Westerbeke 55B-FOUR Service Manual
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Westerbeke 55B-FOUR Service Manual

Marine diesel engine
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SERVICE MANUAL
55B-FOUR and 55e-FOUR
MARINE DIESEL ENGINE
PUBLICATION NO. 049970
2ND EDITION
SEPTEMBER 2006
~
WESTERBEKE CORPORA TION. 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
-~

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  • Page 1 SERVICE MANUAL 55B-FOUR and 55e-FOUR MARINE DIESEL ENGINE PUBLICATION NO. 049970 2ND EDITION SEPTEMBER 2006 WESTERBEKE CORPORA TION. 150 JOHN HANCOCK ROAD ---- MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780 WEBSITE: WWW.W£ST£RB£KE.COM Marin~ AlMM'" Metn«f National Manufacturers Association...
  • Page 2 GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator.
  • Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety carefully. Most accidents are 11Ul1Iual caused by failure follow fundamental rules WARNING: Fire can cause injury or death! precautiJJns. Know when dangerous conditions exist toke the necessary precautiJJns protect yourse1/, your •...
  • Page 4 SAFETY INSTRUCTIONS ACCIDENTAl STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is a deadly gas! death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the' engine.
  • Page 5 SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NfPA and USCG publications could be caught in moving parts.
  • Page 6 INSTALLATION installing WESTERBEKE engines and generators it is important that strict When attention be paid to the following infonnation: CODES AND REGlIATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

  • Page 7: Table Of Contents

    Starter Motor .., ..........Dual Output Alternators ........Wiring Schematic ..........Wiring Diagram ..........61 Tachometer ............Alternator Testing ..........Torque Data ............Nut and Bolt Tightening Method ....... 73 Tightening Torque Standard ......Metric Conversion Formulas ....... 76 WESTERBEKE Engines & Generators...

  • Page 8: Parts Identification

    PARTS IDENTIFICATION INTAKE/AIR AlTER ~UUI"'~' PRESSURE CAP THERMOSTAT ASSEMBLY 1c~~~, ~~ EWXiATERir.U:iliNJECTED ElBOW 1.0. PLATE :\..:.Jf---HI:AT EXCHANGER REAR CONNECTION ANODE D"'.D----- RAW WATER COOlER FRONT LEFT SIDE WATER INJECTED EXHAUST PREHEAT "u,.<NU"U, rlLltH,~ AIR INTAKE/AIR THERMOSTAT PUIRP-~ FUEL UFT 2DACIRCUIT REAR BREAKER ----~...

  • Page 9: Introduction

    OF THE FURNISHING OR USE OF SUCH SOF1WARE. the exhaust manifold injection port is at or below the WESTERBEKE customers should keep in mind the time load waterline will result in raw water damage to the span between printings of WESTERBEKE product software engine and possible flooding of the boat.

  • Page 10: Engine Specifications

    175 - 200 Amps Altemator Regulator Intema! regulator, buitt into altemator EXHAUST SYSTEM Exhaust Elbow 45' elbow Exhaust Hose Size 3.0" 1.0. hose Exhaust Gas Flow 265 cfm at 3000 RPM Muffler Size (min.) 14" x 14" WESTERBEKE Engines & Generators...

  • Page 11: Testing For Overhaul

    4. Be sure to use a torque wrench to tighten parts for which ALTERNATOR TROUBLESHOOTING and MANDO torques are specified. SERVICE in this manual. 5_ Ant time the engine is assembled, new gaskets and O-rings must be installed..WESTERBEKE Engines & Generators...

