Westerbeke 55B-FOUR, Service Manual

Page 1: ...INE DIESEL ENGINE PUBLICATION NO 049970 2ND EDITION SEPTEMBER 2006 WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD I MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE WWW W ST RB KE COM AlMM Metn f National Marin Manufacturers Association ...

Page 2: ...adache Weakness andSleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANYOF THESESYMPTOMS GETOUTINTO THE FRESH AIR IMMEDIATELY Ifsymptoms persist seek medicalattention Shut down the unit and do not restart until it has been inspected andrepaired A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead nearyo...

Page 3: ...uretor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause severe injury or death Do not ...

Page 4: ...e skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO isa deadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds water injected elbow is securely attached Be sure the unit and its surroundings are well ventilated Ru...

Page 5: ... for safety codes and standards Follow their recommendations when installing your engine ABYC American Boat and Yacht Council Safety Standards for S 1IaU Craft Order from ABYC 3069 Solomon s Island Rd Edgewater MD 21037 NFPA National Fire Protection Association Fire Protection Standard for Motor Craft Order from NfPA II Tracy Drive Avon Industrial Park Avon MA 02322 USCG United Slates Coast Guard ...

Page 6: ...aterline will result in mw water dDmoge to the engine andpossibleflooding ofthe boat Ifyou have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the vessel s various operating conditions installa siphon breok JIOIE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphon break ...

Page 7: ...rs 25 Engine Assembly Exploded View 28 Engine Assembly External Parts 34 Engine Assembly 38 Engine Tuning 38 Lubrication Diagram 39 Cooling System 40 Fuel System 43 Governor Drawing 46 Engine Adjustments 50 Testing Compression 50 Oil Pressure 50 Valve Clearance 51 Injection TIming 52 Warning Lights Alarms Circuit Breakers 53 Starter Motor 54 Dual Output Alternators 58 Wiring Schematic 60 Wiring Di...

Page 8: ... AIR INTAKE AIR rlLltH FUEL UFT PUIRP 2DACIRCUIT BREAKER Fua AlTER HaTEXCHIANGJ R SHIFT lEVER Oll T1 WATER INJECTED EXHAUST OIL COOLER Oll SSURE SENOOR RIGHT SIDE Engines Generators 2 1c ___EWXiATERir U iliNJECTED ElBOW 1 0 PLATE Jf HI AT EXCHANGER REAR ANODE COOlER LEFT SIDE All THERMOSTAT _ AlTERNATOR fRONT PUllEY OIL All MOUNT ...

Page 9: ...erial number as they appear on the silver and black nameplate located on the manifold You must provide us with this information so we may properly identify your engine In addition include a complete part description and part number for each part needed see the separately furnished Parts List Insist upon WESTERBEKE packaged parts because willfit or generic parts are frequently not made to the same ...

Page 10: ...as Flow Muffler Size min 12 Vott negative ground 400 600 CCA min 50 Amp rated bett driven 12V Glow plugs 12V sheathed 12 von 1 8 KW w h solenoid 175 200 Amps Intema regulator buitt into altemator EXHAUST SYSTEM 45 elbow 3 0 1 0 hose 265 cfm at 3000 RPM 14 x14 Fuel Fuel Injection Pump Injectors Fuel Rner Air cleaner Fuel Uft Pump General Operating Temperature Fresh Water Pump Raw Water Pump System ...

Page 11: ...t ofoil grease or sealant to parts as specified 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5_ Ant time the engine is assembled new gaskets and O rings must be installed OVERHAUL CONDITIONS Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in Thereafter it decreases gradually with the progress o...

Page 12: ...y 3 Replace battery 4 Clean terminals and correct cables 5 Repair or replace slarter 1 Bleed airfrom fuel system 2 Clean or replace filler 3 Adjust injection pressure 4 Clean or replace nozzle 5 Repair or replace injection pump 6 Adjust injection timing a Adjust valve clearance b lap valve c Replace valve and valve guide d Replace valve spring e Compression leaks through cylinder head gasket e Rep...

Page 13: ...ng 3 Replace ring 4 Worn piston or cylinder 4 Replace piston and rebore cylinder OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace avalve and valve guide EXCESSIVE FUEL ENGINE BODY mOUBLES CONSUMPTION 1 Noisy knocking 1 See KNOCKING 2 SmokY exhaust 2 See SMOKYEXHAUST 3 Moving parts nearly seized or excessively worn 3 Repair or replace 4 Poor compres...

