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W-27
Westerbeke W-27 Service Manual
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ENGINE
PARTS
IDENTIFICATION
DRIVE
BELT---"
,CRANKSHAFT
CRANKSHAFT
PULlEY
7
GEAR
CASE
EXHAUST
VALVE
CBANKSHAFT
GEAR
INTAKE
SILENCER
NOZZLE
HOLDER
CYLINDER
HEAO
INJECTION
PU~P
PUMP
CAMSH~FT
CYLINDER
HEAl
TAPPET
CAMSHAFT
REAR
OIL
SEAL
FLYWHEEL
OIL
SCREEN
SIDE
VIEW
EXHAUST
MANIFOLD
\~-#++-:+----PISTON
CONNECTING
ROD
JIII
...
Il-I----PUSH
ROD
CAMSHAFT
FRONT
VIEW
Engines
&
Generators
16
21
23
Table of Contents
Table of Contents
7
Introduction
9
Product Software
9
Engine/Generator Model Designations
9
Notes, Cautions and Warnings
9
Ordering Parts/Serial Number Location
9
Engine/Generator Specifications
11
Testing for Overhaul
12
How to Judge Engine Overhaul Period
12
Cause of Low Compression
12
Measuring Compression Pressure
12
Overhaul Conditions
12
Disassembly
12
Reassembly
13
Service Standards
14
Technical Data
17
Tightening Torque
17
General Screws
17
Sealants
17
Engine Troubleshooting
18
Engine Parts Identification
22
Cylinder Head
23
Construction
23
Cylinder Head Service
24
Disassembly
24
Inspection
24
Cylinder Head
24
Valve Guide
24
Valve Seat
24
Valve
25
Valve Spring
25
Rocker Arm and Rocker Shaft
25
Reassembly
25
Partial Reassembly
26
Installation of Cylinder Head Assembly
26
Valve Clearance Adjustment
26
Cylinder Block
27
Construction
27
Cylinder Block Service
29
Disassembly
29
Inspection
29
Cylinder Block
29
Piston, Piston Pin and Piston Rings
30
Connecting Rod
31
Crankshaft
31
Main Bearings and Connecting Rod Bearings
31
Gearcase
32
Timing Gears and Lube Oil Pump Gear
32
Camshaft
32
Fuel Injection Pump Camshaft
32
Ball Bearings
32
Tappets
32
Push Rods
32
Reassembly
32
Governor
37
Description
37
Disassembly
37
Inspection
37
Governor Lever
37
Governor Spring
37
Needle Bearing
37
Reassembly and Adjustment
37
Engine Shutoff
38
Engine with Manual Stop (Standard)
38
Optional Key Switch Shutoff (38B and 42B Only)
38
Installing and Adjusting the Key Switch Shutoff Solenoid
38
Key-Stop Solenoid System Operation Checking Procedure
38
Engine Adjustments
39
Tightening the Cylinder Head
39
Adjusting Valve Clearance
39
Adjusting Fuel Injection Timing
39
Adjusting No-Load Engine Speeds
40
Lubrication System Service
41
Description
41
Disassembly
41
Oil Filter and Oil Pump
41
Inspection
41
Oil Pump
41
Reassembly
42
Testing the Oil Pressure
42
Oil Pressure Switch
42
Fuel System
43
Description
43
Fuel System Service
45
Disassembly
45
Fuel Filter
45
Fuel Lift Pump
45
Fuel Injection Pump
45
Injector
46
Inspection
46
Fuel Filter
46
Fuel Lift Pump
46
Fuel Injection Pump
46
Nozzle
46
Reassembly
46
Injection Pump
46
Installation and Adjustment of Fuel Injection Pump
47
Injector
48
Adjustment and Installation of Nozzle
48
Holder Assembly
48
Raw Water Cooling Circuit
50
Description
50
Raw Water Pump Service
51
Pump Overhaul - Raw Water Pump PN 33636
51
Disassembly
51
Inspection
51
Reassembly
51
Pump Overhaul- Raw Water Pump PN 24143
52
Disassembly
52
Inspection
52
Reassembly
52
Fresh Water Cooling Circuit
53
Description
53
Fresh Water Cooling Service
54
Disassembly
54
Inspection
54
Water Pump
54
Thermostat
54
Reassembly
54
Drive Belt Adjustment
54
Admiral Control Panel
55
Description
55
Captain Control Panel
