine the tip for wear and bum erosion; thas eroded t00 much, replace the plug. ‘An accurate way to test glow plugs is with en obmmeter. “Touch one prod to the glow plug’s wire connection, and the ‘ther to the body of the glow plug, as shown, A good glow plug will have a 1.0 1.5 ohm resistance. This method can be ‘used withthe plug in or out of the engine. You can also use & rmultizter to test the power drain (8-9 araps per plug). Resins the plugs in the engine and test them again. The plugs should get very hot (atthe terminal end) within 7 to 15 seconds, Ifthe plugs don’t heat up quickly, check fora short circuit. When reinstalling the glow plugs, use ant-scize compound on the threads. AX WARRING: These giow plugs wit! become very hot to the touch. Be careful not to burn your fingers when testing the plugs. Testing AgLow Pus [ USING A.TEST LIGHT fa TERUINAL 7 AA WARRING: D0 20t keep a gtow plug on for moro than 30 seconde. ‘GLOW? PLUG TOHTENING TORQUE WESTERBEKE_ Engines & Generators 4 THe (10-15 mq)STARTER MOTOR DESCRIPTION The starter canbe roughly divided into te following sections: 1 A motar section which generates a drive power. 1 An ovecrunning clutch section which transmits an enma- ture torque, preventing motor overun aftr starting. A switch setion (solenoid) which is operated when acti- ating the overrunning clutch through a lever and which supplies load curent tothe motor ‘The startr is a new type, smal, ight weight and is called a high-speed intemal-reduction starter. The pinion shafts sep- arate from the motor shaft; the pinion slides only on the pin- jon sha. A seduction gear i installed between the motor shaft anda pinion shaft. The pinion sliding partis not ‘exposed ouside 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 sre 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 (12V) between the starter terminal ‘and the starter body, and the pinion drive should rotale ‘out and stop. A caution: Hover apply battery voltage for ver 10 seconds continuously. 2, Lightly push the pinion back and measure the retum. stroke (called pinion gap). 43. LF the pinion gap is ot within the standard range, 0.0197 = Q0788in (0.5 to 2.0mm), adjust t by increising or ‘decreasing the numberof shims onthe solenoid. The gap is decreased asthe mumber of shims increases. PINION GAP No-Load Test 1. Connect the ammeter, voltmeter, and battery to the starter as illustrated. 2. When the switch is closed, the pinion must protrude and ‘he starter must ran smoothly (at 3000 rpm or more). IF the current or starter speed is out of specification, disas- ‘semble the starter and repair it. A caumion: uso thick wires 28 much as possible and tighten every terminal securely. This i solenold shit- typo starter whieh makes a rotating sound louder than that ofa dect-hve ype starter. When detecting starter rotation at tho pinion tip, be careful not to come in contact with the pinion gear when it protrudes, Perform the following tests. If any test result is not satisfactory, replace the solenoid assembly. 1L Inspect the solenoid for continuity between terminals (¢#) and () and between tecminals § and the body and ‘Mand the body. There should be no continuity found ‘between terminals S and M. Continuity will be found ‘between terminals Sand the body and terminal M and. the body. NOTE: Disconnect the wire om terminal M. 2. Connect a battery tothe solenoi's terminal S for (#) and M for (.). Have aswitch inthe + lead and close it ‘The pinion drive should extend fully out. Ad caution: 0 not apply battery current for more than 10 seconds when testing the solenoid.STARTER MOTOR 45 Retum est: With a battery connected to the solenoid ter- ‘minal M (-) and to the starter body, manually pull out the a pinion fully. The pinion must retur to its original position Serene ‘when released from holding by hand. 84) 3. Holding test. With a battery connected tothe solenoid terminal S (+) and to the starter body, manually pall out the pinion fully. The pinion must remain at that postion even when released from holding with your hand. STARTER ASSEMBLY 7. ull ot the reduction gear lever and lever spring from the 1, Diseonet the wc from the solenoid tnmint MG). OMENS yr 2. Looten eo aetewsfaselog he scenid Remove ® OR be pinion sip he sep ring on, anal the solenoid assembly. _ : 9, Ateach end of the armature, remove dhe ball bearing with 3 Remove the two long through bots aad two screws Py eee pe poy eettotilenar eet fastening the brush holder. Remove the rear bracket ing press-fitted in the front bracket. If that bearing has 4, With the brushes pulled away from the armature, ‘wom off, replace the front bracket assembly. remove the yoke and brush Holder assembly, Thsn pull the armature out. 5. Remove the cover, pry the snap ring du, and remove the washes. 6 Unscrew the bolts and remove the conter bracket, At the same time, the washers forthe pinion shaft end play adjustment vil come of ‘TERMAL 8 NOTE: inspec, clear and dpotareen * (ifnecessary) replace the brush, commutator, solenoid, armature, et. See the following pages.STARTER MOTOR ‘STARTER INSPECTION ‘Solenoid “Inspect the solenoid for continuity between terminals $ and ‘M and between terminals $ and body. No continuity should be found between S and M. Continuity should be found between § and the body and M and the body. Brush and Brush Holder Inspection 1L. Check the brushes, If wom out beyond the service limit, replace the brushes. (CONTINUITY CHECK Inspecting The Armature 1. Check the armature with a growler tester. If it is short circuited, replace the armature. Also check for insulation between the commutator and its shaft. If poorly insulated, replace the armatire. 