Westerbeke W-70GA User manual

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SERVICE MANUAL
25BEG(A)60Hz ANo20BEG(A)50Hz
20BEG(A)60HZANo 16BEG(A)50H:Z
MARINE GENERATORS
SINGLE and THREE PHASE ,
W70GA MARINE ENGINE
PUBLICATION N0.048088
REVISION·3
APRIL 2018
""""""""""" WESTERBEKE CORPORATION•MYLES STANDISH INDUSTRIAL PARK
§PC 150 JOHN HANCOCK ROAD• TAUNTON MA 02780-7319 •TEL. 1·508-823-7677 ·
. FAX [phone]• WEBSITE: WWlilf.WESTERBEKE.COM.

AwARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of carbon Monoxide
exposure can include:
•Dizziness
•Nausea
"•Headache
• Throbbing in Temples
•Muscular Twitching
•Vomiting
• Weakness and Sleepiness • Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. ff symptoms persist,
seek medical attention. Shut down fhe unit and do not restart
until it has been inspected and repaired.
WARNING'
Generators Produce CARBON MONOXIDE.
Regular Maintenance Required
f!!S!/.WESTERBEKE
Engines & Gemvalars
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of youi vessel.
T~ey are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are· known to the State of &alifornia
to cause cancer, birth defects,
and other reproductive harm.

TABLE OF CONTENTS
Parts Identification .................................................... 2
Engine Data ................................................................. 3
Troubleshooting Guide ............................................... .4
Testing for Overhaul ................................................... 6
Control Panels (Generator) ......................................... 7
Alarms/Switches (Generator) ................................... 7A
Instrument Panel (Engine) .......................................... 8
Engine Alarms/Breakers ............................................. 8
Generator Disassembly ............................................... 9
Engine Disassembly ................................................. 9A
Timing Belt ........................................................ 10
Cylinder Head/Valves......................................... 15
Valve Seat........................................................... 16
ValveNalve GuideNalve Spring ....................... 17
Camshaft............................................................. 18
Cylinder Block/Piston........................................ 19
Piston/Piston Ring..............................................20
Connecting Rods ............................................:... 21
Crankshaft .......................................................... 22
Engine Assembly ....................................................... 23
Lubricating System ................................................... 31
Cooling System ......................................................... 35
Fuel System .............................................................. 37
Exhaust Manifold/Heat Exchanger ........................... 38
Carburetor (#039454) .............................................. .39
Carburetor (#052563) .............................................. .42
Carburetor (#052563)Exploded View ....................... .43
Carburetor Troubleshooting .................................. .43B
Engine Adjustments ................................................. .44
Testing the lgnitor ................................................... .47
Tachometer ............................................................... 48
Timing Belt. ............................................................... 49
Starter Motor ............................................................ 51
Mando Alternator ...................................................... 65
BE Generator ............................................................. 72
Voltage Regulator Adjustments.......................... 73
Internal Wiring Schenatic...................................74
BE Troubleshooting ...........................................76
AC Connections .................................................
77
Shore Power Transfer Switch............................. 79
25 and 20 Generator Specifications ........................ 80
25 and 20 Wiring Diagrams ...................................... 82
With Two Relays................................................86
Remote Instrument Panel...................................
88
Remote Start Panel.............................................89
W·70GA Engine ......................................................... 90
W·70GA Wiring Diagram ........................................... 91
W·70GA Transmission ............................................... 93
Service Standards/Limits ......................................... 94
Angular Nut/Bolt Tightening ..................................... 96
Torque Specifications ............................................... 97
Standard Torque Specifications ............................... 98
Sealants and Lubricants ........................................... 99
Metric Conversion Data ......................................... .100
Index ................................................................... 101
Engines & Generators
1

25KW AND 20KW BEG GENERATOR PARTS IDENTIFICATION
RIGHT SIDE
AIR INTAKE FLAME ARRESTOR
EXHAUSTTEMPERATURE SWITCH.
ATER TEMPERATURE SWITCH
'OIL PRESSURE SWITCH
LED LIGHTS .
LUBE OIL DRAIN HOSE
FUEL LIFT PUMP
LEFT SIDE
FRESH WATER COOLANT FIU
70" EXHAUST ELBOW
1
EXCHANGER AIR BLEED PETCOCK
BELT GUARD
lwlWESTERBEKE
l Engine$ &Generators
2

W· 70GA PARTS IDENTIFICATION
COOLANT FILLER PRESSURE CAP
FLAME ARRESTER/AIR FILTER
RAW WATER PUMP
VACUUM ADVANCE UNIT
FRONT
Oil SUMP
DC ALTERNATOR
DISTRIBUTER
EXHAUST ELBOW
WATER INJECTED
EXHAUST
VCONNECTION
STARTER
SOLENOID
.a--- TRANSMISSION
COOLER
LEFT SIDE
FUEL.
FILTER
COOLANT
PRESSURE CAP
PCVVALVE
ZINC
20A CIRCUIT
BREAKER
TRANSMISSION.