  • Page 12: Engine Troubleshooting

    1. Check and retighten connector. 1. Airtrapped in fuel system. 2. Clean or replace filter. 2. Clogged fitter. 3. Contaminated fuel tank. 3. Clean lank. INSUffiCIENT INTAKE AIR 1. Clogged air cleaner. 1. Clean or replace air cleaner. (continued) WESTERBEKE Engines & Generators...
  • Page 13 1. Correct oil level. 1. Excessive engine oil. 2. Excessive rise of oil into combustion chamber. a. Check. a. Poor piston contact. b. Replace or clean. b. Seized piston ring. c. Replace or correct. c. Excessive piston-to-cylinder clearance. (continued) WESTERBEKE Engines & Generators...
  • Page 14 3. Worn delivery valve. 3. Replace. 4. Inadequate injection nozzle spray. 4. Replace injection nozzle. GOVERNING SYSTEM 1. Governor lever manunctioning. 1. Check governor shaft and correct operation. 2. Fatigued governor spring. 2. Replace. (continued) -..v: WESTERBEKE Engines Generators &...
  • Page 15 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1. Main engine troubles. a. Overheated cylinder. a. See OVERHEATING; LOW OUTPUT. b. Clean. b. Carbon deposits in cylinder. 2. Too early injection timing. 2. Correct. 3. Correct 3.

  • Page 16: Engine Disassembly

    ENGINE DISASSEMBLY PROPll.SION ENGINE ENGINE DISASSEMBLY Switch off the batteries and disconnect the battery cables Take the following precautions: from the engine and tape over the tenninals. • Clean the exterior of the engine of any deposits of Drain or pump out all the engine oil and drain the coolant dirt and oil.

  • Page 17: Engine Measurements

    Mark each injection pump as to which cylinder it was removed from. " Do not reuse the shim, replace it with the same thickness that was removed. _ _ _ Injection pump ASM Shim Cylinder block ""'" WESTERBEKE Enginds & Generators...

  • Page 18: Engine Disassembly (Exploded View)

    ENGINE DISASSEMBLY INTERNAL PARTS DiSassembly Steps (11 Rocker Bracket Assembly (21 Push Rods (31 Rear Hanger (41 Front Hanger (51 Cylinder Head Assembly (61 Cylinder Head Gasket Tappets (81 Oil Pan (91 Oil Strainer (101 Oil Pipe (111 Crank Pulley (12) Flywheel (131 Flywheel Housing (14111ming Gear Case...
  • Page 19 ENGINE DISASSEMBLY Timing gear Remove the idle gear and the idle gear shaft. Pull out the sleeve from the tip end of the cam shaft. Remove the lock nut of the cam shaft gear, and then remove the flyweight assembly and the cam gear. Rear hanger--, "Head bolt (M12)
  • Page 20 ENGINE DISASSEMBLY Piston and Connecting Rod Piston ring Remove the piston ring with a ring pliers. Brass bar (\ _ Connecting rod Piston pin Remove the snap rings with a commercially avail· Piston and connecting rod able tool. 1. Turning the crankshaft, position the piston to be With a brass bar attached to the piston pin, push it removed at the bottom dead center.