2. Check the brush spring tension. A weak or defective spring Will cause excessive brush wear, replace the ‘springs if suspect, ‘BRUSH HEIGHT STANDARD 6.6101(0.0 10) Umar. 2. Measure the commutator OD. and the depth of undercut, Repair or replace it ifthe service limit is exceeded. Also, check the commutator outside surface for dirtiness and : roughness, 1f rough, polish the commutator with fine ‘3. Chock for insulation between tho positive brush holder and holder base. If poorly insulated, replace the holder assembly. Also check the brush holders for proper staking, ANSULATION TEST [CORMUTATOR OUTSIDE DIAMETER, STANDARD 1.25 n (32 mum) ‘ear 4.2218 (31 mm) Se 44STARTER MOTOR ‘COMMUTATOR MICA UNDERCUT ‘Measure the undercut of mica insulation between the adja- ‘cent segments. If undercut exceeds the limit, recondition the rica or replace the armature. STANDARD 0.020 in(0.5 mm) ir 8.008 in (0.2 min = yuwoeRout 000 HrcKsaW BLE \ Field Coil Inspection 1L, Check for insulation between one end (brush) of the coil and yoke, 2, Check for continuity between both ends (brushes) of the coll. 1 ‘3. Check the poles and coil for tightness. STARTER ADJUSTMENT AND REASSEMBLY A caumiot: Bofors instating, thoroughy clean tho ee ee eaters agey meena: paint, and rust, Starter performance largely depends on ‘the quality of the wiring. Use wire of sufficient size and grade between the battery and starter and fully tighten to the terminal. ‘Reassomble the sarier assembly inthe reverse order of disassembly, making sure ofthe following: 1. Pinion shaft end play adjustment. Set tho end play (darust gap) to between 0.5 to 2mm by inserting an adjusting washer between the center bracket and the reduction gear. FFit the pinion shaft, reduction gear washer and snap ring to the center bracket. . Measure end play by moving the pinion shaft inthe axial direction, Ifthe end play exceeds 0.5mm, increase the number of adjusting washers inserted, 2. Greasing, Whenever the starter has been overhauled, apply grease to the following parts: ‘a. Armature shaft gear and reduction gear ». All bearings. ¢. Bearing shaft washers and soap rings. ‘Bearing sleeves. e £, Sliding portion of lever. A. caution: never smear tho starter ntting surface, terminals, brushes, or commutator with grease. 3. After reassembly, check by conducting a no-load. test again. HESTERaEE 4RAW WATER PUMP (PN.33636) Disassembly ‘The pump, as removed from the engine, wil have hose atuchment nipples threaded into its inlet and outlet ports. “They may be Left in place or removed if they interfere with the pump disassembly. Note the port location and positioning ifremoved. 1. Remove the six cover plate screws, cover plate, and the cover plate gasket NOTE: Replacement of the cover plate gasket is recom- mended; however, f you are going to reuse i, keep the gasket in water until the pump is reassembled. Fit’ allowed to dry the gasket will shrink and not be 2. Remove the impeller with its drive screw from the pump housing. 3. Remove the serew and sealing washer and remove the cam from the pump housing. 4. Remove the retaining ting. ‘5. Support the pump housing, at the mounting lange end, ‘on an arbor press, and with a def, press out the shaft and ‘earings from the pump housing. (6 With the pump housing supported, push the seals out of ‘the pump housing, Push the impeller side seal out the side, then lt the spacer out. Then push the bearing sie seal out the beating side. 17. Supporting the beating’s inner race, push the shaft out of the beatings. Inspection Inspect all parts and replace those showing wear or corrosion. Reassembly 1L_ Install the seals and spacer in the pump housing. Push the impeller side seal into the housing. Rotate the pump and install the spacer agains the seal face. Push the bearing side sal into the housing from the bearing side. NOTE: The seals’ flat surfaces that have printing and rumbers face toward each other cam #034458. ‘Engines 2. Install the shaft into the bearings. Support the bearings at their center races, Push the shaft into the bearings, push- ing at the impeller drive slot end using the base of the dive slot, Push the shaft through both of the bearings, flush against each other so the fla-sided end of the shaft ‘extends beyond the second bearing center race 19/32 in (5mm) + 1/32 in (5 mm), 3 Support the pump housing atthe impeller side. ‘Apply a small amount of petroleum jelly to the seal's ‘nner lips and to the impeller shaft. Carefully install the shaft, rotating it torough the seals unt the bearings contact the housing from the bearing end. Use a pushing ‘toot that will pus this shaft and the bearing assembly into the pump housing by applying pressure against the ‘outer bearing race. Push the assembly into the housing ‘until the bearings seat fully inthe housing. Install the retaining ring. 4, Position the cam in the housing and secure it in place ‘with the screw and sealing washer. NOTE: Use a small amount of Permatex #1 on the inner cam surface and screw threcds. Remove any excess from the impeller housing. 5. Apply alight film of silicone or petroleum jelly to the ‘nner surface of the housing forthe impeller. NOTE: Coat only the surface, do not over-apply. Install the impeller wit the drive screm Push the assembly into the housing with the drive screw mating inthe slot ofthe drive shaft 6 Install the cover gasket and coves, and secure them with the six cover screws. 17. Reposition and tighten the hose nipples, Assemble the pump to the engine, and attach the hoses. RETAINING RING #033044 ‘APPLY GLYCEAINE TOSEAL #030326 ‘WHEN ASSEMBLING: APPLY 4 THIN COAT OF [GLYDERIN TO THE INSIDE OF THE COVER, THE (GOVER O-RING, AND THE IMPELLER Paes ‘GeneratorsRAW WATER PUMP (PN. 48080) Disassembly NOTE: Reforto the following page for parts list and exploded view. ‘The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet and outlet ports. ‘They may be left in place or removed if they interfere with the pump disessembly. Note the port location and positioning if removed, 4, Remove the sig cover plate screws, cover plat, andthe cover plate pasket. NOTE: Replacement ofthe cover plate gasket is recom- mended: however, if you are going to reuse it, keep the asker submerged in water untl the punp is reassembled. Wits allowed to ry, the gasket will shrink and not be reusable. Remove the impeller with ts drive screw from the pump housing. Remove the screw and