Page 14: ...D AND CONNECTING ROD BEARING 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace PISTON PISTON PIN AND PISTON RING 1 Worn cylinder 1 Rebore cylinder to oversize and replace piston 2 Worn piston pin 2 Replace piston 3 Piston seized 3 Replace piston and rebore cylinder 4 Piston seized and ring worn or damaged 4 Re...

Page 15: ...ng b Repair or replace nozzle c After injection drip c Repair or replace nozzle d Nozzle needle valve seized d Replace INTERMITTENT 1 Fuel fi er clogged 1 Clean or replace EXHAUST SOUND 2 Water mixed in fuel 2 Replace fuel OVERHEATING 1 V belt slackening or slippery wnh oil 1 Adjust replace or clean 2 Damaged water pump 2 Replace 3 Lack of coolant 3 Add 4 Low oil level or poor oil quality 4 Add or...

Page 16: ...ttansmission separated from the engine begin the following step by step procedure to disassemble the engine I Remove the transmission damper plate from the engine flywheeL 2 Remove the engine oil cooler and oil hoses Note oil hose connections from the oil cooler to the engine 3 Remove the engine heat exchanger Ifpossible leave one end of each hose connected to the part being removed 4 Remove the b...

Page 17: ...6 Governor cover Control link I Injection pump 1 center position n ection pump rack pm 1 Mark each injection pump as to which cylinder it was removed from 2 Do not reuse the shim replace it with the same thickness that was removed ___ Injection pump ASM Shim Cylinder block Backlash oftiming gear STANDARD CRANK GEAR 0 04 IDLER GEAR 0 0017 CAM GEAR 0 03 IDLER GEAR 0 0012 IDLER GEAR END PLAY STANDARD...

Page 18: ... Rear Seal Retainer 20 Piston Assemblies 211 Crankshaft 00 nat pull out this bolt t 191 ENGINE DISASSEMBLY 111 Rocker bracket Push rod 1 Remove the rocker bracket assembly M6 x 1 5 bolts and 6 nuts 2 Pull out the push rods 8 pes nuts 6 Cylinder head 1 Remove the rear and front hangers 2 When removing the cylinder head bolts loosen them slowly a little at a time starting with the outside working in...

Page 19: ...spring seat valve spring and valve connecto r lll A G lo w r 1 udsareappHed wfih sealing agent Do not pull them out Nozzle holder 3 5 locations e t Hot plug F1I Split collar 4 10 11 Spring seat 151 lveSprlng lSI Seat valve insert J t Remove the lock nut of the cam shaft gear and then remove the flyweight assembly and the cam gear Camshaft 1 Remove the snap ring which holds down the front bearing o...

Page 20: ... carbon deposit off the cylinder wall 2 When pushing out the piston assembly care should be taken not to damage the cylinder wall 3 Attach a tag with a cylinder number to the removed caps and bearings to keep them in order Piston ring 4 r 1 ri Piston _1 Con rod bolt The drawing out ofthe con rod bolt must be limited to only when replaced Connecting rod 7 i c k Snap r n9 5 Bearing 3 Piston ring Rem...

Page 21: ...3464 3 3468 85 011 85 020 3 3468 3 3472 85 021 85 030 3 3472 3 3476 mm in Grade A B C Cylinder Body Upper Face Warpage Use a straight edge D and a feeler gauge to measure the four sides and the two diagonals of the cylinder body upper face Regrind the cylinder body upper face if the measured values are greater than the specified limit but less than the maximum grinding allowance If the measured va...

Page 22: ...face taking care nO to damage the hot plug surfaces 2 Use a straight edge and a feeler gauge to measure the hot plug depression in a straight line from the No 1 hot plug to the No 3 hot plug If the measured value exceeds the specified limit the hot plugs must be replaced rotPIug Depression mm in Limit 0 05 0 002 Combustion Chamber Inspection 1 Remove the carbon adhering to the inside of the combus...

Page 23: ...nd off any hot piug sur face protuberances The hot plug surfaces must be perfectly flush with the cylinder head lower face 7 After grinding make sure that the hot plug surfaces are completely free of protuberances The hot plug surfaces must also be free of depres sions Once again lightly tap the hot plug heads to make sure that they are firmly seated Heat Shield Replacement Heat Shield Removal Aft...

Page 24: ...1 Carefully place the attachment j having a small outside diameter than the valve seat insert on t valve seat insert Note The smooth side of the attachment must contact the valve seat insert 2 Use a bench press to gradually apply pressure to the attachment and press the valve seat insert into place 4 000 kg 8 819 Ibs Note Do not apply an excessive amount of pressure with the bench press Damage to ...