  • Page 21: Engine Inspection And Repair

    (in.) Engine Bore Diameter Grade ® 85.000 - 85.010 Cylinder Body Height (Reference) mm (in.) (3.3464- 3.3468) Engine Standard 85.011 - 85.020 307.94 - 308.06 (3.3468 - 3.3472) (12.123 -12.128) 85.021 - 85.030 (3.3472 - 3.3476) WESTERBEKE Engines & Generators...
  • Page 22 63.90 - 64.10 contact with the hot plug. (2.515 - 2.523) Lightly tap the bar with a hammer to drive the hot plug free. If the cylinder head lower face is reground, valve depression must be checked. WESTERBEKE ,.y: Engines & Generators...
  • Page 23 ENGINE INSPECTION AND REPAIR Hot Plug Inspection Heat Shield Replacement Inspect the hot plugs for excessive wear and other dam- Heat Shield Removal 'e. Replace the hot plugs if either of these conditions After removing the hot plugs, use a hammer and a e discovered.
  • Page 24 Do not allow the valv .. cutter pilot to wobble inside the valve guide. Apply abrasive compound to the valve seat insert surface. Insert the valve into the valve guide. WESTERBEKE Engines Generators &...
  • Page 25 (in) Tension at 29.9 mm (37.479) (33.069) ,f'-'} Set Length _______ ________ Standard Limit '~~I Tappet and Tappet 0.020 - 0.054 0.08 Travelling Bore (0.00315) (0.00079 - 0.00213) Clearance .,.. (.) c WESTERBEKE . Engines & Generators VALVE SPRING TESTER...
  • Page 26 ENGINE INSPECTION AND REPAIR PUSH ROD Use a filler gauge to measure the valve push rod runout. Roll the push rod along a smooth flat surface (illustra- tion). _ .• -PUSHROD Uneven wear of journal (in) Nominal Limit Repair method 52 III 0.05 (0.002) Replace...
  • Page 27 If the ridge or scoring is severe, the rocke'r arm must be --.~ ( ----=-]-- ® SCORING RIOGES'(li'r"---...----... mm (in.) Model Nominal Limit Remarks Replace if worn 25.0 24.97 (0.9831) beyond limit (0.9843) WESTERBEKE Engines & Generators...
  • Page 28 --------.--------------------------------~----- ENGINE INSPECTION AND REPAIR CONNECTING ROD AND CONNECTING Clearance between piston pin and piston pin hole ROD BEARING mm (in.) Standard 0.002 - 0.012 (0.00008 - 0.00047) Piston ring gap With the ring inserted into the cylinder bore, push it in with the piston head so that it becomes a right angle to the cylinder, and then measure the gap of the piston ring.
  • Page 29 ENGINE INSPECTION AND REPAIR Connecting· Rod Bearing Inspection CRANKSHAFT AND CRANKSHAFT BEARING Fit the connecting rod bearing lower half into the Outside diameters of journal and pin connecting rod bearing cap. If worn beyond the limits-replace Check the connecting rod bearing lower half tension. Crank journal mm (in.) If the tension is insufficient, the bearing must be...
  • Page 30 ENGINE INSPECTION AND REPAIR REMOVING THE RING GEAR Ring Gear Installation Heat the ring gear evenly with a gas burner to invite thermal expansion. Runout of crankshaft Do not allow the temperature of the gas burner to Replace if beyond limit exceed 200·C (390·F).

  • Page 31: Engine Assembly

    ENGINE ASSEMBLY GENERAL INFORMATION Bolts and Fasteners • Be careful not to mix bolts and nuts. Metric and S.A.B. Lightly oil head bolts and other fasteners as you assemble bolts are used on various engine assemblies. them. Bolts and other plugs that penetrate the water jacket •...
  • Page 32 ENGINE ASSEMBLY CYUNDER HEAD ASSEMBLY Valve Stem Oil Seal Glow plug Lul1ricate the oil seals and valve stem sealing are ~5eal;VaIVe(1) with engine oil. Use a valve stem oil seal installer to install the oil seal. (6)~ INSTAlLER Nozzle holder Intake and Exhaust Valves Place the cylinder head on a flat wooden surface.
  • Page 33 ~hen Install the connector to the glow plug, and tighten m~;'~'lk:e,./o(;~~~t . until snug. Isuzu .. kg·m Ibs) Cylinder Parts TIghtening torque stamped side Glow plug 1.5 - 2.0 (11.0 - 14.0) WESTERBEKE EngInes & Generators...

  • Page 34: Engine Assembly (Exploded View)

    ENGINE ASSEMBLY Reassembly Steps INTERNAL PARTS Crankshaft (2) Piston Assembly (3) Rear Seal Retainer (4) Camshaft (5) Cam Gear (6) Idler gear and Shaft 011 Pump Assembly (8) TIming Gear Case (9) Flywheel Housing (10) Flywheel (11) Crank Pulley (12) Oil Pipe (13) Oil Strainer (14)011 Pan (15) Tappets...
  • Page 35 ENGINE ASSEMBLY Reassembly Steps INTERNAL PARTS 111 Crankshaft 121 Piston Assembly (31 Rear Seal Retainer (41 Camshaft 151 Cam Gear (61 Idler gear and Shaft Oil Pump Assembly (81 TIming Gear Case: (91 Flywheel Housing (101 Flywheel (111 Crank Pulley (121 Pipe (131 Oil Strainer...
  • Page 36 ENGINE ASSEMBLY Installation of retainer Apply engine oil to the shaft of the sleeve and the After applying engine oil to the lip of the oil seal. install slide of the flyweight. the retainer. Apply sealant. With the lip of the sleeve placed in the cavity of t Tighten bolts on the retainer to the specified torque in flyweight.
  • Page 37 ENGINE ASSEMBLY Crankshaft bearing Note that there is an oil hole and an oil groove in the upper bearing (on the block side), but not in the lower bearing (on the bearing cap side). Fit the bearing tang firmly into the slot machined on the cylinder body bearing archEls.
  • Page 38 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) Apply engine oil WESTERBEKE Engines & Generators...
  • Page 39 (ft. Ibs.) Tightening torque 0.8 - 1.2 (6.0 - 9.0) ",~ Rocker arm ..Apply stem of sealant ROC~ Avoid the application 1l1~>- ~ of seQlant to this ~groc\le. Oil gallery (Rocker bmcket bottom s~r.ace) WESTERBEKE Engines & Generators...

