Westerbeke 3.0KW BPMG User manual

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SERVICE MANUAL
3.0KW BPMG 60Hz and 50Hz
SINGLE PHASE
GASOLI ENERATORS I
rPiJBLiCt~ NO. 52089 I
SECOND EDITION
MARCH 2009
~ WESTERBEKE
WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAO
MYLES STANOISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: www.WESTERBEKECOM
~ Membu Nlltional Mllrln~ Manufacturers Association
... .

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

A WARNING
Exhaust gasses contain t:arbon Monoxide, an odorless and
colotless gas. t:arbon Monoxide Is poisonous and can cause
u/lt:llllSCiDusness and death. Symptoms of Corbon Monoxide
exptJSII1fI can Include:
-Dizziness
- Throbbing In Temples
-..".. - Muscular Twitching
-'''stew -
Vomiting
-WubIIss and Sleepiness
-Inability to Think Coherently
IF YOII DR All'f0NE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
BET DIIT INTO THE FRESH AIR IMMEDIATELY. If symptoms pelSlst,
... mtldical attBntion. Shut down the unit and do not restart
_I Inspected and repaired.
A WARNING DECAL Is plOvlded by
WESTERBEKE and should be fixed to a
bulkhtlBd near your engine Dr generator.
WESTERBEKE also recommtllllls Installing
!o!o!~ \ CARBON MONOXIDE OETECTORS In the
Ilvlng/s/eeping quartelS of your vessel.
They 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 California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety 1TUlnual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
toJre the necessary precautions to protect yourself, your
personne~ and your machinery.
The following safety instructions are in compliBnce wiJh
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do nat touch AC electrical connectiollS
willis BIlIlne Is running, Of wilen connected to shore
power. Lethal voltage Is p/TISBnt at these connections!
• Do not operate this machinery without electrical
enclosures
and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes)
when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels AC generator may
result ifthis procedure is not followed.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Of
BXhaust system components. A running engine gets
reryhot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause Injury Of death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Of death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate without a Coast Guard Approved flame
arrester. Backfire can cause severe injury or death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: ExplosiollS from fuel vapolS can cause
injury Of death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area
away from spark-producing
equipment
and out ofthe reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
...v" WESTERBEKE
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
III dIIath!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
IAnERY EXPLOSION
A WARNING: Battery explosion can cauS/J injury
III ",.",!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or
by lit tobacco products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any comparttnent containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns
or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections.
Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid In batteliBS can cauS/J
stmIf8lnjury /11 death!
• When servicing the battery or checking the electrolyte
level, wear rubber
gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
offat once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) Is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly
for leaks and make sure the exhaust
manifolds/water-injected
elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation ofapproved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odollllSS gas. Inhalation PlOdUCBS flu·like symptoms,
naussa 01 dealh!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause In JUlY
01 death!
• Do not service the engine while it is running. Ifa
situation
arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment;
tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caugbt in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places
at all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught
in these rotating parts.
HAZARDOUS NOISE
A WARNING: High nDlse lelll1ls can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do nDt work Dn machinery when YDU are
IfIBIIta/Iy or physically IncapaCitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOUNE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination of
the American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation
P-I Exhaust Systems
P-4 Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order
from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order
from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast
Guard)
"USCG 33CFR183"
Order
from:
U.S. Government Printing Office
Washington, D.C. 20404
~ WESTERBEKE
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention
he paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must he complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will he helow the vessel's waterline, provisions must he made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must he looped a
minimum of
20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust l1Ul1Iifold injectiDn POI1 is oJ orbelow the load woJerline will result in
raw water domage to the engine aad possible/Wading of the boaJ.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
MI1'E: A siplwn-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine domage. Consult the siplwn-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must he certified for marine use. The system must he designed to
prevent water
from entering the exhaust under any sea conditions and at any angle
ofthe vessels hull.
A detailed Installation Manual is furnished with the generator. The
Operators manual also has specific installation data for the 3.0 generator.
