Westerbeke W-27 - Engine Break-In Procedure

TABLE OF CONTENTS
Introduction ......................................................................... 3
Engine Shutoff ................ ~ ................................................. 32
Product Software .................................................................... 3
Engine with Manual Stop (Standard) ..................................
32
Engine/Generator Model Designations ................................. .3
Optional Key Switch Shutoff (38B and 42B only) ............ .32
Notes,
Cautions and Warnings .............................................. .3
Installing and Adjusting the Key Switch
Ordering Parts/Serial Number Location ................................ 3
Shutoff Solenoid ........................................................
32
Engine/Generator Specifications ........................................ 5
Testing for Overhaul ............................................................ 6
How to Judge Engine
Overhaul Period ................................. 6
Cause of Low Compression ........................................... 6
Measuring Compression
Pressure .................................. 6
Overhaul Conditions .............................................................. 6
Key-Stop Solenoid System
Operation
Checking
Procedure ................................................... 32
Engine Adjustments ........................................................... 33
Tightening the
Cylinder Head .............................................. 33
Adjusting Valve Clearance ................................................... 33
Adjusting Fuel Injection Timing .......................................... 33
Disassembly ................................................................... 6
Reassembly .................................................................... 7
Adjusting No-Load Engine Speeds ......................................
34
Lubrication System Service ............................................... 35
Service Standards ............................................................... 8
Description ........................................................................... 35
Technical Data ................................................................... 11
Tightening Torque ..... ~ .......................................................... 11
General Screws ..................................................................... l1
Sealants ................................................................................. 11
Engine Troubleshooting . .................................................... 12
Disassembly ......................................................................... 35
Oil Filter and Oil Pump ............................................... 35
Inspection ............................................................................. 35
Oil Pump ...................................................................... 35
Reassembly ..........................................................................
36
Testing the Oil Pressure ....................................................... 36
Engine Parts Identification ............................................... 16
Oil Pressure Switch .............................................................. 36
Cylinder Head ... .................................................................. 17
Construction ......................................................................... 17
Fuel System ... .. , .................................................................. 37
Description ........................................................................... 37
Cylinder Head Service ....................................................... 18
Disassembly ......................................................................... 18
Inspection ............................................................................. 18
Cylinder Head .............................................................. 18
Valve Guide .................................................................. 18
Fuel System Service .......................................... ' ............... .39
Disassembly ......................................................................... 39
Fuel Filter ..................................................................... 39
Fuel Lift Pump ............................................................. 39
Fuel Injection Pump ..................................................... 39
Valve Seat. .................................................................... 18
Injector .........................................................................
40
Valve ............................................................................. 19
Inspection .............................................................................
40
Valve Spring ................................................................. 19
Rocker Arm and Rocker Shaft ..................................... 19
Fuel Filter .....................................................................
40
Fuel Lift Pump ............................................................ 40
Reassembly .......................................................................... 19
Partial Reassembly ....................................................... 20
Installation of Cylinder Head Assembly ...................... 20
Valve Clearance Adjustment ....................................... .20
Cylinder Block .. .................................................................. 21
Construction ......................................................................... 21
Cylinder Block Service ...................................................... 23
Disassembly ......................................................................... 23
Inspection ............................................................................. 23
Cylinder Block ............................................................. 23
Piston, Piston Pin and Piston Rings ............................. 24
Connecting Rod ............................................................ 25
Crankshaft .................................................................... 25
Main Bearings and Connecting Rod Bearings ............ 25
Gearcase .......................................................................
26
Fuel Injection Pump .................................................... .40
Nozzle .......................................................................... 40
Reassembly .......................................................................... 40
Fuel Filter ..................................................................... 40
Fuel Lift Pump ............................................................. 40
Injection Pump ............................................................. 40
Installation and Adjustment of Fuel
Injection
Pump ........................................................... 41
Injector ......................................................................... 42
Adjustment and Installation
of Nozzle
Holder Assembly ........................................................
42
Raw Water Cooling Circuit ............................................... .44
Description ........................................................................... 44
Raw Water Pump Service ................................................. .45
Pump Overhaul - Raw Water Pump PN 33636 .................. .45
Timing Gears and Lube
Oil Pump Gear ...................... 26
Camshaft ...................................................................... 26
Disassembly ................................................................. 45
Inspection ..................................................................... 45
Fuel Injection
Pump Camshaft .................................... 26
Ball Bearings ................................................................ 26
Tappets ......................................................................... 26
Push Rods ..................................................................... 26
Reassembly .................................................................. 45
Pump Overhaul- Raw Water Pump PN 24143 .................. .46
Disassembly ................................................................. 46
Inspection ..................................................................... 46
Reassembly ..........................................................................
26
Reassembly .................................................................. 46
Governor ............................................................................ . 31
Fresh Water Cooling Circuit ............................................. .47
Description ........................................................................... 31
Description ........................................................................... 47
Disassembly ......................................................................... 31
Fresh Water Cooling Service ............................................ .48
Inspection ............................................................................. 31
Disassembly ......................................................................... 48
Governor Lever ............................................................
31
Inspection ............................................................................. 48
Governor Spring ...........................................................
31
Water Pump .................................................................. 48
Needle Bearing ............................................................. 31
Thermostat. ................................................................... 48
Reassembly and Adjustment ............................................... .31
(continued)
Engines & Generators
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