  • Page 40: Engine Assembly (External Parts)

    ..,!jJ..-! (3) 113) Dipstick Front hanger and rear hanger Oil filter (cartridge) Tiglmln them to the specified torque shown below. Insert the dipstick. kg·m (ft. Ibs.) Tightening torque 1.9-2.9 (14.0-21.0) Rear hanger IO'_-Front hanger ..-v: WESTERBEKE Engines & Generators...
  • Page 41 ENGINE ASSEMBLY Injection pump Align the two (2) holes in the fuel cut lever and the gov- ernor and lock into place with a pin. This will center and hold the control link for the installa- tion of the injection pumps. Injection pump Housing cover center position...
  • Page 42 Put sealant on the water pump where it contacts the block and head. Tightening torque 0.2 -0.4 (1.4- 2.9) Tighten to the specified torque. Cylinder cover kg.m (ft. Ibs.) Tightening torque 1.9-2.9 (14.0-21.0) Gasket Rocker arm bracket WESTERBEKE Engines & Generators...
  • Page 43 ENGINE ASSEMBLY Air inlet pipe Alternator Apply sealant (TB1207C) to the surface in which the 1. Tighten the adjustment plate together with the water air inlet pipe is installed. pump, and then install them temporarily. Install the air inlet pipe to the cylinder head cover, 2.

  • Page 44: Engine Assembly

    ENGINE ASSEMBLY NOTE:The exhaust manifold, which was disassembled ENGINE TUNING OPERATION from the cylinder head, should be inspected before After reassembly, the engine must be tuned. This will reassembly. ensure that the engine operates at its maximum a. Remove the exhaust elbows from the lower surface efficiency.

  • Page 45: Lubrication Diagram

    Clearance between the periphery of the outer rotor and the pump body (in) Standard Limit 0.10 - 0.185 (0.0039 - 0.0073) 0.4 (0.0157) Clearance between the inner rotor and the outer rotor OIL PUMP mm (in) Standard Limit 0.17 (0.0067) 0.2 (0.0079) WESTERBEKE Engines & Generators...

  • Page 46: Cooling System

    COOLING SYSTEM WATER PUMP REASSEMBLY Seal unit DISASSEMBLY -Cover Bearing unit Body With a hole in the bearing unit set in line with one in the body, lock the bearing unit with a setscrew. kg·m (ft. Ibs.) @~setscrew Set screw tightening torque 0.8-1.2 (6.0 -9.0) Cover Cover...
  • Page 47 TO TRANSMISSION COOLER Heat Exchanger Service After approximately 1000 hocrs of operation, remove, clean and pressure test the engine's heat exchanger. (A local automotive radiator shop should able to clean and test the heat exchanger.) THERMOSTAT ASSEMBLY WESTERBEKE Engines & Generators...
  • Page 48 Install the O-ring. #10 and secure the cover plate #11 with the four screws #12. ll.~tall the pulley on the shaft and the hose nipples back mto the pump. Mount the pump on the engine. Check pulley alignment Attach the raw water hoses. WESTERBEKE EngInes Generators &...