~ WESTERBEKE
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification .................................................... 2
Testing For Dverhaul... ............................................... .3
Troubleshooting Gulde ................................................ 4
Disassembly Procadures ............................................ 6
Sealants And Lubricants ............................................ 7
Torque Specifications ................................................. 9
Spacial Tools ............................................................. 11
Servlca Standardslllepair Limits .............................. 12
Engine Disassembly ...... ............................................ 15
Inspactlon And Measurement .................................. 20
Englna Assembly ....................................................... 27
011 Pump ................................................................... .32
lubrication System ................................................... 32
Fuel Pump ................................................................ .33
Fuel Filter ................................................................. 33
Starter Motor ............................................................ 34
Carbartor .................................................................. .35
Raw water Pump ...................................................... .36
Engine Tuning .......................................................... .38
Engine Adjustments .................................................. 39
Compression Test ...............................................39
Water Pump Belt................................................39
Ignition Timing...................................................39
Oil Pressure Test ................................................40
Spark Plugs.........................................................41
Thermostat..........................................................41
Choke Solenoid..................................................41
Valve Clearance..................................................42
Timing Belt Replacement!Adjustment...............42A
Electronic Governor ................................................. .43
Shutdown Switches ................................................. .44
WIring Diagram ......................................................... 45
AC Generator ............ ................................................ .46
Specifications .. ........................................................ .47
Metric Conversion Charts ....................................... .48
....v: WESTERBEKE
Engines & Generators
1

'GNmON ,un,.u, __
MODU1£
fUEL
BAmRY
VOlTAGE
DRIP
PARTS IDENTIFICATION
~"",.,,, ... COIL
ENGINE SERIAL
SERVICE SIDE
FRESHWATER
(COOlANn MODEL
,,.
IGNITION CONTROL
LEFT SIDE
Engines & Generators
2
I
'CONNECTION
TO COOLANT
RECOVERY
TANK
THERMOSTAT
ASSEMBLY
WATER (COOLANT)
TEMPERATURE
SWITCH
1 "'~--- OIL DRAIN
HOSE
+--HEAT
EXCHANGER
ZINC ANODE
SERVICE SIDE
WAltH PUMP

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is
detennined 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 improper oil, clogged filters or a faulty
carburetor.
The decrease in compression pressure is caused by many fac-
tors. It is. therefore, necessary to detennine a cause or causes
on the basis
of data produced by periodic inspection and
maintenance.
Oil analysis on a seasonal basis is a good
means
of monitoring engine internal wear. When caused by
worn cylinders or piston rings, the following symptoms will
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 improper fuel regulation
or a faulty car-
buretor. They are caused also by defective electrical devices
such
as the battery, starter or spark plugs. 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 combus-
tion is obtained only under sufficient compression pressure.
If an engine lacks compression pressure, incomplete combus-
tion
of fuel will take place even if other parts of the engine
are operating properly. To detennine the period
of engine
overhaul,
it is important to measure the engine compression
pressure regularly.
At the same time, the engine speed at
which the measurement
of compression 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.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
OVERHAUL CONDITIONS
co~pressioln pressure tendsdt0alincrease ahli \:-':::"e in a new
engme untl piston
f1ngs an v ve seats a v- ~ b b k '
Thereafter, it decreases gradually with the p""~geen rfo en 10.
f th arts
~ ress 0 wear
o esep .
When decrease
of compression pressure reac::: ---e tl . .
I· .
h' b h led -0.1 S lelepalr
mut, t e engIne must e over au .
The
engine requires overhaul when oil consL.~ t' . h' I
. . ....·.IIpIOI1IS 19l
blowby eVident, and compression values are ~t .. '
b 1 -
mlmmum or
eow.
Engines & Gener.tors
3

TROUBLESHOOTING GUIDE 3.0 KW BPMG
When toubleshooting indicates an electrical problem, see the
ELECfRICAL SYSTEM WIRING DIAGRAM,
as this may
reveal other possible causes of the problem which are not listed
below.