Page 25: ...limit the valve spring must be replaced Valve Spring Tension at 29 9 mm Standard 17 0 37 479 mm in 1 Limit 15 0 33 069 Set Length f I_______ ________ J VALVE ilNr Valve Spring Free Length Use a vernier caliper to measure the valve spr ng free length If the measured value is less than the specified limit the valve spring must be replaced mm in Standard Limit Exhaust and Intake 42 1 40 0 Valve Sprin...

Page 26: ...d cam 1 Cam height A B mm in Standard Limit Repair method Intake 6 13 5 83 Replace 0 2413 0 2295 Exhaust 6 43 6 13 Replace 0 2531 0 2413 2 Center journal diameter mm in Nominal Limit Repair method 52 III 51 92 III Replace 2 0472 2 0441 3 Uneven wear of journal mm in Nominal Limit Repair method 52 III 0 05 0 002 Replace 2 0472 4 Runout of cam shaft mm in Nominal Limit Repair method 0 02 0 1 0 004 R...

Page 27: ...act surfaces for ridges and scoring If the surfaces have light ridge or scoring they may be honed with an oil stone If the ridge or scoring is severe the rocke r arm must be SCORING RIOGES li r PISTON PISTON PIN AND PISTON RING Clearance between piston and cylinder bore 1 Measure the outside diameter of the piston at about 60 mm from the top in a right angle to the piston pin in the unit of 1 000 ...

Page 28: ...arance at several places on the circumfer ence If worn beyond the limit replace the rings or piston mm in Standard Limit 1st 0 085 0 105 0 2 compression ring 0 0033 0 0041 0 0078 2nd 0 050 0 085 compression ring 0 0020 0 0033 0 15 Oil ring 0 030 0 070 0 0059 0 0011 0 0027 CONNECTING ROD AND CONNECTING ROD BEARING Torsion and parallelism of connecting rod If worn beyond the limit repair or replace ...

Page 29: ...pecified torque Tightening torque Fm1NG THE LOWER BEARIIIG kg m ft Ibs 7 5 8 5 54 61 Clearance between bearing and crank pin inside di ameter with bearing installed and without Clearance Standard 0 035 0 073 0 0014 0 0029 mm in Limit 0 10 0 0039 mm in Standard Limit 60 0 2 3622 59 86 2 3567 Crank pin mm in Standard Limit 49 0 1 9291 48 87 1 9240 When there occurs an uneven wear to the crankShaft r...

Page 30: ...gear Ifthe ring gear teeth are broken orexcessively worn the ring gear must be replaced Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it Ring Gear Installation REMOVING THE RING GEAR 1 Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the gas burner to exceed 200 C 390 F 2 Use a hammer to install ...

Page 31: ...oil adapter hoses and the oil filter assembly Coat both surfaces of the oil pan gasket with high temp RED Sll JCONE SEALER When installing gaskets that seal around water coolant passages coat both sides with WHITE SILICONE GREASE Do not use sealant when installing a new gasket mGH COPPER ADHESIVE SPRAYS are useful for hold ing a gasket in position during assembly Specialized gasket sealers such as...

Page 32: ...ert t Split collar 5 e Spring seat 4 I Valve spring 3 dj c J INSTAlLER Intake and Exhaust Valves 1 Place the cylinder head on a flat wooden surface 2 Lubricate valve stems with engine oil 3 Install the valves to the intake or exhaust guides Install the valves to their original lapped valve seats Intake and Exhaust Valve Springs Install the valve springs with their painted end the close pitched end...

Page 33: ...ing torque 4 0 5 0 29 0 36 0 I Nozzle holder ASM Gasket Corrugated washer _ Heat shield tGlow plug I GaSket Connector Glow plug and connector Assemble the glow plug to the cylinder head and then tighten it to the specified torque Install the connector to the glow plug and hen tighten until snug kg m ft Ibs Parts TIghtening torque Glow plug 1 5 2 0 11 0 14 0 Piston ring 5 snap ring 4 Piston 1 _ I J...

Page 34: ...embly 8 TIming Gear Case 9 Flywheel Housing 10 Flywheel 11 Crank Pulley 12 Oil Pipe 13 Oil Strainer 14 011 Pan 15 Tappets 16 Cylindar Head Gasket 17 Cylinder Head Assembly 18 Push Rods 19 Rocker Brac ket Assembly 20 Engine Hangers 11 ENGINE ASSEMBLY INTERNAL PARTS 121 Engines Generators 28 r I i I I I I L _ _ _ _ _ _ _ _ _ _ _ _ ...