sealing washer and remove the cam from the pump housing. ‘Remove the wear plat end leave the pin in place. Remove the front citclip, washer and water seal, Remove the rear crcip ‘Support the pump hovsing atthe mounting flange end. ‘Using an arbor press and with a suitable dct, carefully ‘press the shaft with bearings from the pump housing. ‘The singer and oil seal will remain in the housing. Remove the ol seal and slinge. ‘Suppor the bearings inner race and push the shaft out of the beatings. be yk oe 9. Inspection Inspect all parts and replace those showing wear, cracks or corrosion. Reassembly 1. Suppor the bearings inner race. Pres the shaft into the ‘bearings so that the drive end of the shaft extends beyond the second bearings ier race by 1932” (15mm) 32" (Smm) WOTE: The seals'flat surfaces that have printing and rmumbers face toward each other 2 3 5 Install te oi seal inthe pump housing. ‘Support the pump Labricate the shaft and slide it thra the ‘i seal and prea the bearings with shaft into the housing 0 thatthe outer bearing just leas che rear cirlip, retaining groove. Install the rear circlip and press the shaft with bearings so that the outer bearing seats on the rear circip, Lubricate the singer and slide t onto the shaft o that it is visible midway throngh the sloted openings of the pump housing, Lubricate the inner half ofthe water seal, side it over the shaft and seat it in the pump housing. Install the outer half, washer and front clip o hold the seal in place. Install the wear plate and cam. Apply sealant (Permatex 4#1) to the cam screw threads and inner cam surfaces. Remove excess. LLabricste and instal the impeller. Blade positioning does not matter. NOTE: Use the lubricant that comes withthe impeller Coat only the surface. Do not over-appl. Install the O-ring and cover plate, Refer to #48080 parts list on next page. Cowes TenBere ‘& Generators AlRAW WATER PUMP(PN. 48080) PARTS LIST KEY No, PART NUMBER AND PART NAME ‘uaniry } 1 49080 RAW WATER PUMP 4 AYC2KEB(S) OTD EID BE) 08) 2 agr72 SHAFT ‘ ; 3 49170 IMPELLER COVER 1 wy 4 #3600 IMPELLER KTT(O-AING A GLYCERIN) = 7 5 958 CAM 1 8 aetri. WEARPLWE t OTe 7 302675. DOWEL 1 2 48259" SPRING SEAL WASHER 4 O-f 8 ‘34469 IMPELLER COVER SCREW 6 OF - 10 (48959 IMPELLER COVER O-RING 1 a +1 S901 OAING 4 12 39037 CANWASHER 1 4349082 GamscrEW ‘ 1442254 SPRING SEAL 1 E 46 49109 UP SEAL 1 48 SH4BALLBEARING 2 47 3045 RETAINING INTERNAL FING 4 4830044 AETANING EXTERNAL RING 1 40000 _ PUMP REPAIR KIT (SEE NOTE) 1 7491. PUMPKIT (MOUNTING GASKET & FITTINGS) 1 Note THE Pump Repair rene Coupons is AND 7 TET ALSO WELDES PUMP MCUNTING GASKET WHEN ASSEMBLING: APPLY A THM COAT OF ‘QLYCERI TO THE INSIDE OF TE COVER, THE (COVER O-RING, ANID THE IMPELLERENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT ‘Make the following adjustments when the engine is cold. a, Remove the cylinder head cover. Db. Slightly loosen the cylinder head bolts and retighten them to the specified torque in the number sequence shown below. ‘TOHTEMNG TORQUE 653: 41b-t(@8:=6 tim) ‘¢. Find top dead center compression position for No.1 piston by using the procedure that follows: 4. Turn the crankshaft until TDC mark on the crankshaft pulley is aligned with the mark on the timing gear case. ‘TOC (TP DEAD CENTER) ‘MARK FOR NO.1 ‘AND NO.4 PISTO ‘oc MARK FOR N02 AND HO.3 PISTONS, . With No piston at top dead center on the compression stroke, the rocker arms will not be moved when the cranic shaft is turned approximately 20° in both directions £. the rocker arms move, No.1 piston is at top dead ceater ‘on the intake or exhaust stroke. In such a cas, tur the crankshaft 360° in the direction of engine rotation again No.1 piston is now at top dead center onthe compression stroke. , Loosen the locknut forthe adjusting screw, With a feler _gango inserted between the rocker arm and valve cap, adjust the valve clearence by turing the adjusting screw. ‘Make cxrtain to adjust all the valves. o250m (0.0098 INCHES) TNTAKE & EXHAUST bh, Fold the adjusting screw and tighten the locknut. ik Alter the valve clearance on the valves for No.t eylinder hs been adjusted, turn the crankshaft 180° inthe direction of engine rotation and adjust the valve clearaace con the valves for the remainder of the cylinders in fring coxéer (injection sequence). Iecrion SEQUENCE: S132 240 CRANKSHAFT ROTATION ‘4 1-4-2 100° CRANKSHAFT ROTATION Jj After the vaive clearance on the valves forall the cylinders have been adjusted, tur the crankshaft two or thee times and make certain the clearance is caect, ke, Install the eylinder head cover. HEAD COVER BOLT TORQUE — 2-3 Rib (23-0.45 mq) CER WESTERBEKE Engines & Generators 49ENGINE ADJUSTMENTS TESTING ENGINE COMPRESSION AIR INTAKE FILTER/SILENCER Make certain the oll level (dipstick) is atthe comectlovel and the air intake filter is clean. The battry and starter motor ust also bein good condition. ‘a Warm the engine to normal operating temperature, '. Move the contro lever to postion for shutting off the fuel. Disconnect the wires if fuel shutdowa sofenoid is used). «Remove all the glow plugs from the engine and install the compression gnuge/adapter combination tq the colinder on which the compression isto be measured CCloso the raw water seacock (thru-hall), Crank the engine and allow the gauge to reach a ‘maximum reading, then record that reading. £. Repeat this process for cach cylinder. ‘COMPRESSION PRESSURE 427 ps (60 ktm) at 290 rpm. [MAXIMUM PERYAISIBLEDIFFEREWCE BETWEEN CYLINDERS 427 ps3 kate) NOTE: Ifthe readings are below the lini, the engine needs ; repair ‘The fier cre shuld be leaned every 100 operting 4 hours. Tap the cartridge on a flat suzface to dislodge loose g Re-install the glow plugs (use ant-seize compound on : : ge loo eee ee ee ae (et uvetf torhenin postion, dirtorclean with compressed at Ifthe fier carrie is i rope: 1h, Open the raw water seacock (¢hru-bull). ‘badly contaminated or oily, replace it. e NOTE: Failure to properly maintain the air intake fiter can result in engine oil ‘consumption and fter