PROBLEM
PROBABLE CAUSE
Engine does not 1.
Voltage drop at starter solenoid
crank. terminal.
2. Main 10 amp fuse blown.
4.
Battery is low or dead.
5.
Loose battery connections.
6.
Faulty wire connection.
7.
Faulty start switch.
B Faulty pc board
9.
Faulty starter solenoid
10. Water filled cylinders.
Engine starts, runs 1.
Faulty shutdown switch,(oil pressure,
and then shuts
or exhaust temperature).
down.
2.
Faulty overspeed switch.
3.
Dirty fueVwater separator filter.
4. Clogged fuel line.
5. Low oil level in sump.
6. Faulty fuel pump.
7.
No fuel
B. Clogged fuel filter
Engine starts, runs
1.
Faulty mag-pickup sensor.
but does not come
2.
Electronic governor controller faulty,
up to speed.
3. Fuel pump.
4.
Fuel supply to engine restricted.
5.
Actuator linkage binding.
6.
Actuator or electrical connections
faulty.
7.
Air intake restricted.
B. Exhaust restricted.
Engine cranks but 1.
Out of fuel.
lalts to starl
2.
Engine is flooded.
(Engine wiIl crank
3.
Faulty carburetor. (See Carburetor page)
lor 15 seconds)
4.
Faulty choke solenoid
5.
Faulty ignition coil.
6. Bad spark plugs
Engine hunts.
1.
Controller gain adjustment needed.
2.
Faulty fuel pump.
3.
Faulty PC board.
4.
Improper drive belt tension.
5.
Low DC battery voltage.
6.
High exhaust back pressure.
7.
Dirty fuel filter
B.
Generator overload.
9.
Valves need adjustment.
The following troubleshooting tables are based upon certain
engine problem indicators and
the most likely causes of the
problems
PROBLEM
PROBABLE CAUSE
Engine misfires.
1. Poor quality fuel.
2. Faulty ignition control module.
3.
Dirty flame arrester.
4. Faulty ignition wires.
5.
Spark plugs are worn.
6.
Binding actuator linkage.
7.
High exhaust back-pressure.
B. Valve clearances are incorrect.
9. Valve clearances are incorrect.
Engine backfires. 1.
Faulty ignition control module.
2. Incorrect timing.
3.
Engine is flooded. See Engine is
flooded under Engine cranks but
fails to start.
4.
Dirty flame arrester.
5.
Faulty ignition coil.
6. High exhaust back-pressure.
Engine overheats.
1.
Blockage in cooling water flow: inspect
the raw water intake, intake strainer,
pump impellers, and look for broken or
seperated hoses.
2.
Belts may be loose or broken.
3.
Obstructed by-pass hose.
Low oil pressure.
1. Low oil level.
2.
Wrong SAE type oil in the engine.
3.
Oil diluted with fuel.
4. Relief valve is stuck.
5.
Faulty oil pump.
6.
Faulty engine bearings.
7.
Boat heeled over too much.
B.
Faulty oil filter.
High oil pressure.
1.
Dirty oil or wrong SAE type oil in the
engine.
2.
Relief valve is stuck.
No DC charge to the
1. Faulty connections to
starting battery.
battery charging control.
2.
20 amp fuse blown/faulty.
3.
Faulty voltage regulator.
4. Faulty magneto.
Engines & Generators
4

TROUBLESHOOTING GUIDE 3.0 KW BPMG
PROBLEM
Blue Exhaust Smoke Discharge
from Ihe Engine
Black exhausl smoke Discharge
from the Engine
Poor perlormance
at generator speed
Starler stays energized
alter starl
Unit starts and runs
at Idle speed
Note: MPU voltages to PC board:
Cranking: 1.5 -2.0 VAC
Running: 4.0 - 5.0 VAC
(2200 rpm)
PROBABLE CAUSE
1. Lube oil is diluted.
2. High lube oil level.
3. Crankcase breather hose is clogged.
4. Valves are worn or adjusted incorrectly.
5. Piston rings are worn or unseated.
1. Dirty flame arrester.
2. Faulty carburetor.
3. Idle mixture jet too rich.
4. Accelerator diaphragm leaking.
5. Valves are worn or incorrectly adjusted.
6. Piston rings are worn or unseated.
1. Contaminates in carburetor.
2. Faulty fuel pump/contaminated.
3. Electronic governor controller needs
adjustment.
