Installation manual

ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjust-
ments be
peiformed by a competent engine mechanic. The information
below
is provided to assist the mechanic.
VALVE CLEARANCE ADJUSTMENT
NOTE: Retorque the cylinder head bolts before adjusting the
engine's valves.
See TORQUING TIlE CYLINDER HEAD
BOLTS.
A WARNING: Adjust the valve clearance when the
engine is cold. Valves are adjusted by cylinder in the
firing order of the engine. Tighten the cylinder head
bolts to the specified torque before adjusting the valves.
Pull off the air breather pipe from the rocker cover, and take
off the rocker cover bolts and the rocker cover to expose the
rocker shaft and valve assembly.
Remove the glow plugs from each
of the cylinders to enable
the engine to be easily rotated by hand to position each
cylinder for valve adjustment.
Valves are adjusted with the piston
in the cylinder being
adjusted at TDC (top dead center)
of its compression stroke.
Valve adjustment beginning with cylinder #1. Rotate the
crankshaft slowly and observe the operation of the valves for
cylinder #1. Watch for the intake valve to open indicating the
piston
is on it's intake stroke (the piston is moving down in
the cylinder). Continue to rotate the crankshaft slowly and
look for the intake valve to close. This indicates the piston is
now starting it's compression stroke (the piston is moving up
in the cylinder towards TDC).
Align the TDC mark on the crankshaft front pulley with the
timing marker on the front gear case cover when positioning
the
#1 Piston at TDC of it's compression stroke. Confirm this
by rotating the crankshaft approximately
20 degrees before
and after this point and the two valves for the
#1 cylinder
should not move.
VALVE CLEARANCE
Adjust the valves in #1 cylinder for both intake and exhaust.
Proceed to the #2 cylinder.
Rotate the crankshaft 240 degrees in normal direction
of
rotation and adjust the #2 cylinder.
Adjust each valve's clearance by inserting a
0.010 inch
(0.2Srnm) feeler gauge between the rocker arm and the valve
stem. Make sure to adjust all valves while the engine is cold.
Re-install the glow plugs (use anti-seize compound on the
threads) and assemble the rocker cover and rocker cover
belts. See the TIGHTENING TORQUE SCHEDULE in this
manual.
TESTING FUEL INJECTORS
Remove and check fuel injectors. The injector spray pressure
should be 1991 psi ± 142 psi (140 kg/cm2
±1O kg/cm2).
Undesirable injector conditions, to include after dripping,
should be eliminated.
INJECTION
PRESSURE TEST
NOTE: Fuel injector testing must be
performed in a clean room environment.
AFTER DRIP TEST
WI
GOOD
,BAD
CHATTERING TEST
! SHIM THICKNESS
·O.1mm
O.2mm
O.3mm
O.Smm
For the chattering test, operate the tester level slowly. If the
nozzle sprays sharply and intermittently, the nozzle is consid-
ered good. The nozzle should spray fuel straight
in its axial
direction. A nozzle is defective
if it sprays fuel in a wrong
direction, in several separate strips, or in the form
of
particles. These defects may sometimes be caused by clog-
ging with dust, therefore all parts should be cleaned carefully
before reassembly
Engines & Generators
34