  • Page 49: Fuel System

    Do not disassemble the governor when the performance test cannot be conducted after reassembly. STRUCTURAL DRAWING OF GOVERNOR Idle speed screw spring Start Governor shaft Set spring pum~ [===~]t:===~~~~~~~~~ Injection Governor cover ·<...:S Main spring lever ..Guide lever gear esse Timing Tensioner lever Angleich Sleeve Full/oad stopper Shifter WESTERBEKE Engines Generators &...
  • Page 50 (When assembling temporarily) -A- dimension 2 - 3 (0.0787 - 0.0118) [Operate] [Stop) Governor cover ':::::: (ll!) ""--L Gasket Idle screw Governor lever (Notched groove) Washer Idle spring Washer Snap ring view of the drawing above) ..v WESTERBEKE Engines & Generators...
  • Page 51 FUEL SYSTEM REASSEMBLY OF CONTROL LEVER RELATED PARTS Lever; Main spring Protrusion Bush Apply loctite No.SO' to the peniphery (1) Put the lever (main spring) through the hole ofthe timing gear case lever. Note: Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case lever respectively.

  • Page 52: Governor Drawing

    FUEL SYSTEM STRUCTURAL "DRAWING OF GOVERNOR spring Start Control link spring Sn.p p;n Guide tever Floating fever Link plate Copnut Flyweight WESTERBEKE Engines & Generators...
  • Page 53 (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 before installing the start spring. (4) After assembly, confirm that each lever moves smoothly. And also confirm that each spring operates properly. WESTERBEKE Engines & Generators...
  • Page 54 Packing it If it requires servicing, remove it and take it authorized fuel injection pump service Do not facility. disassemble and repair it attempt He.tsh/eld Injection pump A l - - fdP' Gasket • WESTERBEKE "'t)IY" EngInes Generators...
  • Page 55 FUEL SYSTEM INJECTION TESTING Using the nozzle tester, check the spray pattern and injec- Shim tion starting pressure of nozzle and, if it exceeds the limit, adjust or replace the nozzle. When using nozzle Nozzle spring tester, take thefol\owing precautions: a.

  • Page 56: Engine Adjustments

    ENGINE ADJUSTMENTS TESTING ENGINE COMPRESSION Low Compression certain the oil level (dipstick) at the correct level When low compression is found, determine the cause by Make intake filter clean. The battery and starter motor the air applying a small amount of oil in the cylinder thru the glow must also be good...

  • Page 57: Valve Clearance

    When the intake and exhaust valves are closed, the cylinder is 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 '~/WESTERBEKE Engines & Generators...

  • Page 58: Injection Timing

    ENGINE ADJUSTMENTS . INJECTION TIMING Injection timing BTDC 16· Take care to avoid entry of dust or foreign particles into Note: the pump interior when the timing adjustment is made. The injection timing varies according to the specifica· Remove the injection pipe of the No.1 cylinder. tions of the machine.

  • Page 59: Warning Lights, Alarms, & Circuit Breakers

    In this event most engines will shut down because the opened breaker disconnects the fuel supply. If this should occur, check and repair the source of the problem. After repairing the fault, reset the breaker and restart the engine. BREAKER WIRES WESTERBEKE Engines Generators &...

  • Page 60: Starter Motor

    STARTER MOTOR DESCRIPTION No-Load Test 1. Connect the ammeter, voltmeter, and battery to the starter be roughly divided into the following sections: sttuter as illustrated. • A motor section which generates a drive power. arma- • An ovemmning clutch section whicb transmits an 2.
  • Page 61 STARTER MOTOR 4. Return test:. With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return its original position COIINECTDR OFF ') . AT11IACTION lEST released when from holding by hand.
  • Page 62 STARTER MOTOR STARlER INSPECTION /CRIICUS CLOTH Solenoid Inspect the solenoid for continuity between terminals S and M and between tenninals S and body. No continuity should be found between S and M. Continuity should be found between S and the body and M and the body. Brush and Brush Holder Inspection 1.
  • Page 63 STARTER MOTOR Field Coil Inspection Greasing. Whenever the starter has been overhauled, apply grease to the following parts: 1. Check for insulation between one end (brush) of the a. Armature shaft gear and reduction gear. coil and yoke. bearings. b. All 2.