1. Faulty MPU suspected. Check MPU.
2. Faulty starter solenoid.
1. Check MPU signal. 1.5 - 2.0 VAC cranking.
2. Faulty overspeed board.
~ WESTERBEKE
Engines & Generators
5

DISASSEMBLY I ASSEMBLY PROCEDURES
DISASSEMBLY
• Before disassembly and cleaning, carefully check for
defects which cannot be found after disassembly and
cleaning.
• Drain water, fuel and oil before disassembly.
• Clean or wash the engine exterior.
• Do not remove or disassemble the parts that require no
disassembly.
• Perform disassembly in a 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
of dust and dirt.
• Parts must be restored to their respective components from
which they were removed at disassembly. This means that all
parts must be set aside separately in groups, each marked for
its componen~ so that the sarne 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 check each part or component for any sign of
faulty condition during removal or cleaning. The part
will
tell you how it acted or what was abnormal about it more
accwately during removal or cleaning.
The
parts assembled with the silicone can be easily
disassembled without use ofa special
method. In some case,
however, the sealant between the joined surfaces may have
to be broken by lightly striking with a mallet or similar tool.
A ftat and thin gasket scraper may be lightly hammered'
in between
the joined surfaces. In this case, care must be
taken to prevent damage to the joined surfaces. For removal
of the oil pan, use a special "oil pan remover".
ASSEMBLY
• Wash all parts, except for oil seals, O-rings, rubber sheets,
etc., with cleaning solvent and
dry them with pressure air.
• Always use tools that are in good condition and be sure
you understand how to use them before performing any
job.
• Use only good quality lubricants. Be sure to apply a coat
of oil, grease or sealant to parts as specified ..
• Be sure to use a torque wrench to tighten parts for whieh
torques are specified.
• When the engine is assembled, new gaskets and O-rings
must be installed.
Surface Preparation
Thoroughly removes all substances deposited on the gasket
application
surfaces using a gasket scraper or wire brush.
Check to ensure that the surfaces to which the silicone gasket
is to be applied is ftat. make sure that there are no oils,
greases and foreign substances deposited on the application
surfaces.
Do not forget to remove the old sealant that
remains in
the bolt holes.
GASKET INFORMATION
The engine has several areas where form-in-place RTV
silicone gaskets are used such as LOCTITE 598 or GE
RTV 100. To ensure that the gasket fully serves its purpose,
it is necessary to observe some precaution when applying the
gasket. Bead size, continuity and location are very important.
Too thin a bead could cause leaks and too thick a bead could
be squeezed out oflocation causing blOCking or narrowing of
the fluid feed lines. To eliminate the possibility of leaks from
ajoint, it is necessary to apply the gasket evenly without a
break while observing
the correct bead size.
The gasket material used in the engine is a room temperature
vulcanization (RTV)
type and is supplied in a 140z (400
gram) applicator/tube.
The RTV hardens as it reacts with the
moisture in the atmospheric air and can be used for sealing
both engine oil and coolant assemblies.