REAR
SHIFT LEVER
Engines & Generators
2a
INLET
FILTER
,CARBURETOR
FRONT
RAW WATER PUMP
RIGHT SIDE
REAR

ENGINE DATA
DESCRIPTION
The engine is a "Square" type with a total displacement of
2184cc. It is a watercooled, four cylinder engine with a belt-
driven overhead cam (OHC).
The main specifications are as follows:
COMBUSTION CHAMBER TYPE Multi-sphere type
BORE X STROKE 86mm x 94mm
TOTAL DISPLACEMENT 2184cc
COMPRESSION RATIO 8.6
COMPRESSION PRESSURE 11.5 kg/cm2- 270 rpm
CYLINDER.BLOCK
The cylinder blockconstruction is an integral design where
the block and cylinderliners are cast as one piece. The
cylinder walls are double honed for a fine, precision surface.
The cylinderblock is deep-skirted with chambered cross
sections to reduce noise. There are five main beringjournals
for crankshaft support. ,1
CYLINDER HEAD
This WES'IERBEKE engine is an overhead cam (OHC),
cross-flow design. The rocker arm assembly bolts
independently to the head, rather than using the headbolts.
This makes it possible to remove the cylinder head without
disassembling the rocker arm assembly (and vice-versa)
resulting in improved serviceability. The intake and exhaust
ports are located on opposite sides of the cylinder head
(cross-flow) and theintake ports are designed to swirl the
incoming fueUair mixture.
CRANK MECHANISM
The piston is a tapered type with a recessed combustion
surface, specifically designed for the engine. The piston pin
is offset Imm to the thrust side (direction of lateral pressure
durillg combustion stroke) to decrease knocking noise.
On the crankshaft, the outside ofthe balance.weight is made
thicker to improve the effectiveness of a single,weight,
reducing the conventional eight weights to four.
As a result, the inertial weight is reduced, improving epgine
response. End play of the crankshaftis restricted ~y a ~t ·
bearing at the No.3 main bearing journal.
'·
VALVE MECHANISM
The valve mechanism employs the overhead camshaft
(OFIC). The rocker arm is offset against theexhaust stem to
prevent carbon damage and irregular.
The valve spring is of the double coil type with unequal pitch
inner and outer springs. Itis necessary to set the shorter
pitched side toward cylinder head at the time of installation.
The end play of the camshaft cannot be adjusted. Positioning
of the camshaft and cylinderhead are determinedby the
flange on the cam.
The adjustment of the belt is carried outby the tensioner and
tension spring.
INTAKE AND·EXHAUST SYSTEM
Both intake and exhaustmanifolds·are of aluminum,
consisting of an independentbranch, pipe for each pair
of cylinders.
COOLING SYSTEM
A centrifugal water pump is incorporated in the cylinder
block, driven by the timing belt Awax type thennostat is
employed to ensure proper temperature control. Cooling is
provided bya belt driven raw water pump and a heat
exchanger.
LUBRICATION SYSTEM
A crescenttype oilpump is driven directly by the crankshaft
to feed oilunder pressure. The oil fiher is.:ijill-tlow and a
spin
-on type.
FUEL SYSTEM
The carburetor is a down-draft, one stage, single barrel and the
fuel pump is an electromagnetic type, It performs the pumping
:function throughthe reciprocating motion of aplunger.
A mechanicalbeltdriven governor connectedthe to throttle arm
of the carburetor controls the engine rotational speed, power
outputands torque.
·Nm: For "additional tnjormati0n, refer to the. ·
.ENGWGENERATOR SPECIFICATIONS in'.this 11f21"ual
MEASURING EXHAUST BACK PRESSURE
PSI
GAUGE
Exhaust systems normally produce resistance to the flow of
·exhaust gases, causing back-pressure. Back-pressure must be
kept within a certain limit. Check the back-pressure before
.the generatoris
put back into service.
To test exhaust pressure, connect either a water column or
PSI tube.to the test part on the exhaust elbow as shown.
ChCck ~e exhaust back-pressure before the generatoris put
into service. Measure the back-pressure after the engine has
reachedits nomial operating temperature, and atthe point
where it isabout to reach its rated load at either 1500 rpm
(for SOHz applications) or 1800 rpm (for 60Hz appli'i.ations). •
Back-pressure shouldnot exceed 1.5 psi (0.11 kg/cm J.
A water column can be made by taping one end ofa clear
plastic tube along a yardstick lll!d. fittin~ the other end of the
tube with a l/4".NPf pipe fitting._. . ·• . · ·
Back-pressure should nofexceed 27in (69cm)
·ofwater ui the water column.
Engines & Generators
3
/·
,,
NiEASURiNG EXHAUST .BACK
P-5SURE

TROUBLESHOOTING GUIDE
The following engine troubleshooting guide may be helpful in
determining
if a complete or partial overhaul is necessary.