Page 35: ... 151 Cam Gear 61 Idler gear and Shaft 7J Oil Pump Assembly 81 TIming Gear Case 91 Flywheel Housing 101 Flywheel 111 Crank Pulley 121 011 Pipe 131 Oil Strainer 141 Oil Pan 151 Tappets 161 Cylinder Head Gasket 171 Cy6nder Head Assembly 1181 Push Rods 191 Rocker Bracket Assembly 201 Ei glne Hangers Engines Generators 29 ...

Page 36: ...ll the cam gear to the camshaft so that the tim ing point a dot mark comes to the front side 2 With the flyweight installed tighten the cam gear with a lock nut kg m ft Ibs Tightening torque 7 0 9 0 51 0 65 0 I Cam gear l Timing pOlnt Sleeve Flyweight 3 Apply engine oil to the shaft of the sleeve and the slide of the flyweight 4 With the lip of the sleeve placed in the cavity of t flyweight insert...

Page 37: ...lustration Crankshaft Bearing Cap Bolt Torque kg m ft lbs 8 5 9 5 61 0 69 0 4 Check that the crankshaft turns smoothly by manu ally rotating it LUBRICATE WITH ENGINE OIL fl o Arrow mark 10 6 9 J8 q Front 151 2st Ojl Position the rings as shown making sure the ring gaps are away from the thrust side Piston and Connecting Rod Lubricate the piston the piston rings and the connect ing rod bearings wit...

Page 38: ... in advance 2 Apply engine oil to the bushes provided on both ends of the main spring lever of the governor 3 Apply sealant to the gear case and then install it to the cylinder block or the front plate kg m ft Ibs Case tightening torque 1 9 2 9 14 0 21 0 I Governor cover 4 Assemble the gasket and the governor cover to the top of the gear case and then tighten them to the specified torque kg m ft I...

Page 39: ...rn up the stamp mark of the parts number last 4 digits which is between the No 2 and No 3 cylinders of the gasket Parts number Last 4 digits Stamp mark position Cylinder head assembly Lubricate the bolts with oil Tighten the bolts in the sequence shown in the iIIustra tion to the specified torque kg m ft Ibs Bolt size Tightening torque M12xl 5 8 5 9 5 60 90 8 each 61 69 M8x 1 25 2 5 3 5 4 each 18 ...

Page 40: ...Pump 111 Cylinder Head Cover 14 Injection Pump HouSing Cover 112 Exhaust Manifold 15 Fuel Pipe 113 Starter 16 Leak Off Pipe 114 Generafor 17 Fuel Hose 115 Pulley 18 Injection Pipe 116 Belt jJ 3 14 Front hanger and rear hanger Dipstick Oil filter cartridge Tiglmln them to the specified torque shown below 1 Insert the dipstick kg m ft Ibs Tightening torque 1 9 2 9 14 0 21 0 I 2 Rear hanger IO _ Fron...

Page 41: ... center position RackPin Housing cover Apply portion of sealant About2mm About 4mm in width around the bolt hole from the cover edge Injection pump housing cover After applying sealant TB1207C to the housing cover install it to the cylinder block by the side of the injection pump kg m ft Ibs Tightening torque 0 8 1 2 6 0 9 0 I The areas of the housing cover to which liquid gasket is applied are ab...

Page 42: ...securely before tighten ing it up_ Water pump assembly 1 Put sealant on the water pump where it contacts the block and head 2 Tighten to the specified torque kg m ft Ibs Tightening torque 1 9 2 9 14 0 21 0 I Thermostat Water outlet pipe Assemble the thermostat install the gasket and the water outlet pipe and then tighten it to the specified torque kg m ft Ibs Tightening torque 1 9 2 9 14 0 21 0 I ...

Page 43: ... 9 5 11 5 68 7 83 2 I For starter motor disassembly and repair refer to the starter motor section in this manual Alternator 1 Tighten the adjustment plate together with the water pump and then install them temporarily 2 Install the bottom of the alternator to the timing gear case and then tighten it temporarily with bolts and nuts 3 Install the fixing bolts onto the top of the alternator through t...

Page 44: ...nect the fuel lines 2 Connect the electrical wiring Refer to the WIRING DIAGRAM 3 Connect the air intake line to the air cleaner 4 Connect the exhaust pipe 5 Manually operate the fuel feed pump to feed fuel to the engine 6 Bleed the fuel lines of air 7 Crank the engine with the starter non ignition operation for about twenty seconds This will pre lubricate the engine internal components B Start th...