Engines & Generators
6

APPLICATION OF SEALANTS AND LUBRICANTS
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5900
Cylinder liner
•
Inside wall
Piston •
Ring groove, Periphery
Piston ring
•
Periphery
Piston pin
• Periphery
Connecting rod
•
Inside big and small ends
Metal (Cylinder block. crank case)
•
Both sides
Crank shaft (thrust place) •
Sliding surfaces
Crank shaft oil seal • Lips
Crank case cylinder mating surface
•
Joint part
Valve (IN, EX) • Shaft, Stem head
Valve stem seal (IN, EX) •
Ups
Retainer • Complete
Valve spring seat • Complete
-"
Valve spring
•
Complete
0
0
:0 Camshaft • Bearing. cam
Q)
c
Camshaft oil seal
• Lips
'6>
c
UJ
Cam pulley bolt • Thread
Rocker arm • Bearing. Slipper
Rocker arm shaft
~
Shaft, side
Tappet adjust screw
•
Complete
Washer (rocker arm, 1=0.5),
•
Complete
Washer (rocker arm, 1=2.5)
• Complete
Spring Jrocker arm, free length 30
mman 51 mm}
•
Complete
Fuel pump
•
Periphery of a-ring, end of
plung_er
2ml at Suction port and
Oil pump •
discharge port, Boss part
a-ring
(01.5 -to.7) •
Oil pump O-ring (ot.5 -8,5) •
(ot.5 -15.5) •
Oil pressure switch
•
Thread
~ WESTERBEKE
Engines & Generstors
7

APPLICATION OF SEALANTS AND LUBRICANTS
.,
0
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Items e
.~
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en
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Parts Name
1) c
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F F
1lF F
.9
0 0 0 ;;
o~
ID E 0 "
'"
en
1342 I373B
1741 12ll7B .18 G17
"" ...
.900
Qilliher
• Seal
Oil fiher boh •
Thread
Plungerass'y •
Inside (Pour 1 ml)
Filter cap, O-ring
•
Periphery
Solenoid switch
•
Tenninal
•
Spark plug insertion part
Spark plug cap
.,.,
•
High lentian cord
~
•
Termin~1
.,
Starter motor
c:
•
Spread at pinion part slightly
go
W •
Bolt and screw for Reel
Startercase
Friction plate, reel shaft part,
•
Spiral spring, rachel
Starter seal rubber
•
Engine oil
• Oil;
at oil change 1000rnl
at overhaul 1200ml
Ollpan gasket •
Bolt (upperpump case) • Thread
Upper pump case
•
Impeller sliding surfaces
Joint part for water pipe guide
,..yo WESTERBEKE
Engines. & G.enerators
8

TORQUE SPECIFICATIONS
Item Thread size Bo~ or Nut Tightening Torque
N-m
kg-m Ib-ft
M8 x 1.25
Bo~
28-30 2.&-3.0 20-22
Cylinder Block -Cylinder Head
M& x 1.0 Boll
8-10
0.8-1.0 5.8-7.2
M8 x 1.25 Boll
23-25
2.3-2.5 17-18
CylinderBlock -Crank Case
M8 x 1.0 Boll
8-10
0.8-1.0 5.8-7.2
Connecting Rod
M7 x 1.0 Boll 11-13 1.1-1.3 8.0-9.4
Tappet Lock Nul
M8 x 0.75 Nul
6-8
0.8-0.8 4.4-5.8
Flywhael Cup M18 x
1.5
Nul 70-90 7-9 51-65
Drive [Timing) Pulley M28 x 1.0 Nul 34-38' 3.4-3.6
25-28
Engine Driven (Camshaft) Pulley
M8 x 1.0
Bo~ 10-12 1.0-1.2 5.&-&.7
PlungerAssembly M16 x 1.5 -19-21 1.9-2.1
.12-15
Oil Filter
M20 x 1.5 -
1&
1.& 13
Oil Pressure Switch
PTI/& -
7-9
0.7-0.9 5-8
Cylinder Head Cover
M6 x 1.0 Boll
8-10
0.8-1.0 5.8-7.2
InlelManifold
MS x 1.0
Bo~
8-10 0.S-I.0 5.8-7.2
SparkPiug M12 x 1.25 -
15-20 1.5-2.0 11-15
Engine Assembly
M8 x 1.25 Boll 29-31 2.9-3.1 21-22
Engines & Generators
9

REQUIRED TOOLS
~~~y~
~jP~~~
~~p~
17
15
~
1. Straight-point screwdriver (200 mm)
-do. -(150 mm)
-do. -(100 mm)
2. Phillips screwdriver (200 mm)
-do. -(150 mm)
- do.-
(100 mm)