  • Page 64: Dual Output Alternators

    IISTAl1ATlON If an optional dual alternator already been factory installed, . simply follow the WESTERBEKE wiring diagram and the engine installation instructions. If the new dual alternator is being added to an existing ''in- the-boat" engine, carefully follow the alternator installation...
  • Page 65 DUAL OUTPUT ALTERNATORS TROUBLESHOOTING Alternator Testing NOTE: Before troubleshooting, mrzke certain that the drive The regulator is functioning properly and the batteries belts are tight the batteries are in good condition. are in condition. good 1. Test the voltage at the alternator plug with the engine Regulator Testing off·key on.

  • Page 66: Wiring Schematic

    & 04 02 " " ~ r,~; " "61' lJ.=:J ",-UN '1[101[101 SIlIrCti • WIRING SCHEMATIC #39144 ' , sruuW:: lWIT~';.'W,) OPT IONAI AI IERNATORS® 'J~A, 1&0.1., I!OA. ltsT[1I ALHRNAlORi no rv ue ,nRD '9MjXIQNI~ AVAI'An'{qM WESTERBEKE 'Englnes Generators &...

  • Page 67: Wiring Diagram

    A PANEL switch with continuous tating amps at 12 will normally serve WIRING DIAGRAM #39144 this function, but swiJch must never be used to I· "make' the sIllrter circuit " CAPTAIN PANEL ----------------------------~ r~~f~~~==R-: WESTERBEKE Engines & Generators...

  • Page 68: Tachometer

    Zero the tach and bring it to the the tachometer. indicated by the strobe or hand tach. (Verify the idle and at high speed and adjust the tach as needed). WESTERBEKE Engines Genellltors &...

  • Page 69: Alternator Testing

    WESTERBEKE 51A MANDO ALTERNATOR DISASSEMBLY AND TESTING WARNING: A failed alternator can become very hot. Do not touch until the alternator has cooled down. REAR HOUSING WARNING Before starting the engine, make certain that everyone is clear of moving parts! Keep...
  • Page 70 MANDO ALTERNATOR SERVICE e. Remove the regulator cover. TESTING THE EXCITER LEAD f. Temporarily re-install Jumper (A) and all associated nuts. Leave Jumper (B) installed. g. Remove the plastic plug from the side of the regulator. b. Connect a jumper between the top brush lead and the ground.
  • Page 71 MANDO ALTERNATOR SERVICE 10. Place an oversized V-belt around the pulley and fasten REMOVE ALTERNATOR the pulley in a vise. Disconnect the negative (-) battery ground cable. 11. Use a 7/8 in. box wrench to loosen and remove the Disconnect the wiring leads. pulley nut.
  • Page 72 MANDO ALTERNATOR SERVICE 2. Inspect and test the diode-trio assembly: Using a commercial diode tester, a 12-volt DC test lamp or an ohmmeter, check the resistance between BEARING LOCKING each of the three diode terminals and the indicator SCREWS light stud. light stud FRONT BEARING DIODE TERMINAL...
  • Page 73 MANDO ALTERNATOR SERVICE 4, Clean and inspect the front and rear housings: a. Inspect the rear housing for cracks or breaks in the casting, stripped threads or a damaged bearing bore. Replace the housing if any of these conditions exist. b.
  • Page 74 MANDO ALTERNATOR SERVICE 2. Place the rotor (pulley end up) on the bed of an arbor press, on two steel blocks. 3. Press the front housing and bearing assembly down onto the rotor shaft. Press against the bearing's inner race only, using a sleeve driver. Take care to insure that ANGERS the rotor leads clear the steel blocks.
  • Page 75 MANDO ALTERNATOR SERVICE INSTALL ALTERNATOR 7. Install the spacer and the fan. Then push the pulley, lockwasher and nut onto the shaft. Tum the nut a few 1. Install the alternator, screws and washers. turns. 2. Connect the wiring leads. 8.

