Westerbeke WPDS-20 Technical Manual
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Westerbeke WPDS-20 Technical Manual

Westerbeke WPDS-20 Technical Manual

Marine diesel engine/marine diesel generator
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TECHNICAL MANUAL
WESTERBEKE 60
Marine Diesel Engine
WESTERBEKE WPDS-20
Marine Diesel Generator
Publication #15204
Edition Four
September 1979
j'-.v-
'WESTERBEKE
WESTERBEKECORPORATION
~
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

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  • Page 1 TECHNICAL MANUAL WESTERBEKE 60 Marine Diesel Engine WESTERBEKE WPDS-20 Marine Diesel Generator Publication #15204 Edition Four September 1979 'WESTERBEKE j'-.v- WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 TECHNICAL MANUAL WESTERBEKE 60 Marine Diesel Engine WESTERBEKE WPDS-20 Marine Diesel Generator Publication #15204 Edition Four September 1979 'WESTERBEKE j'-.v- WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 4 SECTION INDEX GENERAL Introduction Operation Installation Maintenance ENGINE OVERHAUL OTHER OVERHAUL Marine Engine Electrical System Cooling System (External) Transmissions GENERATOR SETS HYDRAULIC CRANKING SYSTEM SERVICE BULLETINS...
  • Page 5 YOUR NOTES...
  • Page 6 INTRODUCTION IMPORTANT THIS MANUAL IS A DETAILED GUIDE TO THE INSTALLATION, START-UP, OPERATION AND MAINTENANCE OF YOUR WESTERBEKE MARINE DIESEL ENGINE. THE INFORMA- TION IT CONTAINS IS VITAL TO THE ENGINE'S DEPENDABLE, LONG TERM OPERA- TION. READ IT KEEP IT IN A SAFE PLACE...
  • Page 8 J. H. to position as soon as the restriction has been passed. Westerbeke Corporation. In case it is necessary to hoist the RIGGING AND LIFTING engine either front end upwards or reverse The engine is fitted with lifting rings.
  • Page 9 FOUNDATION FOR ENGINE PROPELLER COUPLING A good engine bed contributes much Each Westerbeke Diesel engine is regu- toward the satisfactory operation of the larly fitted with a suitable coupling for engine. The engine bed must be of rigid connecting the propeller shaft to the construction and neither deflect nor twist engine.
  • Page 10 ment at frequent intervals and to correct In making the final check for alignment, any errors when they may appear. the engine half coupling should be held in Misalignment between the engine and the one position and the alignment with the propeller shaft is the cause of troubles propeller coupling tested with the propeller which are blamed often on other causes.
  • Page 11 cause rapid deterioration. Galvanized support for the rubber hose to prevent iron fittings and galvanized iron pipe is sagging, bending, and formation of water recommended for the exhaust line. The ex- pockets. haust line must be at least as large as Always arrange that water discharge the engine exhaust manifold flange and be into the rubber hose section is behind a...
  • Page 12 ELECTRIC PANEL interior is gel coated to prevent fibers The Westerbeke all-electric panel util- from contaminating the fuel system. izes an electronic tachometer with a Copper or galvanized fuel tanks should not built-in hour meter.
  • Page 13 plied, especially those relating to fuse/ cicuit breaker requirements. Starter batteries should be located as close to the engine as possible to avoid voltage drop through long leads. It is bad practice to use the starter batteries for other services unless they require low amperage or are intermittent'.
  • Page 14 OPERATION BLEEDING THE SYSTEM PREPARATION FOR FIRST START The engine is shipped "dry" ... with lub- The fuel injection system of a compres- ricating oil drained from the crankcase sion ignition engine depends upon very and transmission. Therefore, be sure to high fuel pressure during the injection follow these recommended procedures care- stroke to function correctly.
  • Page 15 Fig. 1 for mechanically governed and Fig. bleeding proceeds as follows. 2 for hydraulically governed pumps. Leave the governor bleed screw "D" slackened. Next slacken any two injector pipe line connections at the injector end. Set the throttle to the fully open pos- ition and turn the engine until fuel free from air flows from the unions.
  • Page 16 Do be careful to check with the engine cap when refueling - see that it doesn't parts list regarding whether the engine pick up dirt or grit - this is how quite requires injector seating washers or not. a lot of dirt gets into the tank. Additionally, spare banjo bolts and Avoid dubious sources of fuel.
  • Page 17 gine can be warmed up with the clutch reading after a stop does not neces- in neutral at 1000 rpm. Warming up sarily signal alarm against restarting. with clutch in neutral takes longer and If there is no functional difficulty, tends to overheat the transmission, if temperatures will quickly return to partial engagement occurs, which can be...
  • Page 18 TEN MUST RULES IMPORTANT IMPORTANT IMPORTANT ... for your safety and your engine's dependability. ALWAYS - 1. Keep this Manual handy and read it whenever in doubt. 2. Use only filtered fuel oil and check lube oil level daily. 3. Check cooling water temperature frequently to make sure it is 190 or less.
  • Page 19 YOUR NOTES...
  • Page 20 MAINTENANCE PERIODIC ATTENTION: After you have taken delivery of your engine, it is important that you make the following checks right after the first fifty hours of its operation: FIFTY HOUR CHECKOUT (INITIAL) Do the following: 1. Retorque the cylinder head bolts. 2.
  • Page 21 CAUTION: The use of different brands of 3. Fill fresh water cooling system with lubricating oils during oil changes has antifreeze of a reputable make. (Refer been known to cause extensive oil sludg- to Cold Weather Precautions.) ing and may in many instances cause com- 4.
  • Page 22 LUBRICATING OILS Lubricating oils are available for Westerbeke Diesel engines which offer an improved standard of performance to meet the requirements of modern operating conditions such as sustained high speeds and temperatures. These oils meet the requirements of the U. S. Ordnance Specification MIL-L-2l04B (API Service CC).
  • Page 23 YOUR NOTES...
  • Page 24 Additional operating characteristics are included in the Operation Section of this manual. Any replacements should be made only with genuine Westerbeke parts.