deterioration and ingestion into the engine, ‘When low compression is found, determine the eause by applying a small amouat of oil in the cylinder thra the glow plug bole. Allow the cil to settle. Install the pressure gauge and repeat the above test, If the compression reading rises dramaticelly, the faulis with the rings. Ifthe compression valve does not rise, the problem is with the valves. ‘A slight rise in compression would indicate a problem with ‘both the rings and the valves. CES WESTERBEKE Engines & Generators 50ENGINE ADJUSTMENTS FUEL RUN SOLENOID ‘The fuel nin solenoid is mounted in a threaded hole on the ‘engine's block just aft of and below the engine's fue} injec- tion pump. Proceed as follows when installing a replacement ‘or new fuel run solenoid. GENERATOR FREQUENCY ADJUSTMENT (HERTZ) ‘Once the diesel generator set has been placed in operation, there may be adjustments required for engino speed (Hertz) ‘during thc engine's break-in period (frst 50 hours) or after this period. A no-load voltage adjustment may also be required in conjunction with the engine’s speed adjustment. "These ae not warrantabe adjustments as they relate to ‘oral break-in and maintenance. Frequency isa direct result of engine/generator speed, as indicated by the following: ‘When the generator is run at 1800 rpm, the AC voltage output frequency is 60 Flertz, ‘When the generator is run at 1500 rpm, the AC voltage output frequency is 50 Hertz, ‘Therefore to change the generator’s frequency, the engine speed must be changed. To accomplish the frequency change, pporform the fll 1. With the engine stopped, connect the AC output leads to the AC terminal block in accordance with the AC voltage connections diagram specified for your generator set, and change the Hertz circuit connection tothe capacitor ‘These connections are shown in the GENERATOR section of tis manual. AL WARRING: Before starting the engine make cartain that everyone Is clear of moving parts! Keep 1 2 away from pulleys and belts during test procedures. 2. Start the engine and adjust the engine’s speed to obtain the frequency corresponding to the voltage selected by adjusting the stop bolts and positioning the throttle arm against these stop bolts to either increase or decrease engine no-load speed to adjust the Hertz produced. 3, To arrive at the appropriate frequency, either monitor the speed of tho engine/generator with a tachometer, or ‘monitor the frequency with afrequeney meter, the later ‘method being the more precise ofthe two. ‘Visual access tothe fuel injection pumps fuel rack is needed. To obiain this, remove the small square side cover and gasket just below the fuel injection pump. ‘Thread the locknut onto the solenoid and then apply @ small amount of Teflon sealant to the threads on the solenoid, “Thread the solenoid into the hole onthe engine and observe the solenoid plunger through the cover opening. ‘Allow the plunger to contact the fuel rack and move fully into the injection pump. Do not thread further so as to push the plunger int the solenoid. Back the solenoid out 1/4- 1/2 of tn and secure it in position with the locknut. LoeKMUT TORQUEVALUE | 22.9-96.2000(@.0-S.am4g) ‘Properly connect the three electrical leads from the sole- oid. Two ofthe connections plug into the engine hamess ‘and the third grounds to the engine block at an adjacent inboard threaded hole with an 8mm bolt. Reascemble the cover and gasket and test un the unit Make certain that te unit tops wien the solenoid is de-energized. FUEL AUN SOLENOID ]WESTERBEKE CESTERBEE 51ENGINE ADJUSTMENTS OIL PRESSURE ‘The engine's oil pressure, during operation is indicated by the oil pressure gauge on tho instrument panel During nomnal operation, tbe al pressor will range between 40 and 60 pai (28 and 42 kg/om?) NOTE: A newly started, cold engine can have an ol pressure reading upto 60 psi (4.2 kg/om), A warmed engine can have can oil pressure reading as low as 35 psi (2.5 kglen?). These readings will vary depending upon the temperature ofthe engine ard the rpms. OIL PRESSURE [GENERATOR] Oil pressure at 1800 (or 1500) rpm should maintain a reading of 50 psi TESTING OIL PRESSURE ‘Totest the oil pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place. After ‘warming up the engine, st the engine speed at 1800 rpm and read the oil pressure gauge. ONLPRESSURE Sola 800;pm, ‘SEDER AND SWITCHTORQUE—9-15"b(12-4.8m-H0). ‘iL PRESSURE» 4p sTeH ‘The specified safe minimum oil pressure is 4.3 + 1.4 psi (03 “+01 kgfom?), A gradual loss of oil pressure usually indiazes 1 wom bearings. For additional information on low oil pes- suro readings, see the ENGINE TROUBLESHOOTING chart. OIL PRESSURE RELIEF VALVE ‘An oil pressure relief valve is located on the engine block just below the injection pump. This valve opens at ‘appoximatoly 50 pst [343 kpa] and maintains that pressure CARPWESTEREEKE Engines & GeneratorsENGINE ADJUSTMENTS ‘ADJUSTING THE IDLE SPEED { 4. Loosen the lockmt on the ile adjustment bolt onthe fue injection pump. Adjust the idle adjustment bot so thatthe throtle ‘control lever will hod the engine speed at a smoothistable ile, Reference the RPM Chart below ¢. Tighten the lock, 4. Race the engine several times to ensure the idle speed remains as set NOTE: Should the engine rpm be in question, verity the tachometer readings as shown atthe instrument panel with a mechanical or strobe-type tachometer at the ‘engine crankshaft. RECOMMENDED RPM RANGE Model (dle RPM Cruise RPM Max. RPA 44AJFOUR 800-1000 2500-3000 ‘4B/FOUR 800-1000 2000-2500 2900-3000 ACIFOUR 800-1000 2000-2500 2900-3000 35C/THREE 1000-1200 2500-3000 3500-3600 3SD/THREE 1000-1200 2000-2500 2900-3000 35E/THREE 1000-1200 2000-2500 2900-3000 3500-3600 (OLE ADJUSTMENT BOLT ‘stop CONTROL CABLE Fuel Shutoff Solenoid [Optional] ‘The optional fuel shutoff solenoid allows the engine to be shut down using the instrument panel ey switch. The solenoid has been factory set and does not require adjustment, Refer to the assembly procedure of the fuel shutoff solenoid for the proper