Insufficient Power
Insufficient Compression
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Burned cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston
ring
Cracked or worn piston
Malfunction of Fuel System
Malfunction of Ignition System
Excessive Oil Consumption
Oil Working Up
Worn or sticking piston ring or piston
ring groove
Worn piston or cylinder
Oil Working Down
Bad valve seal
Worn valve stem or guide
Oil leakage
Difficult Starting
Malfunction of Engine-related
Components
Burned valve
Worn piston, piston ring, or cylinder
Burned cylinder head gasket
Malfunction of Fuel System
Malfunction of Electrical System
Abnormal Combustion
Malfunction of Engine-related
Components
Sticking or burned valve
Weak or broken valve spring
Carbon accumulated in
combustion chamber
Malfunction of Fuel System
Malfunction of Ignition System
Poor Id.ling
Malfunction of Engine-related
Components
Poor valve-to-valve seat contact
Failure of cylinder head gasket
Malfunction of Fuel System
Malfunction of Ignition
System
4
Note: The Engine Cooling and Engine Lubrication
Troubleshooting Data are in those sections of this manual.
Engine Noise
Crankshaft or bearing related
parts ·
Excessive main bearing oil clearance
Main bearing seized or heat damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil
clearance
Connecting rod bearing seized or heat
damaged
Piston related parts
Worn Cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent Connecting Rod
Malfunction of Ignition System
Valve or timing related parts
Malfunction of HLA *
Broken valve spring
Excessive clearance between valve
stem and guide
Insufficient lubrication of rocker arm
Others
Malfunction of water pump bearing
Malfunction of alternator bearing
Malfunction of timing belt tensioner
Engine Misfires
Poor quality fuel.
Incorrect timing.
Dirty flame arrester.
Cracked distributor cap.
Faulty ignition wires.
Spark plugs are worn.
High exhaust back-pressure.
Valve clearances are incorrect.
Engine Backfires
Spark plug wires are connected
wrong.
Incorrect timing.
Engine is flooded.
Dirty flame arrester.
Cracked distributor cap.
High exhaust back-pressure.
Choke is stuck closed.
* Tapet noise may occur if the engine is not operatedfor a
period
of time. Tapet noise should stop within 10 minutes
after operating
the engine.

TROUBLESHOOTING GUIDE
Engine Overheats Coolant loss. Pressure test cooling
system.
Faulty raw water pump impeller.
Belts are loose or broken.
Raw water pump worn.
Faulty thermostat.
Heat exchanger is clogged.
Collapsed hose.
Low Oil Pressure Low oil level.
Faulty oil pressure sender
Wrong SAE type oil in the engine.
Faulty gauge
Wrong type oil filter.
Relief valve is stuck.
Faulty oil pump.
Faulty engine bearings.
Starting Battery
Loose alternator drive belt
Faulty battery voltage regulator.
Connections to the alternator are loose
or faulty.
Faulty alternator.
No excitation to the regulator
High Oil Pressure
Faulty sender or gauge
Dirty oil or wrong SAE type oil in the
engine.
Relief valve is stuck.
Blue Exhaust Smoke
Lube oil is diluted.
Discharge from the Engine
High lube oil level.
Crankcase breather hose is clogged.
Valves are worn or adjusted
incorrectly.
Piston rings are worn or unseated.
Black exhaust smoke
Dirty flame arrester.
Discharge from the Engine
Faulty carburetor.
Idle mixture jet too rich.
Accelerator diaphragm leaking.
Valves are worn or incorrectly
adjusted.
Lube oil is diluted.
Piston rings are worn or unseated.
Engines &Generators
5

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
power output, decreased compression
pressure, and increased
fuel and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine itself, but is
sometimes caused by worn plugs or fueVcarburetor
problems .. The decrease in compression pressure is caused
by many factors. It is, therefore, necessary to determine a
cause orcauses
on the basis ofdata produced by periodic
inspection and maintenance. Oilanalysis
on a seasonal basis
is a good means ofmonitoring engine internal wear. When
caused by worn cylinders or piston rings,
the following
symptoms will
occur:
1 Low engine power output
2
Increased fuel consumption
3 Increased oil consumption
4 Hard engine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4
can result also from carburetor performance or worn plugs.
They are caused also by defective electrical devices such
as
the battery, alternator or starter. Therefore it is desirable to
judge the optimum engine overhaul time by
the lowered
compression pressure caused by worn cylinders and pistons
plus increased oil consumption. Satisfactory combustion is
obtained only under sufficient compression pressure. If an
engine lacks compression pressure, incomplete combustion
offuel will take place even
if other parts of the engine are
operating properly. To determine the period ofengine
overhaul, it is important
to measure the engine compression
pressure regularly. At the same time, the engine speed at
which the measurement ofcompression
pressure is made
should be checked because the compression pressure varies
with engine rpm. The engine rpm can be measured at the
front end of the crankshaft.
When the decrease
of compression pressure reaches the
repair limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blow-by evident, and compression
valves are at minimum or
below.
Engine compression slwuld be 198.l psi (14 Kglcm
2) at
400 rpm. Cylinder compression should not vary more than
28.0 psi(20Kglcm2 ).