  • Page 26: Table Of Contents

    ENGINE OVERHAUL CONTENTS DESCRIPTION .......... A4 GENERAL DATA ......... A6 EXTERNAL COMPONENTS ........A8 INTERNAL COMPONENTS ......... A10 REMOVAL AND REFITTING ....... A12 Engine ..........A12 Valve Rocker Shaft and Tappets ....A12 Cylinder Head ........A12 Timing Chain, Chain Wheels and Chain Tensioner ..A13 Camshaft and Front Plate ......

  • Page 27: Description

    The big-ends are fitted are marked features of the engine. with steel-backed lead-indium thin Westerbeke 60 engine is robustly shell bearings, 2.248 in. (57.07 mm) diameter, and the small ends with constructed manufactured exacting...
  • Page 28 LUBRICA TION SYSTEM FUEL INJECTION EQUIPMENT A distributor-type fuel injection pump A full pressure wet sump system is incorporating an all-speed mechanical employed. The eccentric-rotor type governor is fitted. The pump is driven pressure pump is located within the at half-engine speed from stable idling engine crankcase and driven by helical approximately rev / min...

  • Page 29: General Data

    GENERAL DATA Westerbeke 60 MODEL TYPE Indirect injection Number of cylinders Four - Vertical Bore and Stroke 3.50 in. (89 mm) x 4.00 in. (101.6 mm) 154.2 in. 3 (2520 cm 3 ) Piston Displacement Compression Ratio 19.5:1 114.4 lb. ft. (15.81 Kg.m) @ 2,000 RPM...
  • Page 30 Torque Wrench Setting Cylinder head nuts 75 lb. ft. (1 0 . 37 Kg. m.) Manifold Nuts 221b ft. (3.04 Kg. m.) 25 lb. ft. (3.46 Kg. m.) Rocker bracket nuts 50 lb. ft (6.9 Kg. m.) Big End bolts 50 lb.

  • Page 31: External Components

    _·_···,""", ..· . . · · · · .._ . . · _ . . . ·l •••• , •••• ~"'I"'" ++ ..... ++++-+-++++-++ ... +++ . . . ++++ ..1111111111111.1 • • - . -. . 111 •• '111.1.' II 1.11.
  • Page 32 -++ ....- -... + ..++ ... + ......+++++.--. . . --++-+++-++.+ ....++-+ ....+++ ....+++ ....... _ .. + ......+++ .. · ..++-••• ++-... ++-..+++-+ ....+ ....++++.++ · • ·...
  • Page 33 +++ ..... +++++-+-+-+-+-....+-+-+-+-+-+-+-+++ ......++++-+ ....... 8= ---. 3--4~ °-' f,i~'8~~ 2019 18 ' @ > . ~\. 78~~" ~.' ~ ~ \ ~~~..~~1, " ~ ~. 'r~ ''-J : : . • n ' ! 6 0 ' •...