  • Page 76: Torque Data

    TORQUE DATA Kg-m (Ib-H) CYUNDER BLOCK AND OTHER COMPONENTS 2.5 -3.5 (1B.O -25.3) 1.5-2.5 ~10.8 -18.01 1.9-2.9 21.01 (13.7 - CYUNDER HEAD ANo.CYUNDER HEAD COVER POSitiOning) pIn. 0.8-12 7.0- 9.0 15.8-8.4) (50.6 - 65.0) WESTERBEKE Engines & Generators...
  • Page 77 TORQUE DATA Kg-m (Ib-H) CYLINDER BLOCK AND OTHER COMPONENTS bolt) ~hiS COOLING FAN AND WATER PUMP Don't remove from connecting rod. To cylinder head 17.0 -19.0 IApplV engine oi'l.I 1123.0 - 137.4} (.): Apply Locktite No.262 to set up side of stud. (Important) [(1::~:~OII t.:..:::::...=",...
  • Page 78 TORQUE DATA Kg-m (Ib-II) PTO provided) (With 0.8---=-=-12 r - - = - I - - - - (5.8-8.7) . GASKET LOCATION LOCATIONS WHERE GASKETS ARE USED Gasket; joint bolt ----" Corrugated washer •• =ield~i!!I Gasket; water outlet pipe '''' Q-ring;...

  • Page 79: Nut And Bolt Tightening Method

    IS>< COMPRESSION GAUGE ADAPTER FRONT DlL SEAL SmlNG TOOL REAR OIL SEAL SmlNG TOOL WITH DRIVE HANDLE WITH DRIVE HANDLE CONTACT THE WESTERBEKE CORPORATION FOR INFORMATION ON THESE AND OTHER SPECIAL TOOLS VALVE GUIDE SEAL SmlNG TOOL Engines & Generators...

  • Page 80: Tightening Torque Standard

    589+ 11 . 8 *M24 X 3.0 43.1 ±8.6 45.1 ±9.0 51.7 ±10.3 66.4 ::!:13.3 · -11.7 . NOTE: Bolts marked with an asterisk are used for female threaded parts made of soft materials such as castings. WESTERBEKE Engines & Generators...
  • Page 81 17.1-26.5 18.0-27.1 M16x1.5 (85.34 -128.02/115.71 -173.57) (125.85-189.50/170.63 -256.93) (130.19-196.01/176.52 -265.76) 11.2-16.7 16.6-24.9 17.2-25.7 "'16x2 (81.00-120.791109.83-163.77) (120.06-180.101162.79-244.18) . (124.40 -186.611168.67 -253.01) bolt with an asterisk 1*) used for female screws of soft material such as cast iron. WESTERBEKE Engines Generators &...

  • Page 82: Metric Conversion Formulas

    UQUID WEIGHTS Diesel Oil = 1 US gallon = 7.13 Ibs Fresh Water = 1 US gallon = 8.33 Ibs Gasoline = 1 US gallon = 6.1 Ibs Salt Water = 1 US gallon = 8.56 Ibs WESTERBEKE ,Engines & Ge.nerators...
  • Page 83 ENGLISH TO METRIC CONVERSION CHART Multiply Temperature To aet eauivalent number of: Dearee Fahrenheit (OF-32\ : 1.8 (0", Dearee Celsius °C\ Multiply Acceleration To get eouivalent number of: FooVSecond'(ftlsec') 0.3048 Meter/second'(mfs') Inch/second'CinJsec'1 0.0254 Meter/second' Imfs') Multiely Toraue To eel eauivalent number of: Pound-inch(lb·in.) Newton-meters (N·m) 0.11298...
  • Page 84 INDEX A1airms ........53 Engine Compression ...... .50 Alternator Dual Output ....58 Engine Disassembly ......10 Alternator Thsting and Repair ....63 Camshaft ........ .13 Circuit Breaker ......53 Crankshaft End Play ......11 Compression Engine ....... 50 Idler Gear End Play ......11 Cooling System ......
  • Page 85 Tappet and Head Gasket ....33 Timing Injection ......52 Tools and Test Gear ......73 Torque Data ......Transmission ......10 Valve Clearance ......51 Warning Lights ......53 Wiring Diagram ......61 Wiring Schematic ......60 '"" WESTERBEKE Engines & Generators...

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