setting and clearance of the plunger. See FUEL SHUTOFF SOLENOID INSTALLATION. a} Exeme stor ansusTicent 12" POSITION CABLE SO THAT THE Drive Belt Adjustinent Proper inspection, sevice and maintenance ofthe drive belts js important forthe efficient operation of your engine, Dive belts must be properly tensioned. Loose drive bets will not provide proper alternator charging and will ‘eventually damage the alternator, Drive belts that are too tight will pull the alternator out of atignment and/or cause the altemaior to wear out prematurely. Excessive drive belt tension can also cause rapid wear of the belt and reduce the service life of the coolant pumps bearing. A slack belt or the presence of oil on the belt can cause belt slipping, sulting in high operating temperatures and tachometer variations. ‘Tho drive bot is properly adjusted ifthe belt can be deflected no less than 3/8 inch (10mm) and no more than ‘V2 inch (12eum) asthe bet is depressed with the thumb al the midpoint between the two pulleys onthe longest span of the belt. A spare belt or belts should always be carried on board. AX WARNING: Hever attempt to check or adjust the tirive belt's tension while the engine is in operation. Adjusting Bett Tension ‘a, Loosen the alternator adjusting strap bolt and the base ‘mounting bolt, ‘b. With the beit loose, inspect for wear, cracks and frayed cages. Pivot the alternator on the base mounting bolt to the Tet ight as required, o loosen or tighten. 4. Tighten the base mounting bolt and the adjusting strap welt ‘e, Run the engine for about 5 minutes, then shut down ‘and recheck the belt tensions. Coy pweSTERBENE Engines & Generators 53SERVICE DATA - STANDARDS AND LIMITS ‘Component ‘Standard Repair Limit ‘Component ‘Standard Repair Limit mm (Inches) (inches) rm (inches) ENGINE COMPONENTS ENGINE COMPONENTS: Conpsén press, A2 ptt 28-9 Lobel atnton abaigew pap eae. M0178) (13069 ee Fates ond (OOD) ann. (00H57 taoimum pores cower 427 ‘between average compression — (3.04g/or') ‘Gisarance between tappet tris ofa ners Zetie nd of od ecnenenne 45 (0058) Inn i BD nee Seance vee era pee clr ao oa, 18910-8580 ‘ : Cannes hve des, 18-0. oe aneieiie carenvat iinet 1 “Warpage of oyfinder block macseeieeebee top face... dete ae 0.05 (0.0020) max.. Sind det ol deat). 0012-0080 Born fc ot 780% (07 ee “Tapar and out-o.. 001 (0.0004)max Vii enn 280 (8.8) rot oleae skate Pst PaO. 2o94s-2200 tate 8808 100 OB Vacs 25 008) ena sent ge creas a 199-1198. ‘ie. 22-095 (008-002) 0.40 0.059 ‘Geet - 3.0689) ai Ee ee 0.25 (0.0008). nn TO 18 7820 Ya rt nnn (008) 5 02 One ‘iar a0re (ice pices) (0.50 (0.0197) nn TBAB = TBAB eens We sae 18 2025 erent Greate ins Sess lctaeaes easecerertte Clearanoe batwoan piston 0.008 - 0.018 .. Veet © sina sn ‘Genes ocr cae any ae chee been pt gd poove wn. iS TWiaesi-oar) 25,0086 zn gonna oN, was, ie tg “onto Ss a 1-00.05 - 0.09. aoe S529 ‘ro ined “ac Tete 92:1 (158) jase Sea seventy ‘ages on icra a8) or ents pti ee ae 1% ner iem erin, oy ssn eat (OCH) ee tg (0.0089 - 0.0118) (0.059), Na C0 enn - 095 connnrnn 8D aati. 7 ano a oe Ot ar a cata sho. 93 (001 es ——— ty ‘Tiving Gear Gactash ‘Clearance DStWO8M wnat. 095 ~ 0.086 0,300 Crash comer er. 004 05 —an pounce" Yocoae-cooss a1) ,0016 - 0.0087) (porte) anes ier Hg 04 On Snare edb Yotos-ouedy "wey ost xe ff enn 010-038. 050 ‘sz ger an. ait Sesser onus: eonay a) Comeding red tendtst 001001020894) Casta 0. 8 08 - B19 one DD oe (0.0031 - 0.0078) (0118) eee, Fu neoton pump canst 0.07 - 020 gerne ol pump ger (A028 00073) 120 ‘oott8) Love ih of cai nnn 3872 (1.4088 472 (1 8589) CS] WESTERBEKE Engines & Generators 54SERVICE DATA - STANDARDS AND LIMITS Component Speciod Value /Standard Repalr Limit Snches{onm) inches(ram) Component Sealant Mating Pat ENGINE COMPONENTS ‘THREAD PARTS Cand penne iaran pan S09 et enn OH 887 UR Be on GOVE (eovees- 201720 Wt dalton ott Gasket Sear 2 Ce bok Dimes oferanin 47950-47985, er Teck Gasket Se 49877926895 presse Lita Gosh Str 2 ..Cyinde tack png eee CCE pa io or Higrlack Gait Sear (couse) Or) “Torq sping st ct #57 Ut nn PETE Coane bebe ut ne O80 O07 nnn 010 PRESS FIT PARTS eer eae teaere Senge» _-otte Gastt Sor 2. Ofer lock Carne atwean rtp ..0025-0.072 1150 ‘ortho Gasket Seale and comoctig os being (00093-oonzs) (005) fea 2 eee serrated fd pe aright Gasket Seat ng nen ah ast Ser ender & ook righ Tack Gasiet Slr 0 nn tt Gash Sele #2...Goveor Back THaRTCRTION SVSTEN ee Hgnck Gat Sea Pres ll eanenenne BOS sh oenneen et Selt 72 va seting ‘35205 bent cela Sethe ast Satie ao si eabiee a tianalgemnns asc tint Sie 6 seen 587 Ut Bu ..OlderDlckand Sub oved sive iin ear aps Min eating Cnn ot 87 Uta Be... Ofer lk (Grostan a) FUEL SYSTEM ON ns nnenneninenL Oot #5609 Ultra Gray... .O¥inder Bock Ingo pres. a8" Bs on eee (rave peng ight resus) 1379 Pe Pano tcommutator. last of comms. Unrcut of ica.SPECIAL TOOLS - ENGINE i ETT TOOL 10 \ 33682 OR PISTON PIN REMOVAL ANO INSTALLATION ‘COMPRESSION GAUGE ADAPTER (939254) FDR COMPRESSION PRESSURE NEASUREMEUT 9258 ‘IL PRESSURE SWITCH SOCKET WRENCH TO REMOVE THE Ol. PRESSURE SWITCH ‘CAMSHAFT BUSHING BVSTALLER (033589) FOR REMOVING AND INSTALLING THE FRONT CGAMSHAET BUSHING THE ABOVE TOOLS ARE AVAILABLE FROM YOUR WESTERBEKE OP (MITSUBISHI DEALER. NOTE: WW ADDITION TO THESE TOOLS THE FOLLOWING ADDITIONAL TOOLS WOULD BE NEEDED: BEARING PULLER, VALVE SEAT CUTTER TOOL, PROPER DIAL GAUGES, VALVE GUIDE ISTALLER TOOL, VALVE SPRING COMPRESSOR, SNAP FING PLIERS, ET ‘ALSO REFER TO SPECIAL TOOLS - GENERATOR IN THIS MANUAL CER WESTERBEKE ‘Engines & Generators 56Bott or Nut ‘Atemator Bracket Back Plats Connecting Rod Cap Coolant Pump Coolant Purnp Pulley Coolant Temperature Sender Coolant Temperature Switch Crankshaft Pulley Nut Cylinder Head Bolt Damper Pate Deivory Valve Holder Engine Mounts Exhaust Manifold Flywheel Bolt Fuel Filter Assernbly Fuel Injection Nozzle Holder Fue! Injection Pip Nut Ful Leak-Oft Pipe Nut Fuel Solenoid Locknut Glow Plug ‘Glow Plug Connection Plate Infeke Manifold ‘Main Bearing Cap Bolt i Fitar it Pan Bolt ‘01 Pan Drain Plug Oil Pressure Sender (li Pressure Switch Pressure Refit Vahe Rear Plata Bott (stamping) Rear Plate Bolt (standard) Reicning Nut for Delivery ‘Valve Holder Body Rocker Cover Bolt Rockor Shatt Bracket Bolt Sliding Sleeve Shaft Special Nut for ‘Torque Spring Set Stater 8 Terminal Stop Solenoid ‘Thermostat Housing Thermosuiteh TORQUE SPECIFICATIONS MAJOR BOLTS AND NUTS Width Clamp Diameter Pitch across flats length Mo 10 Mi 15 io 1.25 mia 125 20 15 i 15 Miz 15 1.25 wa 07 Mio 125 20 15 MB. 125 wig 18 ge 22 18 Me 1.25 mata, 1.25 m6 075 ue 1.25 ve 1.25 wo 1.25 2 10 MB 1.25 30 15 ie 18 581 TORQUE kg-m = ft-Ib 3853 27-38 3348 24-35 3552025 27272 16224 12417 16224 1247 12218 © 913 12218 9413 176225 127218 gs05 5 +4 19227 14-20 45205 32454 82247 23-04 16224 1217 185205 9824 46268 B49 55205 40244 3205 = 224 2754025. 