  • Page 34: Internal Components

    r·······-···· .. ·-··--······ .. ····_-·· .. ···-·····-·-.. ······· ....--.. -.. --.---.. -... --.----... -... -... -.. -.. -..- .. -.-.-.. -. . --... ·-·-..· .. · · KEY TO INTERNAL COMPONENTS Description Description Description Rocker shaft.

  • Page 35: Engine

    ENGINE Removing Drain fresh water system. refer to "Cooling System". Pump lubrication oil from sump. Disconnect battery cables from engine. Disconnect electrical leads from terminals board. Disconnect fuel pipe clips and fuel pipe from lift pump. Disconnect exhaust pipe from exhaust manifolds. Disconnect stop control from injection pump lever.

  • Page 36: Timing Chain, Chain Wheels And Chain Tensioner

    NOTE: The combustion chamber inserts are a loose fit in the cylinder head. They must be refitted in their original positions because the cylinder head face is machined with the inserts installed. 17. Refitting. Reverse the procedure in 1 to 16, noting: The cylinder head gasket is marked to ensure correct fitting.

  • Page 37: Camshaft And Front Plate

    Fig. 3 Fig. 4 ::,,- l :- 1·,.-- Fig. 5 ' .. ~-~..I , __ Fig. CAMSHAFT AND FRONT PLATE Removing Refer to Timing Chain. Chain Wheels. and Chain Tensioner". Step 1 through 12. Remove the oil thrower from the crankshaft. Retract the chain tensioner slipper as shown in Fig.

  • Page 38: Oil Pump, Connecting Rods And Pistons

    NOTE: The front plate must be removed to renew the chain vibration damper. Remove the timing chain tensioner. 10. Disconnect the throttle and stop controls, and the throttle return spring, from the injection pump. 11. Disconnect the fuel feed and return pipes from the injection pump. 12.

  • Page 39: Flywheel Housing, Flywheel And Backplate

    FLYWHEEL HOUSING, FLYWHEEL AND BACKPLATE Removing Take weight off rear of engine with sling attached to rear lifting eye. Remove rear mounting brackets from transmission housing. Remove nut securing each rear mounting bracket to flexible mount. Close inlet and outlet sea water cocks. Disconnect raw water from transmission oil cooler (hose between oil cooler and heat exchanger).
  • Page 40 20. Check the backplate for flatness. Examine the backplate two dowels locating holes for the cylinder block dowels are free from burrs. Examine the two locating dowels in the backplate for the alignment of the flywheel housing are free from burrs. 21.

  • Page 41: Crankshaft

    CRANKSHAFT Removing Remove engine. Remove flywheel housing, flywheel and backplate. Remove timing chain, chain wheels, and chain ter;.sioner. Pump lubrication oil from sump. Remove sump. Release the oil delivery pipe from the crankcase. Remove the dowel screw shown in Fig. 5, and withdraw the oil pump. Remove the big-end caps and separate the connecting rods from the crankshaft.

  • Page 42: Valve Rocker Shaft And Tappets

    VALVE ROCKER SHAFT AND TAPPETS Valve rockers Remove the shaft locating screw from the rear rocker bracket. Withdraw the split pins from the shaft ends. Slide the components off the rocker shaft. Unscrew the pi ug from the front end of the shaft to clean the shaft internally.
  • Page 43 CYLINDER HEAD Detach the spring clips from the valve cotters. Remove the valves and their components, using tool 18G 106. Renew the valve spri ngs if they are not as specified in Data..s--. If the valve gUides are worn, drive them out clio through the upper face of the cylinder head.

  • Page 44: Timing Chain Tensioner

    Length: mm.) Inlet 2·14 in. (54·36 Exhaust 2·5 in. (63·5 mm.) Inside diameter: Inlet (reamed in position) ·3438 to ·3443 in. (8·733 to 8·745 mm.) Exhaust (reamed in position) ·3433 to ·3438 in. (8·720 to 8·733 mm.) Outside diameter: Inlet and exhaust ·5645 to ·5650 in.