3. Set of wrenches (6 pieces)
4. Box wrenches (10 x 13)
-do. -(17 x 21)
- do.- (21 x 23)
5. Adjustable wrench (300 mm)
6. Pliers
7. Needle-nose pliers
8. Snap ring pliers
9. T-bar'socketwrench (10 mm)
-do. -(12 rnfTl)
- do.-
- do.-
(13 mm)
(17 mm)
10. T·bar universal wrench (10 mm)
- do. -(12 mm)
- do. -(13 mm)
11. Plastic hammer
12. Hammer
13. L·shape hexagon wrench (8 mm)
- do. -(10 mm)
14. Box wrench (16 mm)
15. Socket wrench (16 mm)
16. Torque wrench (100 N - m)
-do.- (12N-m)
- do.- (5 N - m)
Pre-setting type box torque wrench
(10 mm, 7N - m) .... for the tappetiock nut
17. Socket wrench set
",y" WESTERBEKE
Engines & Generators
10

USING SPECIAL TOOLS
5. How to Use Special Tools
1. Flywheel cup puller
<D When disassembling
Fasten the tools ®and I8i to the flywheel with
the tlolls iQ) and remove the magneto nut
(right-
hand screw) with the socket wrench of
the
correct size 24.
Next.
screw tool 0 into tool I8i and tighten 0
with the socket wrench of the correct size 24.
The flywheel can be removed. Be sure to
usebaHs (D), /~
.' -;://
@When reassembiing
«~
r:::Y'
5°
•
Before replacing the flywheel make sure that
the magneto key has properly been set. After
setting
the washer and nut on the crank shaft.
fasten
tools@and B>to the flywheel and tighten
the nut.
TIghtening torque: 70-90
N-m (7.0-9.0 kg-m)
(51-65Ib-ft)
2. Piston pin tool
After removing the piston pin clip, insert the tip of
the piston pin tool into the piston pin hole and
lightly tap the other end ofthetool with a hammer.
Hold the piston with your hand to prevent damage
to the connecting rod. (When inserting the piston
pin again, take the same care as removing.)
Piston pin
Piston pin tool
3. Piston slider
This tool is to be used for inserting the piston into
the cylinder. After inserting the piston into the
tapered end of the piston slider. set
the piston
slider together
with the piston tightly on the top of
the cylinder and insertthe piston into the cylinder
by pushing the piston crown with fingers.
Note:
Dont stop inserting the piston into the cylinder
until all the piston rings enter the cylinder.
Piston slider
---Ifl---J t---f'l- Top 01 cylinder
Engines & Generators
11

SERVICE STANDARDS/REPAIR LlMITS/MAINTENANCE
Part Name
Check/lnsaect
Standard ValueJMalntenance Repair limit
Cylinder Head
1. Carbon deposit on the combustion 1. Remove carbon deposit and clean.
chamber
2. Scratch depth and distortion of the
2. Scratch depth or distortion is O.lmm (0.004in)
2. Repair (set /240·#400 sandpaper
mounting surface.
or more.
the suriace plate and pOlish the
surface for repair. Use #600 sandpaper
for finishing).
3. Corrosion in the mated surface.
3. Repair or replace depending on the situation.
4. Clogged cooling water passage.
4. Clean and remove foreign matters.
Cylinder
1. Deposit in the water jacket. 1. Clean and remove foreign matters.
2. Wear of the inside cylinder 2. 59.00mm (2.3228in)
2. 59.06mm (2.3252in) or more
diameter. Measure the bore with
(If wear is exceeding the repair limit,
a cylinder gauge
replace or bore the cylinder and finish
by honing. Over-sized piston is O.Smm.
refer to item 4).
3. Seizure 3. Replace or use an over-sized piston
after boring the cylinder.