202 40205 28.9962 1752025 12272 0125 0.025 0.9202 16224 12-17 52540.25 382 12401 © 7+ 07 28403 20.9222 40205 2924 12218 913 120200 7214 50205 3624 1152015 83214 65401 4727 3752025 272 1452015 83214 18205 1184 38206 2624 2205 14d i201 8027 45205 32454 03045 23 23204 © 16623 N-m 366 325 34.8225 72 72 122 122 17222 8845 ag 425 at 72 13225 447 5425 925 2425 39.18 17.2225 1.2202 162 515#25 121 27453 3025 122 1042 495 3815 64210 7225 119215 1475 3526 2025 1081 4a25 a7 22624PROPULSION MODELS WIRING SCHEMATIC #39144 co Won assests a Thon comPROPULSION MODELS WIRING DIAGRAM #39144 Sarto ey ‘an emergency and when "GyyD ‘ae ae a tata oa 20 to Ee ae, $RRERAE tart f we RE seems fg ears CAPTAIN Banet44A, 44B, 44C FOUR ENGINE SPECIFICATIONS SEs eer EL SYSTEM ate Del ofc te cnt Cots ini Sel ease ona ma pe ten nt oto et Dsplatemert reac bes (1.7588) fu itn Pop lode perp (BOSH. deseon veo Note Tre Omimincmin Salome rele Det ho p09 axed Sole 207x382 ns (8292 mn) tnt oa Fer PO078} *Fiing Order 1-3-4-2 Ar cleaner be aetna tat eee fon (a0. eerie ewan viewed from he ro (engine combustion) Spam eobonn) 3000 pm ‘Compression Ratio rh Feel Lift Purp 12 volt DC ltt capacity of 5 (1.5 men) wet an Corin ¢ “Temporary 25° (not to exceed 30 min.) eer Tesh rane nt, eres Sgt a ah hdl change Corgan Pay 2] kG 20 pn rae ee a ga ees cam aeriaeG eons fee ees rhe PoC pe inp a en, bog ae FevWanrPing Poste dea, Eeetelueron) She IietrPresue ——1801471- Ops (4045 -Olte aware augur Spee d me tira Sogpnstso en veers wile SGhagetoetast Grou 80 gpm at3E00 pr. Valve Cl ‘0.25mm (0.0098 inches) Ate he Chaance re ka {engine cal) range 80 US ats (7 s} ante oan aran LUBRICATION SYSTEM 3000 pen (44CB/Four) i ‘Horsepower 4AA/Four 40Hp at 3600 rpm — Pressure fod syst. rao inher RBA bn oar Fu on see nae 41H 212000 om ‘Sump Capacity ‘57 US. ats (5.4 Mere) faba) ‘Operating Ol Pressure §0~ BO psi (35-42 kgfor) Say aey «VR end Sones ‘Battery Capacity 600 ~ 800 Cold Cranking Amps (CGA) ‘Ol Grade ‘APL Specification OF or CG-4, DC Charging Alternator 51 Amp rated, belt-driven SAE OD, $OWFS0, TE surat So ns statu pe sur 12Ne ncn ge oat arty 110-1700 ms Reta WESTERBEKE35C, 35D, 35E THREE ENGINE SPECIFICATIONS Beau ey agi Type ‘ieee four yl, taeda rash water ‘ove, vertical iene overhead vate mechan. Dipacement 4 cab inches (1.318 te) Aspiraion tray spate, Combustion Chambor Swipe. Bore & Suoke ‘307x382 ches (78x 82.0) Fring Order 1-8-2 DBealon of Rtlon Claas, whan vowed rom he fot. Compression Rao 22 Incaton Gontinsous 4° “amoorary 25° (nt to exaed 30 in) GUE Cmeession Pressure 427 pl 3 a 260 rm fic Stee ng Ting reese 23° STDS (seme) Inetor Pressure 1801 +71 - Opel (140+ 5 - Okan Vee Sea bake ar ae aust 20" ‘Ya lance (025mm (@2.0088inces) (eeghe cl) Eng Spe 2200 pm sees) 500 pn (350/Tee) S000 rpm (Eis) Horsepower 386/40 at 95 pm Pat ‘50/Tiee tp a 3000 rpm ‘befTires 41H) a 2000 Stang Batlery +2 Vol) negative round ater Capac (600-200 Cod Cranking Amps (CCA) Do Charging Aerator 81 Amp ated baecven ‘Sting Ad lou pugs, sheathed ype ‘Sater 12 rucon ear Colt renking 150-178 DEAS ‘Ap Dave | UELSYSTEM General ‘pen oy sl pring Fut Wo. 2 ese cetanerang of 45 or ihe, Fulton Pump rte plunger yp BOSCH). Nie Tht ype, Fu Fer ‘args Type Pueog200) (ret Fuel tar PAOAECTE) Arokaner eplcabl pape iter cate, AeFow 1837 em (3c) at 9800 rm. (engi combustor) 627 em (19 ern 3000 rm, Fos Lit Pare ‘vet De copay a (1.5 man wat CIS ‘Genera Fresh wat coled bel thermostat console wth heal exchanger COpwatngTemperture 170-190" F(77-83°C) Fresh Water Pump —_Certtualtypa, metal inet, bet-van Few Wet Pum Posv depacement, eer iat, bain, Paw Wier Fw s8t/firen 95 gpm at 2600 rpm. (maseuredboore ‘ss0jfhree 80 gpm zt3000 pm. decarge ino ethaust — SHEMes 8D gpm at 000m. bo Aoproximai ‘System Capacty S50US gs (7 tas) (Fresh Wiser) GES General Pressured gjstem, a iter Fufow, paper eamert,spiton ype. Sump Capacity 9US. qs (7 hers) (pot inelting ta ‘Opeting Ol Pressure 50-€D px (35~4:24ger) (engine ft) o1srado ‘BL Spectcaon Fo 06-4, SAE 2, 10890, 150440DC ELECTRICAL SYSTEM ALTERNATOR ‘The charging system consists of a DC belt driven alternator ‘with a voltage regulator, an engine DC wiring hamess, a mounted DC circuit breaker and a battery with connecting cables. Because of the use of integrated circuits (IC's), the electronic voltage regulator is very compact and is mounted internally or on the back of the alternator. ALTERNATOR TROUBLESHOOTING Use this troubleshooting section to determine if a problem exists with the charging circuit or with the alternator. I itis determined that the altemator or voltage regulator is faulty, have a qualified technician check it. ‘The altemstor charging circuit charges the staring battery and the service battery, An isolator with a diode, a solenoid or 2 batery selector switch is usually mounted in the circuit to iso late the batteries so the starting battery is not discharged along with the service battery. If the alternator is charging tbe start- ing battery but rot the service batter, the problem is in the service batery’s charging circuit and not with the alternator Testing the Alternator CAUTION: Betore starting the engine make certain that everyone fs oloar of moving parts! Keep away from sheaves and belts during test pracedares. AA WARNING: tinen testing with a multimeter: BC and AC circuits are often mixed together in matine applications. Always disconnect a shore power cord, isolate DC and AC converters, and shut down the engine before performing DC testing. No AC tests should be [nao without a proper knowledge of AE circuits. 