  • Page 45: Injection Pump Chain Wheel

    INJECTION PUMP CHAIN WHEEL If the chain wheel bearing requires renewal (see Data). remove the driving flange from the chain wheel. Press out the old bearing and press in a new bearing from the chamfered end of the chain wheel bore. Finish the bore ofthe new bearing to the size given in Data.

  • Page 46: Flywhee 1

    OIL PUMP Remove the pump cover. Check the rotor lobe clearance (in two positions) against the figure in Data. Renew the rotors if Check the rotor end-float against the figure in Data. Excessive end-float can be corrected by clearance is excessive. Reassemble the components, ensuring that the lapping the pump body face.

  • Page 47: Camshaft Bearing Liners

    CAMSHAFT BEARING LINERS 1. Withdraw the front bear- ing liner, using the tools shown in Fig. 1. Fig. 1 2. Withdraw the rear bear- 18GI24B ing liner, using the tools shown in Fig. 2. Fig. 2 3. Withdraw centre laG 124H bearing liner, using the tools shown in Fig.
  • Page 48 5. Fit a new rear bearing liner. lining up the oil 18GI24B holes and using the tools shown in Fig. 5. \-,."...----,"-I~§C~",';J.., ~~~~~~~~ Ii i Fig. 6. Fit a new centre bearing 18GI24D 18GI24H liner. lining up the oil holes and using the tools shown in Fig.

  • Page 49: Connecting Rod And Piston

    CONNECTING ROD AND PISTON 1--'---- Separate the piston from the connecti ng rod. Check the gudgeon pin clearance in the little-end bush against the figure in Data. If the clearance is excessive, renew the little-end bush. Position the new bush with its jOi nt on the cap side of the connecting rod as shown in Fig.

  • Page 50: Cylinder Bores

    CYLINDER BORES If the cylinder bores cannot be cleaned up at the Press in the cylinder liners and then bore them to maximum oversize given in Data bore them to the the standard bore size. dimension given for fitting cylinder liners. Data Standard cylinder bore 3·4995 to 3·501 in.
  • Page 51 INJECTION PUMP Removing Remove the three securing nuts and withdraw the Disconnect the battery and remove the engine injection pump and qUill shaft from the engine. cover panel. Refitting Remove the high-pressure pipes from the pump Reverse the procedure in 1 to 6, noting: and injectors.
  • Page 52 7. Tighten the anti-stall screw locknut and check the operation of the stop control. Note.-After every adjustment of the anti-stall screw ensure that the idling speed is controlled by the idling stop screw and not by the anti-stall screw. INJECTORS Removing Disconnect the battery and remove the engine cover panel.
  • Page 53 A • .30 VALVE ROCKER CLEARANCE (Fig. C.3) The correct clearance between the valve rockers and stem is given in "General Data". Unscrew the rocker cover nuts and lift off cover. Check the clearance at the position illustrated and the order as follows: Check No.
  • Page 54 AIR INTAKE SILENCER The air intake silencer is located behind the heat exchanger and exhaust manifold. The intake is covered by a metal screen which does not have to be replaced. Depending on operating conditions check to see the screen is clear when performing maintenance checks.

  • Page 56: Overhaul

    OTHER OVERHAUL CONTENTS SECTION PAGE MARINE ENGINE ELECTRICAL SYSTEM ....Activation by Fuel Pressure ......Q.2 COOLING SYSTEM (EXTERNAL) ......R TRANSMI SS IONS ........S Type SAO Manual ..•......S . 9 SAl and SAO Clutch Adjustrnents ..... S.2l SAl and SAO Reduct:i_on Units ....•...