NOTE: Make certain the engines valve clearances are
properly adjusted. An incorrect valve clearance can cause
symptoms that might, incorrectly, suggest an engine
overhaul (cylinder misfire, white smoke, noise, etc).
Before preparing for an engine overhaul, adjust the valve
clearances to the correct specification, install a new cover
gasket andtest
the engine.
DISASSEMBLY
NOTE: Before disassembly and cleaning, carefully check
for
defects which cannot be found after disassembly and
cleaning.
• All disassembled parts should be carefully arranged in
the order ofreassembly. Mark or label the parts
as
needed to insure proper mating and reassembly in the
proper directions and positions.
• If the disassembly procedure is complex requiring many
parts to be disassembled, the parts should be disassembled
in a
way that will allow them to be efficiently reassembled
without
any change in the engine's external appearance or
its performance.
• Do not remove or disassemble parts that require no
disassembly.
• Carefully inspect each parts after removal for damage,
deformation, and other problems.
• Carefully check gaskets, packings and oil seals, even if
checking is not specified. Replace with new ones if defective.
• Be Careful not to damage the disassembled parts. Keep the
parts
clean.
• Use the proper tools. Apply oil when necessary. Take
special care to keep the fuel system parts free from the
intrusion ofdust and dirt.
Engines & Generators
6

GENERATOR CONTROL PANELS
DESCRIPTION
The generator mounted control.panel is equipped with an
ON switch (black), a START switch(white) and a STOP
switch (red).
The ON switch provides power to the start circuit. This
switch by-passes the protective oil pressure
shutdown switch
until the
oil pressure reaches 5 - 10 psi.
The START switch energizes the start solenoid/starter which
cranks
the engine. This s.witch will not operate unless the on
switch
is depressed and held at the same time.
The STOP switch will turn offthe engine/generator. This
switch must be depressed until the stop sequence is complete.
The panel also has two
fuses to protect the DC circuit:
• A 15 amp slow bluw fu.se protects the start circuit.
•An 8 amp fuse protects the engine operating circuit and
any optional remote start/stop orinstrument panel.
8AMP FUSE
REMOTE START/STOP PANEL (OPTIONAL)
An optional remote start/stop panel is available for
controlling the generator from a remote location.
This panel has the same ON, START, and STOP functions
previously described. Also included
is a green LED light
which glows once the engine/generator
has reached 600
rpm's. The purpose ofthe LED is to alert the operator to
release the START switch. It is also an indication that the
engine/generator
is running.
REMOTE INSTRUMENT PANEL (OPTIONAL}
An optional remote instrument panel is available which
includes a water temperature gauge, oil pressure gauge,
DC charging voltmeter, operating hourmeter, and start/stop
switches.
REMOTE INSTRUMENT PANEL INSTALLATION
The remote instrument panel has two sending units to be
installed on the engine block, a water temperature sender and
an oil pressure gauge sender. Plugged ports for each are
located on the engine. The water temperature sender is
installed in the thermostat housing and the oil pressure sender
is adjacent to the oil pressure switch. Use sealing compound
on the threads ofboth senders. Electrical connections for
each sender are tied offnext to the senders location ( in the
wiring harness).
The blue wire is for the oil pressure sender and the tan wire
is for the water temperature sender. If there is ajumper
between terminal board connections T-1 and T-2, it should be
removed. Refer to the REMOTE INSTRUMENT WIRING
DIAGRAM in this manual.
7
NOTE: When installing the optional remote panels, it is the
installers responsibility to comply with the U.S. Coast Guard
standards 33 CFR part I 83.

GENERATOR ALARMS AND SHUTDOWN SWITCHES
SAFETY SHUTDOWN· SWITCHES
The engine is prote~ted by three automatic shutdown
switches. Should a shutdown
occur, do notattempt to restart
withoutfinding and correcting the cause. Refer to the head-
ing Engine starts, runs an.d then shuts down in the ENGINE
TROUBLESHOOTING section of this manual.
The following
is adescription of these automatic shutdown
switches:
High Exhaust Temperature SWitch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the DC voltage
(shutting offthe engine) should the switch's
sensor indicate
an excessive exhaust temperature (an inade-
quate supply
of raw water causes high exhaust temperatures).
This switch
opens at 260-270°F (127-132°C). This switch
resets at approximately 225°F
(107°C).
HIGH EXHAUST
TEMPERATURE
SWITCH
MOUNTED AT THE
EXHAUST ELBOW
High Water Temperature SWitch
A high water temperature switch is located at the thermostat
housing. Normally closed, this
switch, shouid the fresh water
coolant's operating temperature reach approximately
210°F
(99°C), will open and interrupt the DC voltage thereby
shutting offthe engine. This switch resets at 195°F (107°C).
HIGH WATER
TEMPERATURE ·SWITCH
LOCATED AT THE THERMOSTAT
HOUSfNG UNDER THE
GOVERNOR
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the
engine's oil gallery. Normally open in a static state, this
switch's sensor monitors
the engine's oil pressure. Should the
engine's
oil pressure fall to 5-10 psi, this switch will open
interrupting the DC voltage thereby shutting off the engine.