4. Scratch and wearing down in the 4. When the liner cannot be repaired by means
4. Bore and hone to 059.5KO.Olmm
cylinder liner.
of #400·#600 sandpaper because it is (02.3425 ±0.0004in).Use oversize
extremely scratched or scored, or the
piston and rings.
difference between the maximum wear and
minimum wear is 0.06mm (0.0024in) or more.
5. Mating suriaces of the cylinder and
5. When the depth of scratch or distortion
5. Use 1400 sandpaper on the suriace
cylinder head. in/of the mating suriace is O.lmm (0.004in)
plate and pOlish the suriace. Use #600
or more.
sandpaper for finishing.
Piston
1. Outside Diameter 1. Diameter: 58.960mm (2.3213in)
1. Outer Diameter: 58.90mm (2.3189in)
or more.
0) Measure the diameter at a point
7mm above the lower end of the
piston skirt.
b) Piston Clearance
b) Piston clearance: 0.020·0.055mm b) Piston Clearance: 0.15mm
(0.0008-0.0022in)
(0.0059in) or more
2. Carbon deposit on the piston crown 2. Remove carbon residuum and clean.
and in the piston ring groove.
3. Scratch on the sliding suriace.
3. Repair with #400·#600 sandpaper depending
on the situation.
4. Measurement of clearance between 4. Top: 0.04·0.08mm (0.0016·0.0031in)
4. Top: 0.10mm (0.004in) or more
the piston ring and ring groove. 2nd: 0.03·0.07mm (0.0012·0.0028in)
2nd: 0.09mm (0.0035in) or more
Oil: 0.01·0.18mm (0.0004· 0.0071in)
Oil: 0.21mm (0.0083in) or more
NOTE: To be replaced wifh a new oil ring, when
replacing with new top and/or second rings.
Sandpaper means water proof pap.,
5. Measurement of diameter of the
5. Clearance between pin and hole
5. 0.04mm (0.0016in) or more
piston pin hole. Loose: 0.002·0.012mm (0.00008·0.00005in)
Piston Ring 1. End Gap 1. Replace with new piston ring n wear of the
NOTE: Measurement of the end gap: cylinder liner is within the repair limit.
when no ring gauge is available,
measure the lower part of the
cylinder bore.
a) Top a) Top: 0.15·0.35mm (0.006·0.014in) 0) Top: 0.5mm (0.020in) or more
b) Second
b) Second: 0.30·0.50mm (0.012·0.020in)
b) Second: 07mm (0.028in) or more
c) Oil c) Oil: 0.20.Q.7mm (0.008·0.028in) c) Oil Ring: to be replaced with a new
oil ring. when replacing with new top
and/or second rings. Sandpaper
means water proof paper.
Piston Pin
1. Outer diameter
1. 16.00mm (0.6299in)
1. 15.97mm (0.629in) or less.
Crankshaft 1.Deflection of the crankshaft.
1. Less than 0.05mm (0.002in)·both ends.
1. 0.05mm (0.002in) or more.
Both the main bearings of the
crankshaft should be supported
with V·blocks.
2. Outer diameter of the crankpin. 2. 29.98mm (1.1803in) 2. 29.95mm (1.17910) or less.
3. Outer diameter of the bearing. 3. 31.99mm (1.2594in) 3. 31.97mm (1.259in) or less.
4. Oil clearance of the bearing. 4.0.012· 0.044mm (0.0005· O.OOI71n) 4. 0.06mm (0.002in) or more.
5. Side clearance of the crankshaft. 5. 0.1 • 0.2mm (0.004 ·0.008in)
5. 0.6mm (0.024in) or more.
-..v: WESTERBEICE
Engines & Generators
12

SERVICE STANDARDSIREPAIR LlMITS/MAINTENANCE
Part IIaIIIe
Check/lllSllect Standard Value/Maintenance Repair Limit
Connecting Rod
1. Inner diameter of the small end. 1. 16.01mm (0.630in)
1. 16.04mm (0.631 in) or more.
2. Oil clearance of the big end. 2. 0.Q15 - 0.041mm (0.0006 - 0.0016in)
2. 0.060mm (0.002in) or more.