  • Page 57: Marine Engine Electrical System

    MARINE ENGINE ELECTRICAL SYSTEM ACTIVATION BY FUEL PRESSURE (Push Button Start) This system is supplied on all four and six cylinder Westerbeke engines beginning January 1975. Basically, the system is very simple and eliminates the need for a separate switch position to activate the engine alarm system, when supplied.
  • Page 58 SECTION ACTIVATION BY FUEL PRESSURE (PUSH BUTTON START) WIRING DIAGRAM WIRING (N5EFtT F"OR WESTERB£KE LZoS 5TARTER hoIOTOR. r-------l !!il, c;::., lEh· " F'RE-HEATER<:';:.J ® wl-4,.-e I SEE NO'T'E-A IZ;~~ r----------, PANE~ START SW. ASSEMSL.Y. Isr ..~w.1 ... E ..I..
  • Page 59 Marine Engine Electrical System ACTIVATION BY LUBE OIL PRESSURE (Keyswitch Start) This system is supplied on all 4 and 6 cylinder Westerbeke diesels produced prior to January 1975. Operation is very simple. Putting the start switch in the Run posi- tion energizes an alarm system (when sup- plied).
  • Page 60 ACTIVATION BY LUBE OIL PRESSURE (KEYSWrrCH STARn ..• I· Te l >-- _t-o ® ~.,~ ''''''I''''' " • • 101[" -------.., "'L.TOO .•. ® *':' .sENDER FOUR-EC FOUR-91 FOUR-154 FOUR-230 SIX-346 :---1----------1 ~--~-----------~ c. .. o- ~r..u"~ @@@@®: IIIOT uKO L ______________ L...
  • Page 61 <;.6 YOUR NOTES...

  • Page 62: Cooling System (External)

    SECTIONR COOLING SYSTEM (EXTERNAL) DESCRIPTION The 4 and 6 cylinder marine diesel engines are equipped with a fresh water cooling system. Transfer of heat from the fresh water (closed system) circuit to the sea (raw) water is accomplished by a heat exchanger, similar to an automobile radiator.
  • Page 63 SEA WATER SYSTEM The engine is indirectly cooled by the unrestricted fast-flowing stream of sea water which absorbs the heat from the freshwater via the heat exchanger. This raw water is picked up from the sea by a powerful neoprene impeller sea water pump, and passes through the oil cooler to the heat exchanger.
  • Page 64 Test the opening temperature by placing th.e ttterrnostat in the water. Raise to the temperature stamped on bottom of thermostat. If thermostat fails to open, fit new thermostat. Allow the temperature to cool. If it sticks open, renew new thermostat. Install thermostat with new gasket and secure thermostat housing to cylinder head.

  • Page 66: Transmissions

    SECTION S TRANSMISSIONS...
  • Page 67 TYPE SA1 MANUAL Description The Westerbeke-Paragon manua Ily operated re- The number of hours that can be run between verse gear unitsconsistofa multipledisc clutch oi I changes varies with the operati ng con- and a planetary reverse gear train. These units ditions.
  • Page 68 Never press a ball bearing so that the force Slide entire reverse gear housing straight backapproximately 3 inchesuntil housing is carried through the balls. is c lear of engine gear (92) and lift re- Use only properly sized wrenches in re- verse gear housing assembly c lear of en- moving or securing nuts and capscrews.
  • Page 69 Remove cotter pin from reverse gear 16. Press gear half coupling (68) from boll tai Ishaft and remove reverse gear tai Ishaft bearing (63) and press ba II bearing from nut (69). direct drive plate (61). Support reverse gear housing face down so 17.
  • Page 70 Early models: 1/4" thick _---../-1 4 1/8 long - - 4 1/2" long _ _ 5/8" th i ck - --,._. -;-- Late models DISASSEMBLY OF GEAR CASE DISASSEMBLY OF THE REVE RSE BAN D-TOG- GLE OPERATED TYPE Remove. thrust washer (73) from end of (55), (58) Remove screw...
  • Page 71 Properlysupport gear case on clutch plate disassembly. However, donotdisassemble carrier (27) and press tailshaft (29) or unless required. (28) from prope "er gear (24) and clute h Lift clutch plate car- plate carrier (27). 11. Drive pinion shaft (6) of one of the short rier from gear case.
  • Page 72 ASSEMBLY OF REVERSE BAND AND YOKE TO GEAR CASE ASSEMBLY ·78 TOGGLE OPERATED REVERSE BAND ASSEMBLY STANDARD...
  • Page 73 YOUR NOTES...