56
Description
56
Control Panel Troubleshooting
57
Tachometer/Hourmeter
57
Hourmeter Inoperative
57
Tachometer Inoperative
57
Tachometer Sticking
57
Tachometer Inaccurate
57
Manual Starter Disconnect (Toggle Switches)
58
Troubleshooting Water Temperature and Oil Pressure Gauges
58
Control Panel - Early Models
59
Activation by Key Switch
59
Starter/Solenoid Service
60
Description
60
Adjustment and Repair
60
Pinion Gap Inspection
60
No-Load Test
60
Solenoid
61
Starter Disassembly
61
Starter Inspection
62
Solenoid
62
Inspecting the Armature
62
Brush and Brush Holder Inspection
62
Field Coil Inspection
63
Starter Adjustment and Reassembly
63
DC Electrical System
64
Description
64
Engine 12-Volt Control Circuit
64
Charging System
64
Alternator Troubleshooting
64
Checking for ~Roper Voltage
64
Battery Maintenance
65
Glow Plugs
65
Alternator/Regulator Service
66
Description
66
Alternator Troubleshooting
66
Testing the Charging Voltage
66
Output Test
67
Disassembly
67
Inspection
68
Diode
68
Checking for Short Circuit
68
Checking for Open Circuit
68
Checking Diode Trio
68
Stator
69
Field Coil (Rotor)
69
Checking Brush and Brush Spring
69
Checking the Slip Ring
69
Regulator
69
Reassembly
70
Transmissions
71
DC Electrical System
72
Engine Wiring Diagram #24666
72
Engine Wiring Schematic #24666
73
Engine Wiring Diagram #33685
74
Engine Wiring Schematic #33685
75
Engine Wiring Diagram.#36467
76
Engine Wiring Schematic #36467
77
Engine Wiring Diagram #36844
78
Engine Wiring Schematic #36844
79
Engine Wiring Diagram #39144
80
Engine Wiring Schematic #39144
81
Standard Hardware Torques
82
Metric Conversions
83
Generator Information
84
Use of Electric Motors
84
Required Operating Speed
84
Generator Frequency Adjustment
84
Generator Maintenance
84
Generator Troubleshooting
84
WMD Generator
85
Description
85
Disassembly
85
Inspection
85
Reassembly
85
WMD Generator Troubleshooting
86
No Electrical Output
86
Flash Field Coils
86
Replacement of Field Coij(S)
87
Low Voltage Output
87
High Voltage Output
88
Solenoid with Throttle Linkage
88
WMD Generator AC Internal Wiring Diagrams
89
WMD Generator DC Electrical System
90
WMD Generator Wiring Diagram #24700
90
WMD Generator Wiring Schematic #24700
91
BT Generator
92
Description
92
BT Generator Troubleshooting
93
Residual Voltage Check
95
Bridge Rectifier
95
Testing the Bridge Rectifier for Faults with an Ohmmeter
96
Internal Wiring Diagram
96
Component Resistance Values
97
Models 11.0 & 12.5(A) BT
97
Component Resistance Checks
97
Exciter Stator Windings
97
Exciter Rotor/Field
98
Main Stator Windings
99
Compound Transformer
99
Selector Switch
99
Bridge Rectifier Wiring
99
No-Load Voltage Adjustment
100
Voltage/Hertz Connection Bar
100
BT Generator AC Voltage Connections
101
Generator Frequency
101
BT Generator 6 Terminal Block
102
Wiring Connections
102
BT Generator DC Electrical System
104
BT Generator Wiring Diagram #34651
104
BT Generator Wiring Diagram #36412
106
BT Generator Wiring Schematic #36412
107
Other manuals for Westerbeke W-27
Operator's Manual
29 pages
Information Sheet
5 pages
5
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Westerbeke W-27 Specifications
General
Brand
Westerbeke
Model
W-27
Category
Engine
Language
English
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