MOUNTED TO THE ENGfNE
NEXT TO THE Ofl FfLTER
LOW OIL PRESSURE $WITCH
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring will cause the breaker to trip. In this
event the generator
will shut down because the opened
breaker interrupts the DC circuit. If this should occur, check
and repair the source of the problem. After repairing the
fault, reset the breaker and restart the generator.
High RPM Shutdown Switch
OVERSPEED TERMINAL
BOARD
An overspeed switch in the DC circuit shuts off the
generators engine by grounding out the ignition system if the
~ngine's speed reaches 2175 rpm(approx.imately). After
correcting the problem, this switch can be reset by momen-
tarily depressing the stop switch. Refer to the WIRING
DIAGRAMS in this manual.
7a
~· . -·
NOTE: To by-pass the overspeed when troubleshooting a
shutdown, lift TS and connect it onto and with T4.
Do not leave the switch in this configuration as overspeed
protection will
be lost.

GASOLINE ENGINE INSTRUMENT PANEL
NOTE: Be certain to install the instrument panel in a location
that
is accessible and where the gauges can be continually
monitored by the helmsman.
DESCRIPTION
The marine gasoline engine is equipped with an [optional]
key start instrument panel. This panel connects to the engine
wiring harness thru a
15 foot plug-in harness.
Included separately is an alarm buzzer with a 4 pin plug-in
harness. This alarm buzzer will sound when the ignition key
is turned on and should silence when the engine has started
and the oil pressure rises apove 5 psi. The installer is respon-
sible for installing this alarm buzzer in a dry location where it
will be audible to the operator with the enginerunning.
The following is a description ofthe panel components.
Tachometer -Registers revolutions per minute of the engine
and measures the engines total elapsed time in hours and
1110 hours. Refer to TACHOMETER for calibration.
Key switch -Turned to the 2 o'clock position (on], the key
switch energizes the panel. {Illuminates the gauges and
activates the start button.]
Prestart Button -A "push-to-start" rubber booted pushbutton
that is energized by the key switch. Pressing this button
activates the fuel lift pump.
Start Button -Identical to the prestart button, the start but-
ton, when pressed, energizes the starter which cranks the
engine.
Oil Pressure Gauge -Measures the engines oil pressure in
pounds per square inch. The alarm buzzer will sound a
pulsatingsignal if the oil pressure falls below 10 psi. This
alarm
will briefly sound when the engine is first started as the
oil comes to pressure.
Voltage Gauge, -Measures the voltage in the DC circuit [the
amoup.t the battery is being charges 13V to 14V].
Water Temperature Gauge -Indicates the temperature of the
enginecoolant.
If the coolant temperature reaches 210°F
[99°C], the alarm buzzer will sound a continuous signal.
NOTE: The water temperature gauge will register the last
reading when the engine is shut down. The true temperature
will register when the power is turned back on.
-~
~~~~~~~~~~~~
~ · ENGINE ALARMS AND CIRCUIT BREAKER
ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by, an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive currentdraw
or electrical overload anywhere in
the instrument panel wiring or engine wiring will cause the
breaker to trip. In this eventmost engines will
shut down
because the open breaker disconnects the fuel supply.
If
this should occur, check and repair the source of the problem.
After repairing thefault, reset the breaker and restart the
engine.
LOW OIL PRESSURE ALARM SWITCH
Allow oil pressure alam1 switch is located offthe engine's oil
gallery. This switch's sensor monitors the engine's oil pres-
sure. Should
the engine's oil pressure fall to 5 -10 psi
(0.4 -0.7 kg/cn).2), this switch will activate a pulsating alaim.
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the them1ostat
housing. This switch will activate a continuous
al aim if the
coolant's operating temperature reaches approximately \
210°F (99°C). .
Engines &Generators
. 8
~
\
-~

· GENERATOR DISASSEMBLY
GENERATOR
Disconnect the AC wiring and unplug the engine's DC
wiringharness at the generator control panel. Disconnect the
battery cable connections and the engine ground cables.
Separate the exhaust hose at the water injected elbow and
disconnect the ~I _supply and return lines.
NOTE: Label any lines, hoses or cables as you separate them.
Drainthe engine oil and the coolant from the engine.
Carefully support and then unbOlt the ·generator backend
from the engine. See SPECIAL TOOIS - GENERATOR in
this manual.
Additional generator infonnation will be found in the
GENERATOR section of this manual.
FOR MAIN ENGINE DISASSEMBLY
SEE THE FOLLOWING PAGE
NOTE: Remove the MPU before disassembly
of the generator to prevent damaging the MPU.
_Engines & Genera.tors
9
. LABEl. THE TERMfNAL
MARINE GENERATOR
[TYPICAL]

ENGINE DISASSEMBLY
-
WHEN REMOVING
THE MOUNTING BOLTS.--"""'-..!,!.;-"
LOCK THE FLYWHEEL
WITH A RING GEAR
BREAK TOOL
HBW
HURTH
TRANSMISSION
PROPULSION ENGINE
Switch off the batteries and disconnect the battery cables
from the engine and tape over the terminals.