Page 45: ...pection and replacement When there is wear damages or any other defects found repair or replace the rotor Clearance between the outer rotor or inner rotor and the pump cover mm in Standard Limit 0 040 0 085 0 0016 0 0033 0 15 0 0059 Clearance between the periphery of the outer rotor and the pump body mm in Standard Limit 0 10 0 185 0 0039 0 0073 0 4 0 0157 Clearance between the inner rotor and the...

Page 46: ...ond No 4 to the surface where the seal unit comes into contact with the body and then assemble the seal unit 2 Press in the impeller with a press until the clearance between the pump impeller and the body gets to the specified value Cover 1 Apply liquid gasket to the surface to which the cover is installed and then install the cover 2 Apply Screw lock to the cover installation screws and then tigh...

Page 47: ...R I S Heat Exchanger Service Afterapproximately 1000 hocrs ofoperation remove clean and pressure test the engine s heat exchanger A local automotive radiator shop should be able to clean and test the heat exchanger WESTERBEKE Engines Generators 41 A CAUTION anyDfthe VIIJIBS hare IIml uff tire Impeller hey IIIDSfbefDrmd fD pmentIIIDCkageln tire cooling 1 11 TheyDflBn can be fDtmd In tire heat mhang...

Page 48: ...t seal 5 in the pump body Apply some glycerin to the lip ofthe seal 2 Install the circlip 13 on the shaft Support the outer bearing 18 and push the shaft into the bearing until the bearing contacts circlip 3 Install spacer 17 against the circlip Support the inner bearing 16 and push the shaft into the bearing until it contacts the spacer 4 Apply some glycerin onto the O ring 6 and install it on th...

Page 49: ...ing to ensure the same dimensions in reassembly 3 Do not disassemble the governor when the performance test cannot be conducted after reassembly STRUCTURAL DRAWING OF GOVERNOR Idle speed screw Start spring Governor shaft Set spring Injection pum t Governor cover Main spring lever S Guide lever Timing gear esse Tensioner lever Angleich Sleeve Full oad stopper Shifter WESTERBEKE Engines Generators 4...

Page 50: ...etum spring securely to the notched groove at the bottom of the cover and the bent up arm of the lever respectively 3 After reassembling the govemor cover confirm that the governor moves smoothly 4 When assembling the timing gear case to the gover nor cover tighten the An dimension shown in the illustration to 2 3 mm temporarily The parts given in the square indicated by are assem bled after perfo...

Page 51: ... the bushes apply Loctite 601 to the periphery of the bushes 4 Hook both ends of the return spring control lever securely to the protrusion and the pin of the lever main spring respectively Assemble the control lever Assemble the O ring to the groove of the bushes control lever first and then assemble the washers and the control lever before tightening up the control lever with a nut kg m ft Ibs I...

Page 52: ...FUEL SYSTEM STRUCTURAL DRAWING OF GOVERNOR Start spring Set spring Sn p p n Guide tever I t Control link Floating fever Link plate Copnut l Flyweight WESTERBEKE Engines Generators 46 ...

Page 53: ...iming gear case Notes when assembling governor related components 1 When assembling components apply engine oil to each slide such as the end face of the lever the hole in the shaft and the periphery of the shaft 2 Install the set spring securely to the groove of the pin connecting the floating lever with much care to its assembling direction 3 Confirm that each lever moves by its dead weight befo...

Page 54: ...quires servicing remove it and take it to an authorized fuel injection pump service facility Do not attempt to disassemble and repair it FUEL UFT PUMP Periodically check the fuel connections to and out of the pump and make sure that no leakage is present and that the fittings are tight and secure The DC ground connection at one ofthe pumps mounting bolts should be clean and well secured by the mou...

Page 55: ... spray condition and the injection pressure are normal Adjust them to the specified value respectively when they do not meet the standard value Use shims to adjust the injection pressure Body Nozzle holder ASM GLOW PLUGS Shim Nozzle spring Spring seat Spacer NozzleASM RETAINING NUT The glow plugs are wired through the preheat solenoid When PREHEAT is pressed at the control panel this solenoid shou...

Page 56: ...MPa NORMAL AT CRANKING SPEED OF 250 RPM 44 1 PSI BETWEEN CYLINDERS 7 Re install the glow plugs use anti seize compoundon the threads and reset the fuel shut off to the run position S Open the raw waterseacock tbru hull Compression ga Jge Low Compression When low compression is found determine the cause by applying a small amount ofoil in the cylinder thru the glow plug hole Allow the oil to settle...