11. Sturt the engine. 2. After the engine hes rum fora few minutes, measure the starting battery voltage atthe battery tomminals using a ‘multimeter set on DC volts. aif the voltage is increasing toward 14 volts, the alterna tor is working; omit Steps 3 through 8 and go directly to “Checking the Service Battery” on the next page. Dlf the voltage remains around 12 volts, a problem ‘exists with either the alternator or the charging circuit; continue with Steps 3 through 8. ‘TESTING THE STARTING BATTERY/ALTERNATOR (ENGINE RUNNING) 3. Tum off the engine, Inspect all wiring and connections. Ensure that te bttery terminals end the engine ground ‘connections ar tight and clean, AX GAUTION: fo avoid damage tothe battery charging circuit, never shut off the engine battery switch when the engine is running! 4 Ife battery selector switch sin the charging cut, ensue that tis on the correct sting ‘& Turon ihe ignition switch, but do not start the engine 6 Check the batery voltage. If the baticry is in good condition, the reading should be 12 to 13 volts. TESTING THE ALTERNATOR VOLTAGE (IGNITION ON - ENGINE OFF) ‘STARTING BATTERY = erouunDC ELECTRICAL SYSTEM 7. Now check the voltage between the alteatoecutpottemi- hacking the Service Battery ral (Bs) and ground, the rei is good, he voltage atthe atemaor wl be the same asthe batery, orien isolators in the circuit the altemator vollage wil be zo Ifreiter ofthe aboveis te, a problem exists in the cit between te alemator an the baer. Check ll the omections «cok for an opening inthe charging oui. (Check the voltage of the service battery. This battery should have a voltage between 13 and 14 vols when the engine is running, f not, there is a problem inthe sevice batery ‘charging circut, Troubleshoot the service battery charging circuit by checking the wiring and connections, the solenoid, isolator, battery switch, and the battery itself. TesmNa THE stanTING BATTERY/ALTERHATOR ENGINE (ENGINE RUNNING) + Rout & Start the engine again. Check the volage between the altematoeoatput and ground. ‘The voltage reading for a properly operating alternator Should be between 13.5 and 14.5 voll Ifyou sliomaior isover-or underchargng, have it epaited a reliable + : service facility. BATTERY (ENGINE RUNNING) NOTE: Before removing the alternator for repain, use a olmeter to ensure that 12 volts DC exctation is present wear ternal ite previ tet showed ony bat. | 4 CAUTION: To avoid damaging the ateator des, try voltage at the B output terminal. do not use a high voltage tester (Le. a megger) when ‘porforming tests on the alternator charging circuit. If T2 volts is not present at the EXC terminal, trace the ‘wiring and look for breaks and poor connections. 12 VOLT DC CONTROL CIRCUIT Battery Care ‘The engine has a 12 volt DC electrical control circuit that is ‘Review the manufacturer’s recommendations and then shown on the wiring diagrams in this manual. Refer to these establish a systematic maintenance schedule for your diagrams when troubleshooting or when servicing the DC engine’s starting batteries and house batteries. clectical system. 1 Monitor your voltmeter for proper charging during engine operation, AR GAUTION: fo avoid damage to the attary charging | Check the eects lve ant specie gravity witha rircult, ‘shut off the engine battery switch Pestietehentonf rn depan bleer Use ony wate to ring erly ta proper however, to avotd electrical shorts when working on the ote eae Cate crn tt ty te ome cana Bae (5 Keep your batteries clean and fee of corrosion, ‘The minimum recommended capacity of the battery used in the engine's 12 volt DC control circuit is 600-900 Cold AA WARNING: suitor acid in oad batteries can (Cranking Amps (CCA). ‘cause severe burns on skin and damage clothing. Wear protective gear. CERIWESTERBEKE Engines & Generators 63WESTERBEKE 51A MANDO ALTERNATOR DISASSEMBLY AND TESTING TESTING THE OUTPUT CIRCUIT 1. Connect the positive voltmeter lead to the output terminal B and connect the negative lead to the ground terminal E on the aerator, 2, Wiggle the engine wiring hamess while observing the volimeter, The meter should indicate the approximate batery voltage, and should not vary. If no reading is ‘obiained, or ifthe reeding varies, check the alternator cutput circuit for loose or dirty connections or damaged wiring. OTE: Prior 10 any alternator testing, inspect the entire ‘alternator system wiring for defects. Check all connections for tightess and cleanliness, particularly battery cable ‘lamps and battery teminals. Inspect the alternator drive belt for excessive wear and replace ifnecessary, Also adjust Jor proper belt tension. AXA WARNING: 4 tated atternator can become very hot, Do not touch until the alternator has cooled down, AL WARING Before staring the engine, make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. AR WARNING Mattimeters and D6 Circuits (DE and AC circuits are ofter mixed together in marine applications, Always disconnect shore power cords, Isolate DC and AC converters and strut down generators before performing DC testing. Mo AC tests should be ‘matte without proper knowledge of AC circuits. Wing DIAGRAMS FOR THE ABOVE WIRING HARNESS CONNECTIONS TESTING THE EXCITATION CIRCUIT 1. Connect the positive (+) voltmeter lead to the excitation terminal R on the ellemator and the negative (-) lead to the ground terminal E on the alternator. 2, Turn the ignition switch to the on position and note the voltmeter reading, The reading should be 1.3 to 2.5 volts (se illustration). 3, If the reading is between .75 and 1.1 volts, the rotor field circuit probably is shorted or grounded. Disassemble the alternator end test the rotor as deseribed under CLEAN AND TEST ALTERNATOR ‘COMPONENTS in tis section. 