Drain or pump out all the engine oil and drain the coolant
from the engirie and engine hoses.
Unplug the instrumental panel wiring harness. Drainthe
transmission fluid and the transmission oil cooler hoses.
Detach the oil cooler hoses and unbolt the transmission from
the engine.
NOTE: Label any lines, hoses or cables as you separat~ them.
\ ""-ftm
FLYWHEEL
INSPECT THE DAMPER'
PLATE FOii WEAR ANO
BROKEN SPRINGS
Transmission
. .
.. DAMPER Pl.ATE
;_BOLTS
If the transmission is not being rebuilt, it should be visually
inspected. Flush out and pressure test the· oil cooler and
replace the cQOlant hoses. Inspect'and lubricate the gear shift
linkage and the propeller shaft. coupling. Clt:mn and repaint
the
transmission and change the transmission fluid.
-~ ..
Fortransmisdonservice and niaintenance;refer to your
transmis.9ion manual. To.rebuild a transmission,contact
your
WFSTERBEKE dealer oran authorized ·
transmission service centir.
-. . -- -~
MAIN ENGINE PART$ DISASSEMBLY
• Clean or wash the engine exterior.
• Do not remove or disassemble the parts thatrequire :ilo
disassembly.
• When disconnecting sensor wires, label and tape the ends.
• Perform disassembly ina proper order using proper tools.
Keep disassembled parts in order. Apply oil when ·
necessary. Take special care to keep the fuel system parts
from intrusion ofdust and dirt.
• Parts must be restored to their l'eSpectiVe components from
which they were removed at disassembly. This means that all
partsmust be set aside separately in groups, each marlced for
its component, so that the same combination or set can be
reproduced at assembly.
• Pay attention to marks on assemblies, components and
parts for their positions or directions. Put on marks, if
necessary. to aid assembly.
• Carefully checkeach part or component for any sign of
faulty condition during removal or cleaning. The part will
tell you how it acted or what was abnonnal a~out it more
accurately during removal or cleaning. · · ··
-
NOTE: Mount the engine on a suitable stand or work bench.
1. Remove the engine oil hose connections.
2. Remove the engine heat exchanger. If possible, leave
one end of each hose connected to the part being
removed.
3. Remove the engine back plate. . .
4. Remove the start motor, drive belt and the alternator.
Label the wires and cables.
5. Remove the engine mounted raw water puinp,
adapter mountingplate, and drive from the front
cover.
Th.e drive is removed by turning in a counter
clockwise direction. See RAW WATER PUMP for parts
breakdown.
6. Remove the coolant recirculating pump. See
cool.ANT RECIRCULATING PUMP for parts
breakdown.
7. Remove the air intake silencer and the intake
manifold.
Engines & Generators
'9a

ENGINE DISASSEMBLY
8. Remove the thermostatassembly. Leave the
temperature sender in place. ·
9. Remove the crankSbaft pulley. To prevent the
crankshaft pulley from rotating, insert two bolts into
the gap at the rear end ofthe crankshaft.
Remove the six bolts that secure the drive plate and
loosen the timing pulley lock bolt.
Using a 6rnm hex wrench, remove the six bolts holding
the crankshaft pulley.
Remove the deflector.
TIMING BELT
COVER .
(UPPER)
10. Remove the following p~ and assemblies.
Fuel pump/gasket
The carburetor and
governor with the gasket
and insulator
Spark plugs
Dipstick
The distributor assembly/High tension leads
The exhaust manifold
Oil filter and oil pressure switch
NOTE: All assembledparts should be carefully arranged in
order of reassembly. Mark or label the parts as needed to
insure proper reassembly.
REMOVE THE TIMING BELT ASSEMBLY
TIMING BELT·
COVER
(LOWER)
GASKET
TIMING BELT
'
~,l .. )WI ~.·.·~~···~·
/
'" ~ ~
:; ~» ~~IDLER.
If l ., TENSIONER .
~ LOCKBOLT
11. Remove the timing belt covers, upper and lower.
12. Loosen the timing belt tensioner lock belt and
remove the spring.
13. Remove the bolts to remove the timing belt tensioner
and remove the timing belt.
NOTE: Mark the nonnal rotation of the belt (clockwise as
viewedfrom the front -belt end
of the engine) on the belt.
For INSPECTION and ASSEMBLY, refer to TIMING BELT
in this manual.
1 TENSIONER'
le LOCK BOLT .
TIMING BELT
PULLEY
14. Remove the camshaft pulley. Remove the pulley
by inserting a T-wrench
or similar tool to prevent it
. from turning.
·~
Engines &Generators
10

ENGINE DISASSEMBLY /INSPECTION
FRONT HOUSING ASSY
1. Remove the front housing assembly by removing the bOlis :
and nuts.