  • Page 74: Type Sao Manual

    TYPE SAO MANUAL DESCRIPTION The Westerbeke Paragon manually operated reverse gear units consist of a multiple disc clutch and a planetary reverse gear train. The units are self con- tained and are independent of the engine lubrication system. OPERATION On the forward drive, the reverse gear case and multiple disc clutch are locked together as a solid coupling.
  • Page 75 S.10 TROUBLE SHOOTING CHARTS Ch art GEAR DRAGGING DRIVE SHAFT ROTATES EITHER FORWARD OR REVERSE WITH SHIFT LEVER IN NEUTRAL Check For DEFECTIVE FORWARD CLUTCH PLATES 3. BINDING IN PLANET MY ASSEMBLY 4. OVER ADJUSTMENT ON 2. REVERSE BAND ENGAGING GEAR CASE FORWARD AND REVERSE ------------------------------REMEDy------------------------------- hearin~s...
  • Page 76 S .11 TROUBLE SHOOTING CHART Chart GEAR INOPERATIVE DRIVE SHAFT OOES NOT ROTATE WITH SHIFT LEVER IN FORWARD OR REVERSE Ch.,(.~ 1. FAILURE OF PLANETARY ASSEMBLY 4. REVERSE BAND NOT ENGAGING G EAR CASE 2. FAILURE OF REDUCTION GEAR 5. BROK EN OUTPUT SHAFT 3 ..
  • Page 77 S.12 SAO MANUAL TRANSMISSION...
  • Page 78 S.13 SAO MANUAL TRANSMISSION...
  • Page 79 S.14 REMOVAL OF REVERSE GEAR HOUSING ASSEMBLY FROM ENGINE Remove capscrews and lockwashers that secure reverse gear housing (3) to front end plate (5). Slide entire reverse gear housing (3) straight back approximately 3 inches until housing is clear of front plate engine gear (1) and lift reverse gear housing assembly clear of front plate (5).
  • Page 80 S.IS 11. Remove capscrews and lockwashers that secure reduction adapter plate (85) to reverse gear housing (3). Remove reduction adapter plate with attached bearing (88) and reduc- tion drive gear (87). Press bearing with drive gear from adapter plate. Press bearing from drive gear. DIRECT DRIVE UNIT (perform procedl..res 1 through 6 above) 12.
  • Page 81 S.16 INSPECTION All parts should be thoroughly cleaned before inspection. Parts showing excessive wear should be replaced. Ball and roller bearings should be examined for indication of corrosion and pitting on balls or rollers and races. Long and short pinion bushings should be examined for wear. Pinion shafts should be examined for wear or "brinellingll.
  • Page 82 5.17 Insert pmlOn shaft (42) plain end first, into unthreaded end of gear case and push through pinion as far as rear wall of gear case, forcing out the dummy shaft. Remove dummy shaft, and start pinion shaft into rear wall of case. Do not drive pinion shaft all the way into gear case until all shafts are inserted.
  • Page 83 S .18 CAUTION: The forward clutch is not properly adjusted at the end of this assembly. Proper adjustment is made after installation in boat is complete. Follow instruc- tions as outlined under section on adjustments. ASSEMBL Y OF REVERSE GEAR CASE IN REVERSE GEAR HOUSING REDUC TION MODEL Place new gaskets (8).
  • Page 84 S.19 washer and install Woodruff key (27) in keyway in tailshaft. removed for replacement, pre-ss new oil seal (21) into direct drive plate (15). Press ball bearing (25) into direct drive plate. 24. Place direct drive plate, oil seal and ball bearing assembly on suitable support and press gear half coupling (14) into oil seal (21) and ball bear- ing (25) until gear half coupling is seated against ball bearing.
  • Page 85 S.20 YOUR NOTES...
  • Page 86 S.21 MANUAL CLUTCH SA1 AND SAO ADJUSTMENTS I. Back out the lockscrew (42) unti I the dog With the transmission secured to the engine, on the end of the lockscrew is clear of the replace all water lines, etc. However, do hole in the pressure plate (35).
  • Page 87 S.22 If further adjustments are necessary, continue the adjustments outlined above until satis- factory operation is reached. It should be noted however that the adjustments should be carried out only unti I satisfactory operation is reached since it is possible to over-adjust the transmission.
  • Page 88 S.23 SA1 AND SAO REDUCTION UNITS DESCRIPTION The Westerbeke/Paragon reduction gears consist of an internal ring gear and a drive gear that offers a variety of reduction ratios. ADJUSTMENTS There are no adjustments necessary to maintain the reduction gears in proper running condition.
  • Page 89 S.24 removed for replacement. press new oil seal (79) into reduction gear housing. Place flanged shaft over ring gear (71) and line up holes in flange with those in ring gear. Place lockwasher over capscrew and insert capscrew into hole in flanged shaft and secure flanged shaft to ring gear.
  • Page 90 S.25 TYPE RB - FREEWHEELING The Volvo Penta reduction-reverse gear, type Remove the bolts holding the reverse gear to the engine and pull the reverse gear RB, has a bui It-in reduction gear, with reduct- ion ratio 1 .91: 1. Engagement "Ahead" or "As- carefu Ily aft, without breaking, so that it tern"...
  • Page 91 S.26 Fig. 2. Cross-section of reduction-reverse gear, ratio 1.9 : 1 sure is applied ta the shaft journal for the ponents shou Id be carefully cleaned. At the same bearing (35). Take care to ensure that the time inspect the parts and replace those that are worn.
  • Page 92 S.27 Fit the bearing (36) and the gear wheel 12. Fittheflange(9), shaft (1), locking plung- (37), also press the shaft into the housing. er (8), sleeve (4), spring (5) and the plung- er housing (6). Oil the parts liberally be- Fit the gear wheel (31) with bearing (34) fore fitting.
  • Page 93 S.28 the lever retainer and the shaft must Set the reverse gear lever in the neutral turned. position. a. Remove the spring housing (1, Fig. 3) Remove the bolts whic h hold the bearing and lift out the locking plunger (2). housing (6, Fig.