3. Side clearance of the big end. 3.0.1 - 0.25mm (0.004 - 0.01 in)
3. 0.6mm (0.024in) or more.
Magneto
• Inition liming
BTDC 5' - 5' (electric ignition advance)
• Spark performance
10mm (0.4in) or more/500 rpm
(measured by genuine spark tester.
• Spark plug
NGK DCPR6E
• Spark gap
0.8 - 0.9mm (0.032 - 0.035in)
1.2mm 9 0.0047in) or more
• Alternator output
12V. 130W (5000 rpm)
• Resistance of coils
Between white wire and yellow wire
0.27 - 0.410
Between red-white wire and
black wire
148 - 2220
Between black-red wire and blue wire
12.5 - 18.80
Between yellow-red wire and
yellow -red wire 1.40 - 2.100
• ESG for high speed
Restricting at 6250 rpm
• ESG for low speed
Reducing at 2000rpm
Ignition Coil
• Resistance of primary coil
between black wire and orange wire 0.26 - 0.350
• Resistance of secondary coil
between high tension cord and core 6800 - 102000
Battery
Output 12V -70AH to 12V -100AH
12VO.6KW
Clutch Over-running clutch
1) Brush length 1) 12.5mm (0.49in)
1) 9.5mm (0.37in) or less
2) Commutator under-cut
2) 0.5-0.8mm (0.02-0.03in)
2) 0.2mm (0.008in) or less
3) Commutator diameter 3)30mm (1.18in)
3)29 mm (1.14in) or less
Fuse Capacity
120A
Thermostat Operation of thermostat • Start to open: 60'C ± 1.5'C
If the valve opens at room temperature •
(140 ± 3'F)
replace the thermostat.
• Temperature at which valve opens
While immersing the thermostat in water,
full: 75'C (167'F)
raise the water temperature and check the
temperature at which the valve opens.
Pump Impeller Worn-out, crack Replace
Pump Case liner
Worn-out
Replace
Guide Plate Worn-out Replace
Intake Valve 1) Valve Clearance IN: 0.13 - 0.17mm (0.005 - 0.007in)
Exhaust Valve EX: 0.18 - 0.22mm (0.007 - 0.008in)
2) Outer diameter of valve stem IN: 0.13 - 0.17mm (0.005 - 0.007in)
5.46mm (0.215in) or less
EX: 0.18 - 0.22mm (0.007 - 0.008in) 5.44mm (0.214in) or less
3) Inner diameter of valve guide IN: 0.13 - 0.17mm (0.005 - 0.007in)
5.55mm (0.218in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in)
5.57mm (0.219in) or more
4) Clearance to valve stem IN: 0.13 - 0.17mm (0.005 - 0.007in) 0.07mm (0.0028in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in) 0.10",m (0.004in) or more
5) Contact width of valve seat
IN: 0.13 - 0.17mm (0.005 - 0.007in)
2.0mm (0.079in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in) 2.0mm (0.079in) or more
Valve Spring
Free length 35mm (1.38in) 33.5mm (1.319in) or less
Camshaft 1) Height of cam (both IN and EX)
1) 23.90mm (0.94in)
1) 23.75mm (0.935in) or less
2) Outer diameter of bearing 2) Pulley side: 17.98mm (0.0708in) 2) 17.95mm (0.707in) or less
Oil pump side:: 15.97mm(0.629in)
15.95mm (0.628in) or less
3) Clearance of holder (bearing) 3) 0.02 - 0.05mm (0.0008 - 0.0020in) 3) 0.09mm (0.0035in) or more
Rocker Arm 1) Inner diameter
1) 13.01mm (0.512in)
1) 13.05mm (0.514in) or less
and Shaft 2) Outer diameter
2) 12.99mm (0.511in)
2) 12.94mm (0.509in) or less
3) Shaft Clearance
3) 0.006 - 0.035mm (0.00024 -0.00138in)
3) 0.6 mm (0.0024in) or less
Timing Belt Tension and appearance
Wear, crack or lengthen-replace
Engines & Generators
13