2. Remove the inlet manifold.
· 3. Remove the cylinder head cover.
REMOVE THE TIMING BELT PULLEY·"'
1. Remove the lock bolt and lock washer.
INLET
MANIFOLD
2. Using a plastic hammer, strike the whole peripheral of the
spacer on the front side of the pulley.
3. Attach a pulley puller on the spacer. Bring a suitable
washer or pipe into contact with the end of the center bolt
of
the puller.
DIMENSION DF WASHER OR PIPE:
DIAMETER: 24mm (0.945in)
LENGTH: !5mm (0.5~in) -
,r,· ;\ ~
f.._r.::.~~- ....
~·./
/
,--..,..,,..,_,._ (
4. Screw in the pulley .puller, and remove the spacer and
taper ring together. ·
NOTE: While screwing in the pulley, hit the whole
peripheral of the spacer with the plastic hammer.
5. Remove the timing belt pulley.
6. Remove the woodruf key.
7. Disassemble the spacer from the pulley puller.
REMOVE THE ROCKER SHAFT ASSEMBLY
1. Loosen the rocker shaft assembly bolts in several
increments, not all at once. Use the sequence indicated
in the diagram.
. 5
2 6 10 1
2. Inspect the end play by movirig the camshaft forward and
backward using a magnet base and dial gauge.
END PLAY: 0.08 • 0.16mm (0.003 • 0.0061n)
MAXIMUM: 0.20mm (0.008in)
MEASURING
END PLAY.
NOTE: If the end play exceeds specifications, replace the
camshaft and/or cylinder head.
REMOVE THE CYLINDER HEAD ASSEMBLY AS A UNIT
CYLINDER HEAD
AND GASKET ;
TIMING BELT
·PULLEY
Engines &Generators
11

ENGINE DISASSEMBLY /INSPECTION
6 10
1. Loosen the cylinder head bolts in several increments to
remove, following the numerical sequence indicated
above.
REMOVE THE OIL PAN, GASKET AND BAFFLE PLATE
1. Remove the bolts and remove the oil strainer.
Oil PAN
CLEAN OUT THE OIL PAN
AND OIL TUBE WITH KEROSENE.
INSPECTFOR DETERIORATION
AND RUST. REPAINT IF NECESSARY.
OIL STRAINER
REMOVE THE OIL PUMP
)
,OIL PUMP
I
INSPECT THE END PLAY OF THE CONNECTING ROD
LARGE END
1. Use a magnet base and a dial indicator.
STANDARD: 0.110 - 0.262mm (0.004 - 0.010in)
LIMIT: 0.30mm (0.012in)
NOTE: Replace if the measured value exceeds the limit.
2. Inspect the oil clearance on the bearing of the connecting
rod large end.
a. Remove the connecting rod cap nuts and remove the
cap and bearing.
b. Clean any oil off the crank pin and bearing surfaces.
c. Using a piece of plasti-gauge, set it in the longitudinal
direction
of the crank pin. Do not set the plasti-gauge
over the oil port.
d. Install the cap and bearing and tighten the nuts to the
specified torque. -
TORQUE: 660 - 700 Kgcm
/
. . I
REMOVING THE
CONNECTING ~
ROD CAPS
: A~
I
e. Remove the cap and beilririg arid reacfthe plasti-::-gau~
Inspect the oil clearance by comparing he measured
value with the standard value.
STANDARD VALUE: 0.027mm (0.001in)
MAXIMUM LIMIT: 0.1Dmm (0.004in)
f. Remove the plasti-gauge.
-
MEASURING THE
OIL CLEARANCE OF
THE LARGE END
BEARING
REFER TO THE
LUBRICATION SECTION
OF THIS MANUAL FOR A
BREAKDOWN OF THE
OIL PUMP
Engines & Generators
12

ENGINE DISASSEMBLY nNSPECTION
g. If the oil clearance exceeds the limit, replace the
bearing set with a new one and measure again.
If the replaced bearing set exceeds the limit, grind the
crank pin and use an under-size bearing to obtain the
oil clearance required.
CONNECTING ROD BEARINGS- UNDERSIZE (U.S.):
AMOUNT OF UNDERSIZE
D.25mm (D.009in)
0.5Dmm {D.019in)
0.75mm (D.029in)
R DIMENSION: 3mm R
REMOVE THE PISTON AND CONNECTING ROD
ASSEMBLIES
1. Remove the cap nut and remove the connecting rod cap
bearing.
2. Force the piston and connecting rodout (downward) by
tapping gently with the handle of a hammer.
3. Force the remaining piston and connecting rod assemblies
out in the same manner as mentioned above.
INSPECT THE CRANKSHAFT END PLAY.
1. Check the end play by moving the crankshaft forward and
backward as shown using a magnetic base and dial gauge
to measure the amount.
STANDARD: 0.08 • 0.282mm (0.003 • 0.011in)
LIMIT: 0.30mm (0.012in)
2. Adjust the end play at the center main bearing if the
measured value exceeds the limit.