  • Page 94: Paragon P-2L Series, Hydraulic

    5-29 PARAGON P-21 SERIES HYDRAULIC SPECIFICATIONS A. Description Chart MODEL REDUCTION RATIO DIRECTION OF ROTATION P21L DIRECT ALL LEFT HAND P22L 1. 5: 1 AS VIEWED FROM P23L THE OUTPDT END P24L 2. 5: 1 OF THE TRANS- P25L MISSION B.
  • Page 95 S.30 II. INTRODUCTION ward drive is through a multiple disc clU1.d\ a rrangement, while thE: reverse drive uti 1 izes a reverse clamp band and planetary g>::iI' train. The transmission oil circulated :H.d ansmissions have been designed for srilooth cooled through a sep" rate external oi c<)ok r operation and dependability in marine Lise.
  • Page 96 T.59 GENERATOR TROUBLESHOOTING PREPARATION D. AC output voltage builds up, but field breaker A few simple checks and a proper troubleshooting trips. procedure can locate the probable source of trouble and cut down troubleshooting time. To correct a problem, answer the question of the step either YES or NO.
  • Page 97 T.60 Test TABLE A. (continued) Test TABLE B. AC Output Voltage Proc. Proc. Builds Up, But Is Unstable 5. Is exciter field voltage across and F2- on end bell l. Are there any loose or broken terminal block 7.0 VDC or wires or connections on more? voltage regulator assembly...
  • Page 98 T_61 TABLE D. AC Output Voltage Test Proc. Builds UP. But Field Breaker Trips Does AC output voltage build up to 140% or more of rated voltage before Field Breaker trips? ADJUSTMENTS AND TESTS - REFERENCE LIST, pages 8-15. 2. Are there any loose or broken wires or con- A.
  • Page 100 SECTION V SERVICE BULLETINS The following Bulletins contain supplementary and up- dated information about various components and service pro- cedures which are important to the proper functioning of your engine and its support systems. You should familiarize yourself with the subjects and make sure that you consult the appropriate Bulletin(s) whenever your engine requires service or overhaul.
  • Page 101 MARINE ENGINE PRODuCTS SERVICE BULLETIN #16 SUB~ECT: Reduction Gear Ratio Identification MODELS: Westerbeke-Paragon Model SA To identify the reduction gear ratio on SA trans- missions, look for digits marked on the back side of the adapter plate. see Drawing Below...
  • Page 102 Any fittings used to connect the hose to the gallery must be of steel or malleable iron. Brass must not be used for this purpose. 6/15/69 #11967 J H WESTERBEKE CORP· AVON INDUSTRIAL PARK· AVON. MASS 02322 U.S.A· TELEPHONE 617 588·7700· TELEX 92-4444· CABLE WESTCORP...
  • Page 103 ~""""""""""~""·~·A·R·~·;>"E~·G·~·N~"~·R·~·D·~·T·~""'" SERVICE BULLETIN #69 Subject: Exhaust system failures Models: All marine generators and marine engines ~Jhen engine sea water is fed into an exhaust system so that the full stream strikes a surface, erosion may cause premature failures. Proper design of either a water jacketed or a "later injected ("wet") exhaust system to prevent this problem requires that the sea water inlet be positioned so that the entering stream of sea water does not strike a surface directly.