4. If the reading is between 6.0 and 7.0 volts the rotor field cicuit probably is open. Remove the regulator and inspect i for worn brushes or dicty slip rings, Replace the brushes if they are less then L/4in (6 mm) long. If the brushes and slip rings are in good condi- tion; disassemble the alternator and test the rotor, as outlined under CLEAN AND TEST ALTERNATOR s sectionMANDO ALTERNATOR SERVICE e, Remove the regulator cover. Temporarily re-install Jumper (A) and all associated ats, Leave Jumper (B) installed. fg Remove the plastic plug from the side of the regulator. 1h, Connect a jumper between the top brush lead 4 ‘If no reading is obtained, an open exists inthe altenator-excitation lead or in the excitation circuit of the regulator. Disconnect the lead from exc terminal R. ‘Connect the positive voltmeter lead to the excitation Jead and the negative voltmeter lead to ground terminal E. Ifthe voltmeter now indicates an approximate battery vollage, the voltage regulator is defective and must be replaced. If no voltage is indicated, check the excitation " oe | fe ze! a | | eee iGENERATOR WIRING SCHEMATIC #44735REMOTE INSTRUMENT PANEL ese a 7 _ RRWOTE gowTaOL ence cwegm view ee je ey aaa i I 1 i 2 | ‘stant Bette ; | ! a i : | = bgt Teasosasuaaaunensesesescasasaseay { sear ! 1 ' | acorwn TO : OOO i Ty | OOO I vrcnear @@Q@ i { STAR Sere AQ ! gS i mo 1 4 ra i ean vie | essence + nub Yeu URED ! i ea ease Coe IMESTERB ENE ‘Generators 72SPECIFICATIONS - 11.5BTD, 12.6BTD, 10.0BTDA, 8.0BTDA GENERAL Engine Tp Dial four, three-c/iny esh water ‘cold tcl ine verted ve ‘mechan, Discrnnt ‘04 cubic nes (1:18 a) Aspirton way sped, Combustion Camber Sipe Bare & Soke 807 8.52 inches (78x92 men) Fring Order 1-3-2 Diecion of Rein Gockel wate vowed rom th fron. Compression Rao 224 Waight rake On) —«BOBTOA 457s 211.8 os). SGOSTDA 513162327 Ks) A2SBTOR 51885 (2827 kis) etn Continuous 15° Teparary 25" not exceed 30min) Engine Combustion Ar 41 em (1.6mm) aqurements at eH 12209 GUE See eae siege: pwenrean gine ‘Spilled Timing (Static) 17° (spill) cere et oe ee faired til eS —a {angine cold) a TES = —— ‘Sum ‘39US. cts (37 liters) p Cagacty (pot cng tery Opwatng 1 Preseue £060 pl (95-424) ‘erin ‘Grate 10 Spretiain For 024, AES, 000, 158-40 General ‘pan iow, sa primi. at No, 2se ol (lane rating of 45 o ihe), Fuel injection Purp Inne plungr ype (BOSCH) Noe ‘Throtio yp. Ful Fier Cari Type (PADECZO0) Ina Fuel tar #048076) ‘Ac Oeant Replaceable papa tr carie. Fuel Li Pamp ‘2 vet DO capac of (1.5 mn sl tabs RL ‘String Batery “Val (= agave ground ater Capacity 600-800 Co Crkng Amps (CA) ‘NC Chagng Atamatr St Arp rated, be-ven ‘Stating Ait Glow pigs, heated ype Sater ‘12Vat eduoton gear (ol Cranking ‘15 amps (mpresinat) ‘np Dain General Fresh water-cooled block temostaizaly- anol with beat care Operating Terparture 170-180" F(77=88°C) Freeh Wer Purp _Centuga ype, matalimeler, be ive, aw Water Pump Poste dpacement,ubherimpale, beta | aw ia ow ‘T8gpm 259-285 gpm) 1800 pm (assures betore ‘dsharging ito ehust ebo) ‘System capacity 50S ois (47 Hers) (Fresh Wan) CES] WESTERBEKE ‘Engines & Generators 73SPECIFICATIONS 8.0KW BTDA PUT Ta een ae) Brushes, ourpos,revling fi retard, sleterng design Reoonnadal, shge-pras bensformer regulation (ota soBstatevoage ‘eputon). Votage 12900 120240 Vos 60 Het. 250Vots 50 Hera, Vote regutin: 5% no at ed. Froqungyopulton: Hert (607) oad ful od. ating (Vals AD) ‘Sovarz(800epm) ——120Vos SB Amps ow 1RORAO Vos 6893 Amps Sovertz (500m) 2200827 Amp sonw Generator Cooteg 175-200 cm (4.95 8.88 eri) ‘A Ragerens (60 Harz) 211800 pm NOTE: incense supaly 15% for 60 Here pean (1600 rm). Fnge Combustion 42cm (14 em) ‘Peguero (Hate 218009 Engine Comparinent — 100-200cHm (283-568 cm) Gooing ir GeneatorCompatient 120° (60°) maximum ‘bint Temperture Fecormmandaions MOVE: Fred ett should bs pried ‘wo maintangenoator : tonpas ao 12 70°. SPECIFICATIONS 10.0 BTDA AC GENERATOR (Single Phase) PUREE kekunno) ‘SngiePrese Busts, fur, reohing fel. Thee Phase Brushes, spol, mong fl, Seed rebrcatsd, iglearing oes. ‘0 KW - sone lubcated,single-bang design, 12 Led ‘Reconcile, single phase transformer ‘75KW 50H ‘egal for lw voage WE, igh regulon optorlso-st vtsge ‘elage Osta. Sald tat wage epultr wth ae juicy vee {eb or020 ers Hoe \esoe-titae Lovely §——_ 2s Haat: She ae Biome a Voge epuston: 5% no dtu oud, 3 ae oe Frequrey eqn: Hat .6O8) odd. Geshe GRRE Nes ating (Volts AC) Amperage + 3 phase ‘Low Voltage WYE 35 Amps Snohcarpe) ovate agape on 120/240 Volts 63.9/41.6 Amps. (G0 Herts} i pyle wre Shave ‘s0vert2(1500 pm) —«220Vols§—-S2.6Amps. ‘Amparage~3 phase High Voltage WYE Amps iam aed on ines Cena Gobg 25. 2ein 68-887 em) ) ee oe aaa 000m ncn Combuon 42 chm (1.19. 0mm) ; Te ers a spp 18% tr Se ato 1500 (ova om ae Spore Canpuert 10-20 48-888 cnm) Hyneconuon «Ben (s8erm) Soong he | gece rere maa Suetomrinnt Fr naam ( Acomnon” AME in aad FScommmasins NTE are nin tu bpd - temperatures below 122°F (50°C) fennel blar 12 0)SPECIFICATIONS 12.5KW BTDB AND 15.0KW BTDC aE PS Ero pn Dis oso, uci she Gael Ope ows rn St ea is he pal fe 2d ae af 4 ore Dlepcamect {07S cubic bches (1788 te) Fuel Injton Pump ttn plungertyps(@O8CH). Aspiration ‘Naural aspirate. Neato Thro ype, Contsionanter Suit tite cane ie rato2t. bor 8 sie 07 xaszinaws (8x9200) et od tr PRT) eaier aga ir eter Ppl pps i care Dison tReaton cack, te ved ome tnt. Fo tPonp ‘dt OC ayy e515 eet ign 7 mA : RSE rss tees (rm). HSgh 240 ches (6096 nn) a tee ants cone ew ech vaavcned ack hrmoxtataly Lie Seats 78S) ‘cna wh bat change went) 569 ta 52:10) par Tempera 0180" F(7-88°0) Fud! Consumption 1aQnr sow at 1a pm (2S onary Caneel ee ere 49 ph (AD at 1000 pm (125) Raw Weer Pump Pet spear ber nple, ‘HP @ 1800 RPM 25 HP ‘ek crtven ‘HP G@ 1800 RPM 21H ‘System Capacity 8.0 US ots (7.6 lters) : (es a TUNE-UP SPECIFICATIONS ain 7-8 yp (258-226 gn) ‘Compression Pressure 427 psi (90 kg/cm’) at 280 bot ia sien wore Spline) 7 i TOC fata) Vibe Set oe Inka Eine Combuason Ar $6

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