Page 57: ...are closed the cylinder is at TDC in the compression stroke and when only the exhaust valve is open it is at TDC in the exhaust stroke CYUNOER NO 1 COMPRESSION 3 In accordance with the conditions of cylinder No 1 mea sure and adjust ifrequired the clearance ofthe valves marked with eiiher or in the table below Cylinder No 1 2 3 4 Valve arrangement I E I E I E I E When No 1 cylinder is at TOe in th...

Page 58: ... out of the range of the normal injection timhg adjust it accordingly Injection timing I BTDC 16 Note The injection timing varies according to the specifica tions of the machine 6 Adjust the injection timing with a shim between the injection pump and the cylinder block Shim is available in the following 9 types and iden tification mark is stamped or imprinted on the top face Identification mark of...

Page 59: ...ngine block This switch s sensor monitors the engine s oil pressure Should the engine s oil pressure fall to 5 10 psi 0 4 0 7 kgfcm this switch will activate a pulsating alarm ENGINE CIRCUIT BREAKER OIL PRESSURE AlARM SWITCH The DC harness on the engine is protected by an engine mounted manual reset circuit breaker 20 arnps DC Excessive current draw or electrical overload anywhere in the instrumen...

Page 60: ...called pinion gap 3 Ifthe pinion gap is not within the standmd range 0 5 to 2 0 mm adjust it by increasing or decreasing the number ofshims on the solenoid The gap is decreased as the number of shims increases GENTLYPUSH BACK 1 5 2 D PlalOaGAP 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 the starter ...

Page 61: ...rear bracket 4 WlIh the brushes pulled away from the armature remove the yoke and brush holder assembly Then pull the armature out 5 Remove the cover pry the snap ring out and remove the washer 6 Unscrew the bolts and remove the center bracket At the same time the washers f the pinion shaft end play adjustmeDt will come off PINION STARTBI II011IR WEAR CfflP ING SNAPRIUn_ Y LEVER SPRING RETURN TEST...

Page 62: ...service limit is exceeded Also check the comm1i1atoroutside surlace for dirtiness and rouglmess Ifrough polish the commutator with fine aocus cloth CRIICUS CLOTH Brush and Brush Holder Inspection 1 Check the brushes Ifworn out beyond the service limit replace the brushes Brush Height StlJlUiard 17nun 0 669 in limit 6 nun 0 236 in BRUSHES 2 Check the brush spring tension A weak or defective spring ...

Page 63: ...y adjustment Set the end play thrust gap to between 0 5 to 2 mm by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear washer and snap ting to the center bracket b Measure end play by moving the pinion shaft in the axiaI direction Ifthe end play exceeds 0 5 mm increase the number ofadjusting washers inserted 2 Greasing Whenever the ...

Page 64: ...ated ALWAYS USE FINE STRAND CABlEl S Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable 6 Mount the regulator to a flat surface in a cool dry location a Connect the black wire to the ground terminal on the alternator TO A CAUTION DIl nllt CIInnect anypllwerstJUTeB with Ilut first fJ1 Junding the regulatllr b Plug the 2 pin c...

Page 65: ...lls Alternator Testing The regulator is functioning properly and the batteries are in good condition 1 Test the voltage at the alternator plug with the engine off key on The voltage at the alternator terminal F and the voltage in the plug blue wire F from the regulator should read the same 2 Hold a screw driver close 112 to the alternator pulley Ifvoltage is present you should feel the magnetic fi...

Page 66: ...S e II O _ U J gf I I fl I I L U 1 S EA 0 IIDU difcH X I 1 1 lAC_ora VOLTMUtA 1 GAUGE M R I lESf n 1 _I I lQBP 1 30B ONl I I MIIV6i I ADMIRAL PANEL CAPTAIN PANEL 4 LT BLU fl4 PINK 0 R O 1 4 BRN pRESTOI ITE 72 AMP AI T 4 8RN 14 GRA 1114 PINK 414 LT 8L It I YfjRSAl PROPUI SI Wr PR STO ITF 51 AMP A 51 AMP AI TERNATOR ST NOARO AllERtiA10R ON TilE 638 01 63C Il i IB IT 826 IT 1086 D 10SC UN WIRING SCHE...