  • Page 104 2 3/8" dia panel SB #44 -',,..,..,..AM P - cut-out LAMP SND~B+ LAMP+ Wiring diagram SND~B+ Also see SB #36 PN19190 5/29/74 J H WESTERBEKE CORp· AVON INDUSTRIAL PARK· AVON. MASS 02322 USA, TELEPHONE 617 588·7700' TELEX 92·4444· CABLE WEST CORP...
  • Page 105 A list of correct part numbers follows: Enaine model's Part number 11698 Four-107 18136 Four-60,-91,-154 17926 Four-230, Six-345 9~444J· H WESTERBEKE CORP· AVON INDUSTRIAL PARK AVON. MASS 02322 USA TELEPHONE \::17 :,BB 7700· TELEX CABLE ':,,[STeOR? PN 11623 1/24/75 Page 1/1...
  • Page 106 We presume basic understanding of good marine practice on the part of the installer. H WESTERBEKE CORP· AVON INDUSTRIAL PARK· AVON. MASS 02322 US A . TELEPHONE 617 588·7700 TELEX 92·4444· CABLE WESTCORP Page 1/2 PN 19468 10/3/75...
  • Page 107 HYDRO-HUSH BELOW ENGI NE. AIR VE"T . • PN.1317~ HYDRO-HUSH AIR VENT 6' l f-=-"'A I~~' 3"MIN..---' ,~-'- ~.-, "- SEE WATER PUMP EXHAUST 3MIN. " OUTLET. " --..""' ... r"'~~ : : !"-' N SULATK>". 1/7-J.r-~~ ~. I __ /Y""?-,==~' n-rr...
  • Page 108 12 V.D.C. W-120, 115 Horsepower, diesel The ampere hour range shown is minimum. There is no real maximum. J H WESTERBEKE CORP, AVON INDUSTRIAL PARK· AVON, MASS 02322 USA.' TELEPHONE 6i7 588·7700· TELEX 92·4444· CABLE WESTCORP Page 1/l PN 20442...
  • Page 109 In any cases of engine overheating where such a rubber end cap is used, it should be checked for proper positioning along with other routine trouble- shooti ng. H WESTERBEKE CORP· AVON INDUSTRIAL PARK· AVON. MASS 02322 USA· TELEPHONE 617 588·7700· TELEX 92·4444· CABLE WESTCORP Page PN 20684...
  • Page 110 This unit is sealed for maximum life and is not repairable. Continued-Reverse Side WESTERBEKE CORP· AVON INDUSTRIAL PARK· AVON. MASS 02322 USA· TELEPHONE 617 588·7700 TELEX 92-4444· CABLE WESTCORP J f-4 PN 20701 9/75...
  • Page 111 BY-PASSING SPLITTER: In the event of failure, batteries may be charged directly from alternator by connecting either splitter terminal #1 or #2 to terminal A, bypassing the splitter itself. This should not be done simultaneously for both batteries unless they are, and will remain at, the same vo1taqe (state of charge).
  • Page 112 WESTERBEKE MARINE ENGINE PRODUCTS SERVICE BULLETIN 92 ISSUED: April 28, 1976 SUBJECT: Troubleshooting Water Temperature and Oil Pressure Gauges MODELS: DISTR: Distributors, Shipments Given a presumably faulty gauge indication with the instrument panel energized, the first step is to check for 12 VDC between the (8+) and neg.
  • Page 113 Overleaf is a parts list and an illustration showing the proper installation of the fuel pressure switch used on most of our engine products. 9/9/76 PIN 21564 H WESTERBEKE CORp· AVON INDUSTRIAL PARK· AVON, MASS 02322 U.S.A.' TELEPHONE: 617 588·7700, TELEX 92·4444· CABLE: WESTCORP...
  • Page 114 ' c . rUTKIO" DIIIT_I""'1 co.o ",.a,olll •• FUEL INJECTION PUMP. (ON EN"'NE) 19187 HE.- HD. SCREw f:L~r WASHER "0" O o D . / 1"383 RIN6; FUEL PReSSURe SWITCH rDI5 PLUt!; 19~21 '0" RII'I(I 9/t, /9185 ADAPTER COPI'E~ 1f!J26/ WASHee /9204 SCREW ASS'Y (8J.ceD)

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