NOTE: The undersize center main bearings are classified
into the following three types. The center main bearings
vary in width as shown in the table.
UNDERSIZE PARTS
D.25mm (0.009in)
0.5Dmm (0.019in)
0.75mm (0.029in)
STANDARD
WIDTH
WIDTH
28.04 - 28.09mm (1.106 -1.107in)
28.12 • 28.17mm (1.108·1.109in)
28.20-28.25mm {1.111·1.113in)
27.94- 27.99mm (1.1008·1.103in)
3. Inspect the bearing oil clearance of the crankshaftjournal.
a. Loosen the main bearing cap bolts, alternating between
the two bolts of one cap, turning each bolt a few turns
ata time.
b. Remove the cap and bearing to remove the crankshaft.
LOOSENING
THE CAP BOLTS
---'""I/~
c. Remove any oil from the Crank journal and bearing
surfaces.
d. Install the crankshaft and set the plasti-gauge in the
longitudinal direction of the crankjournal. Do not set
the plasti-gauge over the oil port.
Install the cap and bearing and tighten the bolts.
Engines & Generators
13

ENGINE DISASSEMBLY /INSPECTION
e. Remove the cap and bearing. Check the oil clearance by
comparing the measured value with the standard value.
STANDARD: 0.032 - 0.049mm (0.0012 - 0.0019in)
LIMIT: O.OBmm (0.003in)
Replace the bearing set if the oil clearance exceeds the
allowable limit, and remeasure the clearance.
If the oil clearance provided by the replaced bearing set
exceeds the limit, grind the crank journal and use the
undersize bearing to obtain the oil clearance required.
CRANKSHAFT JOURNAl.:S
R DIMENSION: 3mm R
CONNECTING ROD BEARINGS - UNDER.SIZE (U.S.)
AMOUNT OF UNDERSIZE:
0.25mm (0.009in)
0.50mm (0.019in)
0.75mm (0.029in)
2. Disassemble the piston and connecting rod assembly.
a. Remove the piston rings from the piston using a piston
ring installation tool (commercial product).
b. Remove the piston pin from the piston using the piston
pin setting tool.
If the piston pin is tight in the piston, immerse the
piston in hot water
or use a hotplate.
c. Disassemble the remaining piston and connecting rod
assembly in the manner mentioned above.
PULL OUT
PISTON PIN.
,.,PRESS
CONNECTING ROD
I
Heat the piston to 122° - 158° F (50c - 70° C). ,
USING A HOT PLATE TO
HEAT THE PISTON
3. Disassemble the cylinder head assembly.
a. Compress the valve spring and remove the valve
retainer using a valve spring lifter
and pivot.
b. Remove the valve spring and upper and lower valve
spring seats by loosening the valve spring compression.
c. Remove the valve from the valve
guide.
d. Remove the valve seal.
e. Remove the remaining valve assemblies
by repeating
the above procedure.
Engines & Generators
14

CYLINDER HEAD I VALVES
INSPECTION I REPAIR
INSPECTION
Clean off the cylinder head and remove any
gasket fragments.
Inspect for damage, cracks, and leakage of water or oil.
FEELER GAUGE
Measure the cylinder head distortion in the six directions
shown below using a gauge and straight edge.
Distortion: 0.15mm (0.0016 in)
If the cylinder head distortion exceeds specification, grind the
cylinder head surface.
If the cylinder head height is not within specification,
replace it.
HEIGHT: 91.95-92.05mm (3.62D-3.624in)
GRINDING LIMIT: 0.20mm (0.008in ) MAX
NOTE: Before grinding the cylinder head, first check the \
following. Replace if necessary.
• Sinking of valve seat
• Damage of manifold contact suiface
• Camshaft
oil clearance andendplay.
MANIFOLD MOUNTING SURFACE
Use the same inspection procedure for the manifold
mounting surface, measuring distortion with a gauge and a
straightedge in
several directions.
DISTORTION (GRINDING LIMIT): 0.20mm (0.008in)
VALVE AND VALVE GUIDE
1. Inspect each valve for the following. Replace or
resurface ifnecessary.
(1) Damage or bent stem
(2) Roughness or damage to face
(3) Damage or uneven wear of stem tip
2. Check the valve head margin thickness. Replace
if necessary.
VALVE HEAD MARGIN THICKNESS
IN: 0.5 mm (0.020in) MIN.
EX: 1.0mm (0.039in) MIN.
tf STEMTIP
MARGIN J__ r=------">-...
THICKNESST·t:::=.====.
3. Measure the valve stem diameter.
DIAMETER (STANDARD)
IN: 8.03D-8.045mm (0.3161-0.3167in)
EX: 8.025-8.040mm (0.3159-0.3165in)
LIMIT
IN: 7.98Dmm
EX: 7.975mm
MEASURING VALVE ·
STEM DIAMETER
VALVE GUIDE l.D.
IN: B.07-8.09mm (0.3177-D.3185in)
EX: 8.07-8.09mm (0.3177·D.3185in)
Engines &Generators
15