Page 67: ...engine sIllrte typically dtaw200to 300 amps when etanking A switch withacontinuous tating of 175ampsat 12 vacwill normallyserve this function butaswiJch mustneverbe usedto make the sIllrtercircuit WIRING DIAGRAM I Wf A Q II flQSURC mID 1 iI H l 1 I ADM IRAL PANEL r I I 1 IU N ME MODELS rT PUlAI WIRING DIAGRAM 39144 CAPTAIN PANEL r f R o 1 WESTERBEKE Engines Generators 61 1 1 1 1 1 1 ...

Page 68: ...ween tach inp terminaJ and terminal 2 Check for good ground connection between meter terminaJ and alternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachom lnaccurate a With a hand held tach on the front of the crankshaft pulley retaining nut or with a strobe type tach read the front crankshaft pulley pm at idle b Adjust the tachometer with a SmaIl PbilIip...

Page 69: ...m sheaves andbelts during testprocedures A WARNING Multimeters andDCCircuits DCandACCircuits are ottermixedtogether in marine applications Alwaysdisconnectshorepowercords isolate DCandACconverters andshutdowngenerators beforeperformingDC testing No ACtests shouldbe made withoutproperknowledge ofACcircuits REFER TO THE WIRING DIAGRAMSFOR THEABOVE WIRING HARNESS CONNECTIONS TESTING THE EXCITATION CI...

Page 70: ...ding should be between 13 7 and 14 7 volts 3 Ifthe reading is high check for a loose or dirty alternator ground lead connection If the connection is good the voltage regulator is faulty and must be replaced Be sure to disconnect the battery cables before attempting to remove the alternator 4 If the reading is low a Stop the engine and remove the alternator wiring connections b Remove the Phillips ...

Page 71: ... 10 Place an oversized V belt around the pulley and fasten the pulley in a vise 11 Use a 7 8 in box wrench to loosen and remove the pulley nut 12 Remove the pulley nut lockwasher pulley fan and spacer PUUEY AND FAN COMPONENTS A CAUTION DO NOT insert screwdriver blades more than 1 16in 1 6mmJ Damage to the stator winding couldresult from deeperpenetration NOTE Score the stator and the front and rea...

Page 72: ...ls and the indicator light stud light stud DIODE TERMINAL DIODE TRIO ASSEMBLY b Reverse the tester leads and repeat the resistance checks c A very low resistance should be indicated in one direction and a very high resistance should be indi cated in the other direction if the diodes are nonnal d If any diode appears to be defective replace the complete assembly Do not attempt to replace an individ...

Page 73: ...ds I 2 and 3 A lo ohm reading or lit test lamp should be observed HOUSING b Check the resistance from each lead I 2 and 3 to the laminations 4 There should be no continuity if the insulation is good e Inspect the stator windings for signs of discoloration A discolored winding should be replaced d If a winding shows a high resistance or an open circuit between any two of the three winding terminals...

Page 74: ...ONT HOUSING AND BEARING ASSEMBLY ROTOR INSTAlliNG THE FRONT HOUSING ON THE ROTOR ASSEMBLY 4 Install the rectifier assembly into the rear housing 5 Insert the Phillips screw and tighten it RECTIAER ASSEMBLY 6 Assemble the front and rear housings as follows a Put the siator winding in the front housing with the stator leads away from the front housing and the notches in the stator laminations aligne...

Page 75: ...all the nut on the terminal 15 Install the brush regulator assembly cover 16 Install the Phillips screw for the brush regulator assembly cover TORQUE 25 351b tt 2 8 5 1 Nm 17 Install the capacitor 18 Install the tenninal nuts 19 Install the jumper 20 Install the last terminal nut INSTALL ALTERNATOR 1 Install the alternator screws and washers 2 Connect the wiring leads 3 Put the belt on the alterna...

Page 76: ... 01 CYUNDER HEAD ANo CYUNDER HEAD COVER TORQUE DATA Kg m Ib H 7 0 9 0 50 6 65 0 WESTERBEKE Engines Generators 70 CYUNDER BLOCK AND OTHER COMPONENTS i 1 5 2 5 I 10 8 18 01 2 5 3 5 1B O 25 3 POSitiOning pIn 0 8 12 15 8 8 4 ...

Page 77: ...on t remove hiS bolt from connecting rod 1 t 17 0 19 0 1123 0 137 4 IApplV engine oi l I Apply Locktite No 262 to set up side of stud Important TORQUE DATA Kg m Ib H COOLING FAN AND WATER PUMP To cylinder head t 1 OII Engines Generators 71 ...

Page 78: ...TA Kg m Ib II r I 0 8 12 I 5 8 8 7 GASKET LOCATION LOCATIONS WHERE GASKETS ARE USED Gasket joint bolt Corrugated washer 18 ield i I Gasket water outlet pipe Oil seal crankshaft front O ring Oil pump I plug Engines Generators 72 Gasket exhaust silencer ...

Page 79: ...he parts to be clamped TItis line will be in the direction of the specified angle Q across the center E of the nut or bolt 7 Use a socket wrench to tighten each nut or bolt to the point where the line A B is aligned with the line F G Example SpecifiedAngle and Tightening Rotation A B C D E 30 1112 ofa tum 60 1 6 ofa tum 90 1 4 ofa tum 180 112 ofa tum 360 One full tum E Apply a coat of molybdenum d...

Page 80: ... 1 M14 X 2 0 9 1 1 8 9 8 1 9 11 2 2 2 12 8 2 5 13 6 2 7 M16 X 1 5 13 3 2 7 15 1 3 1 17 3 3 5 19 7 4 0 20 4 4 1 M16 X 2 0 12 7 2 5 14 4 2 9 16 5 3 3 18 8 3 8 19 5 3 9 M18 X 5 19 2 3 8 21 7 4 4 24 9 5 0 28 4 5 7 29 3 5 9 4 3 M18 X 2 5 19 2 3 8 21 8 4 4 25 0 5 0 28 5 5 7 29 4 4 3 M20 X 1 5 26 3 5 3 30 0 6 1 34 4 6 9 39 2 7 9 40 4 8 1 6 7 8 M20 X 2 5 24 3 4 9 27 8 31 8 6 4 36 3 7 2 37 4 7 S 7 3 M22 X ...

Page 81: ...4 7 9 11 9 8 7 13 0 40 50 60 75 54 91 82 37 57 14 86 07 77 47 116 69 62 92 94 02l85 31 127 4P 12 x 1 75 3 5 9 5 7 3 10 9 8 1 12 2 37 61 56 41 50 99 76 49 52 80 78 83 71 58 106 89 58 58 88 24 79 43 119 64 M14 x 1 5 8 5 12 7 11 7 17 6 12 6 18 9 61 48 91 85183 35 124 54 84 62 127 301114 73 172 59 91 13 136 701123 56 185 34 14x2 7 6 11 5 11 1 16 6 11 8 17 7 57 14 85 34 77 47 115 71 80 28 120 06 108 85...

Page 82: ...454 Kilograms kg x2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg Inches of Water H o x 07355 Inches of Mercury x 13 783 H20 Inches of Water fi 0 x 03613 psi x27 684 H20 Inches of Water H20 x 248 Kilopascals kPa x4 026 H20 TORQUE Pounds Force Inches in Ib x 113 Newton Meter...

Page 83: ...Lumensimeter lImfm l MuitiDIv Fuel Performance By To get_eguivalent number of Miles aal Imile oaJ 0 4251 Kilometersllner kmlLl Gallons mile eaVmilel 2 3527 LHerlkilometer Ukml Multiely Vetocltv By To oet eauivalent number of Mlles hour mllelhrl 1 6093 Kilometerslhouf kmlhr Mul I Y LenAlh By To aet eaulvalent number of Inch lin 1 25 4 Millimeters Imm Fool Iftl 0 3048 Meters 1m Yard Iydl 0 9144 Mete...

Page 84: ...earing 15 Engine Adjustments 30 Crankshaft and Crankshaft Bearing 23 Engine Tuning 38 Crankshaft Gear 24 External Parts Diagram 34 Cylinder Block 15 Filter Air Intake 41 Cylinder Head 15 Flywheel 32 Heat Shield 17 General Information 39 Hot Plug 16 17 Idle Gear 17 Oil Seal 24 Injection Pump 35 Piston Piston Pin Piston Ring 21 Internal Parts 28 29 Piston Ring Gap 22 Lubrication Diagram 39 Ring Gear...

Page 85: ...dentification 2 Pump Raw Water 41 42 Raw Water Pump 41 42 Rocker Arm Bracket Assembly 33 Schematic Wiring 60 Siphon Break 3 Specifications Engine 4 Standard Torque Specifications 74 75 Starter Motor 54 Tachometer 62 Tappet and Head Gasket 33 Timing Injection 52 Tools and Test Gear 73 Torque Data 70 Transmission 10 Valve Clearance 51 Warning Lights 53 Wiring Diagram 61 Wiring Schematic 60 WESTERBEK...

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